Dankoff Solar Water Feature Manual

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This manual is for the Dankoff Solar Water Feature Solution Kit which uses the SunCentric surface pump for small
orchard irrigation.
Rear
Front
Panel Rack
Fittings and
Hardware
Photovoltaic (solar)
Panels
SunCentric Pump
Disconnect Panel
Installation and Service Manual
The Water Feature Solution Kit
Cables

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Contents
1. WARNINGS ....................................................................................................................................................................... 3
2. WHAT’S IN THE BOX(ES).................................................................................................................................................. 4
3. INSTALLATION REQUIREMENTS...................................................................................................................................... 5
4. MECHANICAL (PLUMBING) SYSTEM HOOKUP ............................................................................................................... 6
5. SOLAR ARRAY WIRING...................................................................................................................................................... 11
6. STARTING THE SYSTEM................................................................................................................................................. 13
7. TROUBLESHOOTING ...................................................................................................................................................... 14
8. MAINTENANCE ............................................................................................................................................................... 16
9. PUMP REPAIRS .............................................................................................................................................................. 17

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1. WARNINGS
Please review the following warnings. These are listed for both personal safety and the safety of the products.
Disregarding or ignoring these warnings can result in SERIOUS INJURY and/or VOID THE WARRANTY. If this system
is being installed without a licensed pump installer, an electrician or knowledge of electrical circuits is HIGHLY
recommended.
If any questions or concerns regarding these warnings should arise, please contact your local Dankoff Solar dealer
or Dankoff Solar Technical Support at 1(505) 395-2491. Dankoff Solar Pumps and/or its parent company, Solar
Power & Pump Co, is NOT LIABLE for any DAMAGE or INJURY.
•The system should be installed and serviced by qualified personnel only. All electrical codes should be
observed. Make ABSOLUTELY CERTAIN all power sources are disconnected prior to wiring.
•Extreme heat can damage the pump. Protect the pump from sunlight or other heat sources.
•Install proper system grounding for safety and lightning protection. Proper grounding can significantly
reduce the chance of extreme damage. See Section 4.4 Grounding and Lightning Protection
•Under-sizing the wires or failing to install a fuse or circuit breaker can cause a Fire Hazard and cause
damage to the motor. Follow all guidelines in Section 4
•Do not touch solar panel or pump wires together to test for a spark.
•Do not run the pump dry.
•The use of a filter is required. For details, see Section 3 Installation Requirements

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2. WHAT’S IN THE BOX(ES)
(1) SunCentric Surface Pump (1) Disconnect switch and (2) mounting brackets
(1) PV Mounting Rack and (2) PV panels (2) 3’ PV Cables and (1) 10’ PV Cable
(1) Footvalve strainer, (3) Hose Adapters, & (3) Clamps (1) Grounding wire, bolts, and clip

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3. INSTALLATION REQUIREMENTS
Kit Overview
The Water Feature Solution Kit is designed for plug-and-play installation and comes complete with all the necessary
hardware and fittings to do so. Because each installation is different a few locally purchased components are
required to complete installation:
-Hoses –Dankoff Solar recommends flexible suction and discharge hoses, and The Water Feature comes
with the necessary fittings and clamps for this type of hose. Inlet hose size is 1 ¼” and outlet hose size is
1”. Simply ask for ‘suction hose’ at your local hardware supply store to purchase the lengths you will need
for your installation
-Rack Mounting Pole –The Panel Rack in The Water Feature Solution Kit includes a gimble that will accept a
3” mounting pole. Dankoff Solar recommends using Schedule 80 pipe, installed 36” below the frost line
using Quickrete, with a minimum of 36” above the ground to accept the rack. PV’s must not be shaded or
blocked at any point during the day to get the stated performance.
-Grounding Rod –Because of the ready availability and to reduce the shipping weight of The Water Feature
Solution Kit, all of the components to properly ground the system are supplied, with the exception of the
grounding rod itself, which can be purchased at any hardware or electrical supply store.
-Pump House/Cover –Because every installation environment is different, the Solution Kit does not include
a generic pump house to shield the pump from the elements, since the pump can be installed in a variety of
ways. Dankoff Solar recommends that the SunCentric pump be shielded from the elements to get the most
out of its 20 year life, and there are many available options that can be purchased locally.
Some ideas include: a curved piece of sheet metal with open ends (the cover should be twice as long as the
pump); a metal barrel cut in half the long way and placed over the pump; any weatherproof box inverted
over the pump; a dog house set it over the pump with the pipes passing through the doorway.
Non-submersible pumps
Do not submerge pump or motor in water, or allow water to drip on the motor.
Filtration requirements
SunCentric Pumps are somewhat dirt tolerant and can be run from many clean water sources without filtration.
However, to prevent possible large debris contamination and to help keep the pump primed, a Dankoff Solar Fine
Intake Strainer Foot Valve (PN –11044) has been provided with the proper fittings.
Pump must not run dry
Water is the lubricant for the pump. If the pump runs completely dry, it will overheat and fail. If pumping from a
tank, cistern or any water source that can run low accidentally, we recommend using a float switch.
A float switch (PN –11004, pump down switch) placed in the supply tank closes when the tank water supply is at a
high level. When the water level drops to a low level, the switch will open and remove power from the pump motor.
This has not been supplied with The Water Feature Solution Kit, as it will only be used in a limited number of
Customer applications.

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4. MECHANICAL SYSTEM HOOKUP
Mount the Pump
The pump may be mounted horizontally or vertically. If mounted vertically, suspend from a rope and face the pump
head downward. Rigid mounting is not required in most installations. Observe the pump and ensure that it does not
overstress or loosen pipes as it starts. In non-battery systems like The Water Feature Solution Kit, starting is
gradual and the pump does not torque with the start. Mounting the pump directly to a wall or wood floor will
increase the noise heard in that structure.
Take every precaution to prevent the pump from freezing. The forged brass pump head will survive most light
freezes, but a hard freeze may damage it. If the pump is insulated for freeze protection, keep the motor exposed to
prevent overheating.
Once you have determined where the pump will be mounted and covered, use the flanges on the pump body to
mount it to a stable location if desired. Follow the chart below in determining the proper location and orientation of
the pump.
It is important to minimize Suction Lift. Suction lift refers to the pressure (negative pressure) on the suction (inlet)
side of the pump. As the vertical distance from the pump inlet to water increases, the suction lift pressure also
increases. The practical suction/intake pipe limit for any pump is 20 vertical feet to water at sea level (subtract 1 ft.
for every 1000 ft. of elevation). Limiting the pipe length to 2 to 3 feet will allow the pump to run quietly and more
reliably. Placing the pump downhill from the water source also helps to minimize suction lift.

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Connect the Hoses
Inlet Hose –Keep the inlet hose lengths as short as possible. Do no use thin-wall hose or soft tubing on the pump's
intake, as it may collapse under suction and restrict the flow. Hose reinforced with steel braid is recommended. If
you elect to use polyethylene pipe (black flexible polypipe) be aware that it can be prone to slight leakage at the
fittings so ensure all connections are watertight.
The inlet must not be obstructed or restricted by undersized pipe, excessive suction lift, or a clogged filter.
Excessive suction at the pump inlet causes cavitation (formation of vapor bubbles). A cavitating SunCentric will not
pump any fluid.
Avoid humps in the intake line that can trap air pockets and block the flow. Ensure the inlet hose is free of leaks.
The supplied foot valve should be installed at the end of the inlet hose at the water intake source. This valve is
important to install because it allows water to flow in one direction only, helping to keep the pump primed when not
running. It is required in any case where the pump is located higher than the low-water level in the source.
Outlet Hose –The length of the outlet hose is not as critical as the inlet hose length, though the SunCentric pump is
not intended to pressurize the outlet side. Maximum performance is achieved when the SunCentric can open flow
to flood the intended irrigation area.
Mount the PV’s to the Rack
Dankoff Solar recommends that you attached the PV’s to the rack hardware first, then lift the entire unit onto the
Rack Mounting Pole.
To do so, lay each PV face down on a soft surface (cardboard works well), and align them together along their long
edge, with cables at the same end. This will be the ‘bottom’ of the solar array. The photo below is an illustration but
may not be the same PV’s in your kit. The installation principle is the same, however.

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The PV Rack comes with two ‘ribs’ and a ‘spine’ that will connect to the gimble. Lay one rib across all four holes at
the top of the solar array and use the supplied hardware to attach the rib to the PV’s. Note the orientation of the rib
in relation to the top of the array, since the spine will pass through it.
Attach the other rib to the lower holes in the same orientation. Once both ribs have been attached to the PV’s,
insert the spine through the lower rib. Center the hole and then tighten the rib bolts. Note the orientation of hole in
the photo below:

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Now attach the gimble to through the hole on the spine, with the gimble opening facing the bottom of the array, as
shown in the photo below:
Take the square pivot and pass it over the top of the spine and connect to the flange on the gimble, as shown in the
photo below. Until the entire array is mounted on the pole, leave the bolts loosely tightened.

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Now the entire array can be lifted onto the mounting pole. The position of the square pivot can now be adjusted so
that the face of the array is tilted (from horizontal) to match the chart below. To maximize sunlight hours the array
can be tilted two times per year in the summer and winter. Else, a year-round tilt is sufficient for most applications.
Now face the array to the south and tighten the three bolts to secure the gimble to the mounting pole. Tighten the
remaining bolts left loose up to the point.

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5. SOLAR ARRAY WIRING
Warning –The photovoltaic array generates hazardous voltages. A 48 Volt (nominal) array can generate nearly 100
volts when disconnected from load.
To prevent shock hazard while working on array wiring, be certain the breaker inside the disconnect is in the “OFF”
position or cover the array to shade it.
Attention –Wiring the panels in the wrong configuration (series or parallel) can damage the pump. Be certain of the
wiring configuration (See Figure below: Solar Panel Wiring Diagram for examples) prior to connecting the array.
Additionally, it is recommended to cover or shade the panels when connecting them to the controller or pump. This
prevents electrical discharge from damaging the equipment. Any damage caused by disregarding these warnings
will NOT be covered under the warranty.
Connecting the Solar Array
Now that the PV Array is mounted on the rack and in place it is time to make the electrical connections. All of the
connections on The Water Feature Solution Kit use standard PV quick connects. The figure below shows the basic
wiring:
Disconnect
Switch

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In practice the connections are more simple than the diagram illustrates. First, connect the two PV’s together by
connecting a ‘male’ wire from one panel to the ‘female’ wire of the other panel, shown by the red line in the photo
below. Connect the two remaining wires (one from each PV) to the left side cables coming out of the disconnect box
using the supplied 3’ cables, as shown below.
Complete the wire connections from the disconnect box to the pump using the supplied 10’ cable. It is important to
note a solid ‘click’ sound when connecting cables to be certain they do not come loose over time.
Grounding the System
To properly ground the system drive the grounding stake until just 6” remains above ground. Connect the supplied
copper cable to the end of the stake and thread it around the rack pole up to the disconnect switch. Use the
supplied bolts to ground the disconnect box and then connect to the PV array directly, as shown in the Solar Panel
Wiring Diagram above.

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6. STARTING THE SYSTEM
Before You Begin
The breaker inside the disconnect switch should remain ‘off’ until the system has been primed and there is enough
sunlight to run the system.
Prime the System with Water
Priming a pump means filling its intake pipe completely with water and must be done if the pump is mounted
higher than the water source.
Prime the pump by removing the inlet hose at the pump intake and pour water into the opening until it is
completely full. The foot valve keeps the pump primed by preventing water from back flowing into the water source.
Replace the inlet hose onto the pump intake.
Power on the System
Flip the breaker inside the disconnect switch to the ‘on’ position. If there is enough sunlight, the pump should start
moving water within a few seconds. As sunlight fades the pump will spin more slowly until it stops. The reverse will
happen as the sun rises and as soon as there is enough current the pump will begin to spin. There is no need to
turn the pump on/off each day.

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7. TROUBLESHOOTING
Motor Doesn’t Turn On
1. Check fuse or breaker and any control or wiring devices in line.
2. Motor starts when hit or tapped lightly - Sticking brushes or other brush problem. Inspect the brushes.
3. Remove the rear cover of motor to check connections. Check for voltage present at motor. If voltage is
present, see next entry.
Pump Spins But Doesn’t Pump Water
1. Check direction of rotation. If not clockwise (viewed from brass front-end) reverse motor polarity.
2. Check Prime - Open and re-prime the pump. Check all the fittings, a pinhole leak in the suction pipe will
cause loss of prime. Inspect, pressure-test, clean or replace the foot valve. Ensure no debris are trapped in
the foot valve.
3. Polyethylene Pipe Fittings –Ensure fittings are tight. Gently heat with torch or hot water and retighten hose
clamp with a wrench. Replace stripped clamps. Use stainless steel clamps.
Noisy Pump –A noisy pump indicates cavitation which can cause rapid pump wear.
Unsteady buzzing sound –Indicates leak in suction line allowing air to enter. Try the following:
1. Check for bubbles in inline (transparent) filter or air in outlet water.
2. Check prime. Open and re-prime the pump. Check all the fittings, a pinhole leak in the suction pipe will
cause loss of prime. Inspect, pressure-test, clean or replace the foot valve. Ensure no debris are trapped in
the foot valve.
3. Some inline filters may have a red push-button valve to release pressure for maintenance. If the filter is
incorrectly installed (too high above the water source) the suction may pull the valve open and introduce air.
To prevent this, seal the push-button with silicone sealant or epoxy, or replace the button with a bolt and
nut, sealed with silicon and tightened down.
4. If no source of air leakage is present, water may have high concentrations of dissolved gases which release
as bubbles in the suction pipe. Reduce suction lift if possible. Install an air chamber in the intake line, with
a valve on top. Pour water in to replace air when problem reappears.
Filter clogs frequently
1. Intake too close to the bottom of well, stream, tank etc. Raise it as high as practical to reduce intake of dirt.
2. Improve the development of the water source. Channel clean water into a settling tank and clean the tank
periodically.
3. Install a larger filter or plumb two filters parallel to each other.
Low Flow Rate / Pump Turns Fast and Draws Low Current –Pump is worn out from dirt, rust or other abrasive
particles in water, or from cavitation, from running dry or age. Replace pump head.
Low Flow Rate / Pump Turns Slowly and Draws High Current (may run hot and/or blow fuses) /Pump is Difficult to
Turn
1. Excessive vertical lift, beyond the system's capacity: Exchange the pump head for a model with correct lift
specifications or increase the size of solar array.
2. Misalignment of coupling shaft - Check rubber shaft coupler for damage.
3. Mineral Deposits - Turn shaft with two fingers. If difficult to turn, use vinegar to dissolve the mineral
deposits in the plumbing. Remove pipes from the pump and allow solution to circulate through the pump by
turning it backwards. Replace or rebuild the pump if deposits cannot be removed.
Pump Will Not Turn –The shaft coupler can't be turned by hand. The fuse is blowing or breaker is tripping.

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1. After a period of disuse or storage, the impeller may lock up. Using pliers on the shaft coupler, gently rotate
the pump backwards (counterclockwise).
2. Debris is jammed in the pump. Disconnect the plumbing, pour water into outlet, and run pump in reverse
(by reversing polarity). Watch for debris exiting inlet. Damage to the pump is likely.
Pump Emits Crunching Sounds, Black Material in Outlet –Internal parts are broken, either by debris in pump,
severe freezing or external shock.
Water Damage, Motor Submerged or Dripped On –Inspect brushes and commutator. If in poor condition, the motor
may need a rebuild (new bearings). In extreme cases the motor must be replaced. Contact Dankoff Solar support.
Correct the cause of damage.
Rusty/Noisy Bearings
1. Pump head - Steel ball bearings are visible at pump head shaft. Rust caused by water drip or submersion.
Pump head must be rebuilt to replace the bearing.
2. Motor - Replace with double sealed "R8" bearing (front) and "R6" (rear). These are common bearings
available from automotive or electric motor suppliers, or directly from Dankoff Solar. A puller tool or a press
is needed for removal.
Pump Frozen by Low Temperature / Blown fuse or circuit breaker tripped –Allow the pump to thaw. Observe
performance. If the motor is damaged, replace or rebuild. Check all plumbing for damage and leaks and protect
from future freezing.
Motor Brushes –Motor brushes are carbon rods that make electrical contact with the spinning copper
"commutator" on the motor shaft. The two brushes are accessible via the cover at the rear of motor. Brushes must
be unbound and slide in and out freely, a spring pushes the brush in as it wears.
Brushes must be at least 3/8" long (longer on motor larger than 5” diameter). They generally last about 5 years
unless the motor has been wet inside (see "WATER DAMAGE").
1. Worn Brushes –Replacement brush part numbers are located on the pump label. Call your dealer or
Dankoff Solar for replacements.
2. Sticking Brushes - Inspect inside each brush holder with a flashlight. Clean if corroded or dirty. If brushes
still don't slide in/out freely, very lightly sand the long sides of each brush.
3. Brush Springs Weak –If the spring looks discolored the motor may have overheated from a severe overload
and lack of fuse protection. Replace the brushes. If the motor does not start, it must be replaced.
4. Broken Brush Holder - Replace the brush holder (contact Dankoff Solar).
5. Commutator - The commutator is visible through the brush holders. The commutator may be damaged by
poor brush contact, overheating or water damage. The wear surface should be smooth, with a uniform
brown color. Commutator damage may require resurfacing on a lathe. Contact Dankoff Solar to perform
these repairs.

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8. MAINTENANCE
Shaft Seals - Seals may last for a few years, but if the water contains abrasive silt, the seals will wear faster. Seals
will be quickly ruined if the pump runs dry. You can purchase spare seals from your Dankoff Solar dealer and MUST
be installed correctly. The smooth white ceramic face must face outward, away from the motor. The part with the
spring presses over the shaft. The all-black end must contact the white ceramic face. The metal and rubber end
faces away from the motor.
Seal and Gasket Kits
If last digit of the pump model number is 1, 2, 3, or 4 —order Dankoff Solar item #37690
If last digit of the pump model number is 5 or 6 —order Dankoff Solar item #37691
Seal and Gasket Kits for High Temperature pumps
If last digit of the pump model number is 1, 2, 3, or 4 —order Dankoff Solar item #37695
If last digit of the pump model number is 5 or 6 —order Dankoff Solar item #37696
The seal is an industry-standard pump seal for 5/8” shaft. In case of emergency, you may be able to obtain one
from a local pump supplier or electrical repair shop. If the paper pump gasket is damaged, a new one can be cut
from thick paper. Manila file folders works fine.
Before pressing the seal parts into place, use your finger to wipe a small amount of oil or grease onto the cast iron,
rubber and shaft surfaces. This will make installation and service much easier. DO NOT get any lubricant onto the
mating white and black faces of the seal. Always replace BOTH parts of the seal (the black part and the black &
white part)
Pump Head –The pump head is maintenance-free. Do not remove its front plate or otherwise tamper with it. The
pump head is not user repairable. It is easy to dissemble, but difficult to reassemble without special tools.
Motor Brushes –Motor Brushes: Typical brush life peak hours = working voltage X 800 / 3rd digit of model
number. EXAMPLE: PV-Direct curve #60 is Model 7526 working at 30V. Typical brush life = 30 X 800 / 2 = 12,000
peak hours. This represents about 5-8 years of service. Your result may differ. New Brushes measure 1.25 inches
(31 cm) in length. You can measure wear after a period of time, to predict the brush life. Worn brushes will not
effect performance, until they are worn to about 1/2 inch (1 cm.). At that point, to motor will stop as contact is
broken. Replacement brushes may be obtained from your dealer or the factory.
Motor Bearings - Ball bearings in the motor are lubricated for life and do not require maintenance. If water enters
the motor accidently, it will damage the bearings. Replacement bearings can be obtained from your Dankoff Solar
dealer. Purchase two bearings #6203Z.

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9. PUMP REPAIRS
FAILURES
Most failures involve the pump head seal, not the motor, and is indicated by a properly primed pump not able to
maintain vacuum and move fluid.
The pump head seal is user serviceable, however it is delicate and difficult to re-assemble. Disassembly of the
pump head will void the warranty. If the pump head seal has failed, it must be replaced with a new one or sent to
Dankoff Solar to be rebuilt.
WARRANTY CLAIMS must include receipt to prove date of purchase.
TO SHIP PUMP TO DANKOFF SOLAR FOR REPAIR:
Please contact your Dankoff Solar dealer to set up a repair and receive an RMA number
[phone]
FAX [phone]
Email: [e-mail]
Have the MODEL & SERIAL NUMBERS available before initiating a return for repair.
WARRANTY
Dankoff Solar products are warranted to be free from defects in material and workmanship for ONE (1) YEAR from
date of purchase.
Failure to provide correct installation, operation, or care for the product, in accordance with instructions, will void
the warranty.
Product liability, except where mandated by law, is limited to repair or replacement, at the manufacturer's
discretion. No specific claim of merchantability shall be assumed or implied beyond what is printed on the
manufacturer's printed literature. No liability shall exist from circumstances arising from the inability to use the
product, or its inappropriateness for any specific purpose. It is the user's responsibility to determine the suitability
of the product for any particular use.
In all cases, it shall be the responsibility of the customer to insure a safe installation in compliance with local, state
and national electrical codes.

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ADDITIONAL DANKOFF SOLAR SURFACE PUMPS FOR LIFT AND PRESSURIZING:
SOLAR FORCE PISTON PUMP
•5-9 GPM to 230 FEET or to 100 PSI
•Extremely rugged and dirt-tolerant
SOLAR SLOWPUMP
•0.5-6.2 GPM to 450 FEET
•Capable of pushing through miles of pipeline
SOLAR FLOWLIGHT BOOSTER PUMP
•2.7-4.5 GPM to 100 FEET
•Provide city water pressure anywhere
SOLARAM SURFACE PUMP
•3-9 GPM to 960 FEET
•Ask your Dankoff Solar dealer or go to
SUBMERSIBLE PUMPS FOR SURFACE AND DEEP WATER LIFT AND PRESSURIZING:
SunRotor® Submersible Pumps, a division of Solar Power and Pump Co.
www.sunrotor.com
Dankoff Solar and Sunrotor are divisions of Solar Power and Pump Co.
301 West 12th Street
Elk City, OK 73644
[phone]
[phone]
Fax [phone]
www.solarpowerandpump.com