ICON iSOLAR PDP Series User manual

iCON iSOLAR 3” PDP Instruction Manual 1
Auto Restart Pump Controller
3” Helical Solar Pump Complete Solution Kit
808691 - BIA-PDP3 SOLAR250
808692 - BIA-PDP3 SOLAR370
808694 - BIA-PDP3 SOLAR750
Brushless
submersible
helical motor
iCON PDP3
Solar Controller
30 meters cable
Non-return
valve
Kit includes:
Nylon safety
rope
Float/Level
Switch with
30 meters cable

2 iCON iSOLAR 3”PDP Instruction Manual
1. Contents
1. Contents.................................................................................................................. 2
2. ISO 7010 Symbols used in this manual................................................................. 2
3. Introduction............................................................................................................. 3
4. Key Features and Protections................................................................................ 3
5. Warnings and Cautions..........................................................................................4
6. Kit Contents and Technical Specifications........................................................... 5
7. Electrical Connections.......................................................................................6 - 7
8. Display..................................................................................................................... 8
9. Display Functions Explained..................................................................................8
10. Alarm Parameters and Meaning.............................................................................9
11. Installation......................................................................................................10 - 13
12. Operation summary.............................................................................................. 14
13. Warranties –Terms and Conditions.................................................................... 15
2. ISO 7010 Symbols used in this manual
Warning - Electrical safety
Warning –Potential consequences of use outside of intended
application(s). Includes environmental condition warnings.
Mandatory warning
Warning to disconnect power
Read carefully

iCON iSOLAR 3” PDP Instruction Manual 3
3. Introduction
Welcome to the iCON iSOLAR revolution!
The 3” helical rotor iSOLAR PDP3 range provides a ‘plug and play’ kitset solution that
requires only moderate DIY skills to install and has little ongoing maintenance
requirements.
The iSOLAR PDP3 can be installed down a bore, in a tank or fitted to a pontoon to
supply from an open body of water.
No more external energy costs! Just harvest the sun to move your water.
While this kit is very simple, please read this manual fully and carefully before you start.
Progressive Cavity / Helical Rotor pumps can produce extremely high pressures and
any electrical energy must always be treated with care. Stay safe and get the important
details right so you can enjoy the benefits of your purchase.
4. Key Features and Protections
•Low voltage permanent magnet DC motor
•High efficiency MPPT and Vector Control
•Dry run protection from low level float
•Easy-to-install output side control from
a float or pressure switch
Glossary of Electrical Terms
Term
Definition
Voc (V)
Volts open circuit, nothing connected
Vmp or Vmpp (V)
Volts maximum power point, under load
Isc (A)
Amps short circuit
Imp or Impp (A)
Amps maximum power point
DC Power in Watts
Vmp x Impp
•Over-load protection
•Over-current protection
•Over-voltage protection
•Low-voltage protection
•Lost Phase protection
•Stall protection

4 iCON iSOLAR 3”PDP Instruction Manual
5. Warnings and Cautions
Please read the manual fully and carefully before starting.
Retain the manual for future reference.
Solar panels create electrical energy when exposed to light.
At all times, treat solar panels as live and handle with care.
Any changes or modification to the wiring must be carried out by
competent, skilled and suitably qualified personnel only.
The iSolar PDP3 controller has internal capacitors that MUST be
allowed to discharge before handling the motor. Allow 2 minutes for
stored energy to dissipate before handling the pump/motor.
Never open the cover while controller is connected to an electrical
supply. Disconnect and allow 2 minutes for the internal electronics to
discharge before opening the cover.
The controller is IP65rated but should not be exposed to direct sunlight.
Install the controller where it has excellent ventilation away from direct
sunlight or exposure to adverse weather.
Solar arrays are an attractive earth path for lightning strikes.
Ensure the panels and controller are well earthed.
Helical rotor pumps must be used in a clean water, sediment-free
environment. Even a small amount of sand may lead to screw wear,
jamming or performance degradation.
This appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure that they do not
play with the appliance.

iCON iSOLAR 3” PDP Instruction Manual 5
6. Kit Contents and Technical Specifications
Model
Part
No
Motor kW/hp
Hmax
Controller
Solar Array
Vmp
Max
VOC
Max
Amps
PDP3 250
808691
0.25kW / 1/3hp
60m
24V
1 x 300W
18 –40V
48V
15A
PDP3 370
808692
0.37kW / 1/2hp
80m
48V
2 x 300W in series
40 –76V
96V
15A
PDP3 750
808694
0.75kW / 1hp
140m
96V
3 OR 4 x 300W in
series
80 –150V
180V
15A
Solar array recommendation indicative only
Solar inputs must respect the Voc and Max Current (Amperage) values
Solar Panels and their mounting system (where applicable) are supplied
separately and come with their own instructions.
The Max Voc and Max Current (A) capabilities of the motor and the controller must always be
respected. Fitting additional or incorrectly rated panels will cause serious harm or irreparable
harm to the controller and motor voiding warranty.
A. Isolator Switch with M/F MC4 solar connecters.
B. PDP3 Solar Controller matched to suit the applicable pump model.
D. Check/Non-return Valve 1” BSPF.
G. iSOLAR PDP3 helical rotor pump and motor fitted with
30m 2.5mm2power cable including earth and supplied with a
weather-proof 4 Pin (IP54 rated) plug. Outlet 1” BSPM.
E. Low voltage, low water float fitted with 30m cable to
provide low water level protection.
C. Earth Strap 2.5m long, 4mm2. Connects externally to the controller.
A
B
C
G
F. 30m nylon safety rope
D
F
E
Maximum Pump Submergence is 100m

6 iCON iSOLAR 3”PDP Instruction Manual
7. Electrical Connections
Any electrical alterations or additional connections should be carried out by a suitably
qualified technician. Isloate the controller before removing the cover to access the low
voltage circuit connections. The controller is IP65 rated. It should not be exposed to
direct sunlight. Install the controller where it has excellent ventilation and away from
direct sunlight or exposure to adverse weather. Installation inside a separate open
fronted enclosure is suggested.
FLOAT
REVERSE
ACTING
PRESSURE
SWITCH

iCON iSOLAR 3” PDP Instruction Manual 7
7. Electrical Connections cont.
Locate the solar array and the controller as close to your water source as possible.
iSolar PDP pumps consume only low levels of input power, so it is important that
energy losses are minimised to ensure performance expectations are met.
808691 - BIA-PDP3 SOLAR250
808692 - BIA-PDP3 SOLAR370
808694 - BIA-PDP3 SOLAR750
If intending to extend the power cable, use this chart as a guide. Exact cable size will vary according to the
input characteristics and technical specifications of the solar panel. Calculations assume 5% loss.
Solar Panel Input
Cable length (Up to ’x’ Meters)
Watts
Panels
Max
VOC
Vmpp
Amps
< 10
< 25
< 30
< 50
< 75
< 100
CROSS SECTION MM2
300
1 x 300
48V
35
10
2.5
2.5
2.5
6
10
10
600
2 x 300
96V
70
10
2.5
2.5
2.5
2.5
4
6
900
3 x 300
150V
105
10
2.5
2.5
2.5
2.5
2.5
4
1200
4 x 300
180V
140
10
2.5
2.5
2.5
2.5
2.5
4
Total cable length measured from the solar array to the pump motor.
The Max Voc (V) and Max Current (A) capabilities of the motor and the controller must be
respected.
Fitting additional panels or incorrectly rated panels will cause serious harm or
irreparable damage to the controller and motor voiding warranty
iSOLAR PDP3-250 power is supplied by a single panel.
iSOLAR PDP3 models 370 and 750 - panels must be wired in series.
30m
51m
96m
Total acceptable cable length per
model, from panels to pump motor,
when using 2.5mm2 cable, to keep
energy losses less than 10%

8 iCON iSOLAR 3”PDP Instruction Manual
8. Display
Before turning the controller on, ensure the pump is completely immersed, that
any isolators are switched on and flow control valves are open.
9. Display Functions Explained
No.
Name
Function
ON/OFF
Press ON/OFF button to turn the pump controller on and
commence operation.
Press again to turn the pump controller off.
To see if the pump is running press SWITCH to display RPM
SWITCH
(Display Scroll)
Repeated presses scroll through real time operating values
Voltage / Pump Speed / Amperage / Wattage.
LEDs illuminate to show which value is displayed
DIGITAL DISPLAY
Displays alpha numeric fault codes and operating values
SET
Used to enter the programming mode
UP AND DOWN
ARROWS
Used to increase or decrease program parameters
ENTER (OK)
Used to accept a programming change
1
2
4
5
6
3

iCON iSOLAR 3” PDP Instruction Manual 9
VOLTAGE
LED illuminated –Display showing voltage value
RPM
LED illuminated –Display showing motor speed
TANK
LED illuminated –Pump operation suspended as the
pressure side input indicates no water required.
Associated with TL, TH and COM terminals.
WELL
LED illuminated –Pump operation suspended.
Low level float indicates insufficient water. 10 min delay
prior to restart. Associated with WEL and COM terminals.
Also serves as a pump failure alarm indicator.
MPPT
LED illuminated –MPPT function active
POWER
LED illuminated –Input power available
AMPERAGE
LED illuminated –Display showing amperage value
WATTAGE
LED illuminated –Display showing wattage value
10. Alarm Parameters and Meaning
CODE
Fault Description
What to look for / Possible causes
P0
Hardware over-current
Motor and Controller mismatched
Motor short circuit or cable damage
P43
Phase protection
Motor phase absence or U,V,W wiring issue
P46
Stall protection
Motor and Controller mismatch?
The wet end may be jammed or connected
incorrectly
Disconnect from power, inspect and clean.
P49
Software over-current
Motor short circuit or cable damage
P50
Low Voltage protection
Input voltage is too low
P51
High Voltage Protection
Input voltage is too high
P48
Dry-run protection
Check the water level and ensure the pump is
fully submerged
P60
High Temperature protection
Controller temperature is too high.
Ensure the controller is installed away from direct
sunlight, protected from the weather and
adequately ventilated
PL
Power shortage or stall
Input power may be too low. The wet end may be
jammed or connected abnormally. Disconnect
from power, inspect and clean.
ALARM
Polarity error
Input power positive / negative wiring error
A
B
C
D
E
F
G
H

10 iCON iSOLAR 3”PDP Instruction Manual
11. Installation

iCON iSOLAR 3” PDP Instruction Manual 11
11. Installation cont.
White International shall not be held responsible for damage caused by improper
installation, use of incorrect cable specifications, negligent or careless handling, lightning,
improper voltage supply, corrosion due to impure water, wear caused by sand, gravel or
other abrasives in the water being pumped.
GENERAL PRECAUTIONS
•Never support the weight of the pump by the drop cable/safety rope or by the power
cable. An unstrained safety rope must be connected to the bore pump suspended on
poly pipe. This line should be fastened to the lifting hook of the pump. The other end
should be fastened at the top of the bore casing/cap.
•The voltage shown on the nameplate of the controller and motor must match.
•Never install additional solar panels other than what has been supplied. The maximum
and voltage and current specifications must be respected.
•Fit the low-level float to ensure the pump switches off should the water level fall to
150mm above the pump suction inlet.
An absent or inactive low water level float will result in damage should the pump run
dry voiding warranty.
•Water temperature has an impact on pump performance. Recommended water
temperature of 10°to 40°C.
•A check valve is included with the kit. It must be installed on the pump outlet or at the
well head. Additional check valves for heads greater than 80 metres may be
necessary. These will reduce water hammer shocks to the pump.
Borehole installations
•Damage to the pump or motor caused by abrasive or corrosive water is not covered
by the Warranty.
To prevent damage to the pump by aggressive water, an analysis of the bore water
should be carried out prior to installation to ensure pump suitability.
Note: Sand content not to exceed 100g/m3 of water pumped.
•The bore must be clean before installation. A helical pump must NEVER be used to
bail a new bore. Warranty does not cover failure or wear due to abrasives in the
water.
•Know the total depth of the bore and ensure that the pump does not rest on the
bottom or in sand. Ensure 1.5 metres clear below the pump to the
bottom of the bore.
•Know the pumping level (drawdown level) of the bore and ensure
that the pump remains submerged.
Minimum water level should be 150mm above the pump inlet
•Never install borehole submersibles in a crooked bore without
first lowering a gauge which is the same diameter and length as
the pump to be used into the bore.
If the gauge does not bind, it is safe to install the pump.

12 iCON iSOLAR 3”PDP Instruction Manual
11. Installation cont.
In-tank installations
•The pump can be installed vertically or horizontally.
•Fit the non-return valve to the top of the pump.
•Rigid piping is recommended to prevent the pump twisting.
•Include a flushing or scour valve on the base of tank to enable
periodic cleaning of the tank bottom to minimise silt build-up.
Pumping from an open body of water –Pond or Stream
•Vertical installation ensures best lifespan, but it is acceptable to
sling the pump horizontally. Ensure the low-level float switch is not stuck.
•Ensure the water is drawn constantly from below the
water surface and without contamination.
•A simple, buoyant method of mounting the pump is
to build a pontoon from PCV fittings.
Solar Array
•The solar array must face True North.
•The solar panel angle should correspond to the latitude of the site.
Consult the instructions supplied with the solar array to assist your
decision regarding the best angle for your situation.
As a rule of thumb, solar panels should be more vertical during winter to gain
most of the low winter sun, and flatter during summer to maximize the output.
•Any shading whatsoever will reduce the solar panel(s) performance so locate the panels
with this in mind.
•Clean the panels periodically to remove dust and bird droppings.
•Ensure the array is earthed to ground in the event of lightning strike.
•Protect the array and controller from stock.
Low voltage low water level float
•The low-level float MUST be fitted to prevent the pump running dry.
•The low-level float must be a minimum of 150mm above the pump inlet.
•If the float shuts the pump down due to a lack of water, the LED on the controller labelled
‘WELL’ will illuminate.
When the water level rises the pump will restart after a 10-minute delay.
Controller and DC input power isolator
•Install the controller where it is shielded from adverse weather and out of direct sunlight.
Mounting in the lee of the array or inside an additional enclosure is recommended.
•Earth the controller body to ground.

iCON iSOLAR 3” PDP Instruction Manual 13
11. Installation cont.
Pressure pipe selection
Helical rotor type pumps such as the iSOLAR PDP are able to generate very high
pressures, particularly if they continue to operate in a no-flow situation.
Where practical, an open loop system is desirable.
Model
Hmax
Approx. pressure Bar/PSI
PDP3 250
60m
5.7 / 82.6
PDP3 370
80m
7.8 / 113.1
PDP3 750
140m
13.7 / 198.7
•Select and use suitably pressure rated water delivery piping.
•It is strongly recommended to fit a switching device to the delivery line to prevent closed
head operation.
Pressure pipe sizing
The iSolar PDP3 range has a maximum output flow of 25 lpm so the resulting pipe friction
losses are low. The correct pipe sizing allows for the possibility of very long delivery piping.
The following table is a ‘worst possible case’ example. The pressure loss values per 100m of
pipe length are for 16 bar rated pressure supply pipe at 25lpm.
Pipe size
Friction loss per 100m
of pipe at 25 lpm
If unsure, increasing the pipe
size by one size will result in
a substantial reduction to the
pipe friction losses.
MD25PN16
14.60m
MD32PN16
4.55m
MD40PN16
1.56m
MD50PN16
0.53m
Note this table does not automatically infer the need to use 16 bar pressure rated pipe.
Optional switching
•An input connected to TL/TH and COM terminals allows the user to fit some form of switch
such as a float in the destination tank to turn the pump off when the tank level has risen.
Alternately, by fitting a double acting ballcock to the tank inlet a suitably adjusted pressure
switch will turn off the pump when the ballock closes (tank full) and the pipe pressure rises
•When the switch circuit stops the pump running, the LED on the controller labelled ‘TANK’
will illuminate. When the float or pressure switch circuit opens again pump operation will
re-commence immediately.

14 iCON iSOLAR 3”PDP Instruction Manual
12. Operation summary
•Ensure all electrical connections are joined correctly and there are no bare wires.
•Ensure any output valves fitted to the system are open.
•Check the DC input isolator is switched on.
The ‘POWER’ LED will illuminate when there is power available.
1. Press the ON/OFF button to commence operation.
The controller assesses the available energy. If the minimum threshold is met the pump will start
immediately. To check whether the pump is running, press SWITCH to display RPM.
The controller varies the pump running speed and therefore flow output depending on the energy
available. Default RPM is 3600.
2. Repeated presses of the controller SET button allows the user to cycle through the Voltage,
Pump speed (RPM), Current (Amperage) and Input Power (Wattage) parameters. The LEDs to
the left and right of the display will illuminate to indicate which parameter value is displayed.
The controller employs MPPT and Vector control to achieve maximum efficiency. Solar energy
changes constantly especially on cloudy days. The display values will be constantly changing as
the pump adjusts to optimise the output based on the available input power.
Note that the wattage value indicates what the pump is currently consuming. It is not a measure
of solar array output. It is normal that the values are constantly changing.
3. Pressing the INCREASE and DECREASE buttons will alter the maximum pump RPM in set
intervals of 4000 / 3600 / 3000 / 2400. The controller will not store this change. Once the power
cycles the controller returns to its default setting (3600 rpm).
4. If the low water level float circuit shuts the pump down due to a lack of water, the LED on the
controller labelled ‘WELL’ will illuminate. When the water level rises again the pump will restart
after a 10-minute delay.
5. Should the output switch circuit (float or pressure switch if fitted) stop the pump running, the
LED on the controller labelled ‘TANK’ will illuminate. Pumping will re-commence immediately when
the float or pressure switch circuit opens again.
6. If for any reason the pump has a fault, or the unit is protecting itself, the controller will display
the appropriate alarm code. The codes are listed in Section 10, Page 9.
7. To suspend operation press the ON/OFF button on the controller.

iCON iSOLAR 3” PDP Instruction Manual 15
13. Warranties –Terms and Conditions
This warranty is given in addition to the consumer guarantees found within the Australian
Competition and Consumer Act 2010 (Cth) for goods purchased in Australia and the
Consumer Guarantees Act 1993 NZ for goods purchased in New Zealand:
1) White International Pty Ltd / White International NZ Ltd (White International) warrant that all products distributed are
free from defects in workmanship and materials, for their provided warranty period as indicated on the top or opposite
side of this document. Subject to the conditions of the warranty, White International will repair any defective products
free of charge at the premises of our authorised service agents throughout Australia and New Zealand if a defect in the
product appears during the warranty period. If you believe that you have purchased a defective product and wish to
make a claim under this warranty, contact us on our Sales Hotline on 1300 783 601, or send your claim to our postal
address or fax line below and we will advise you as to how next to proceed. You will be required to supply a copy of
your proof of purchase to make a claim under this warranty.
2) This warranty excludes transportation costs to and from White International or its appointed service agents and
excludes defects due to non-compliance with installation instructions, neglect or misuse, inadequate protection against
the elements, low voltage or use or operation for purposes other than those for which they were designed. For further
information regarding the suitability of your intended application contact us on our Sales Hotline on 1300 783 601. If you
make an invalid claim under this warranty, the original product will be sent back to you unrepaired.
3) This warranty refers only to products sold after the 1st January 2012, and is not transferable to another product type
and only applies to the original owner, purchaser or end user,and is in addition to the consumer guarantees found within
the Competition and Consumer Act 2010 (Cth) for goods purchased in Australia and the Consumer Guarantees Act
1993 (NZ) for goods purchased in New Zealand.
4) Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.
You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure
does not amount to a major failure. 2 YEAR WARRANTY
5) To the fullest extent permitted by law, White International excludes its liability for all other conditions or warranties
which would or might otherwise be implied at law. To the fullest extent permitted by law, White International’s liability
under this warranty and any other conditions, guarantees or warranties at law that cannot be excluded, including those
in the Competition and Consumer Act 2010 (Cth), is expressly limited to: (a) in the case of products, the replacement of
the product or the supply of equivalent product, the payment of the cost of replacing the product or of acquiring an
equivalent product or the repair of the product or payment of the cost of having the product repaired, is at the discretion
of White International or a 3rd party tribunal elected under the Competition and Consumer Act 2010 (Cth) for goods
purchased in Australia and the Consumer Guarantees Act 1993 (NZ) for goods purchased in New Zealand; and
6) To the fullest extent permitted by law, this warranty supersedes all other warranties attached to the product or its
packaging.
7) In the case of services, supplying the services again or thepayment of the cost of having the services supplied again,
is at the discretion of White International or a 3rd party tribunal elected under the Competition and Consumer Act 2010
(Cth) for goods purchased in Australia and the Consumer Guarantees Act 1993 (NZ) for goods purchased in New
Zealand. 8) Our warranty commences from the date of purchase of the above-mentioned pumps. Proof of purchase is
required before consideration under warranty is given.
Record your date of purchase in the space below and retain this copy for your records.
Date of Purchase ..................................................Model Purchased ..............................................

16 iCON iSOLAR 3”PDP Instruction Manual
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www.whiteint.co.nz 0800 509 506
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