SOLARJACK SDS User manual

SDS SERIES
DC SUBMERISIBLE PUMPS
INSTALLATION MANUAL
Kyocera Solar, Inc. / SOLARJACK, 7812 E. Acoma Drive, Scottsdale, AZ 85260
Telephone [phone] FAX [phone]
E-mail [email protected]
www.kyocerasolar.com

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Section 1
NOTE: Read sections 2 and 3 carefully before attempting to install this pump.
Improper installation will void your warranty.
SOLARJACK’S SDS SERIES DC SUBMERSIBLE PUMPS
SOLARJACK’S SDS SERIES PUMPS are positive displacement, low voltage, DC powered,
submersible pumps. Constructed of high quality marine bronze and stainless
steel, these pumps were designed for corrosion free service in clean potable
water.
They can be installed in a well, cistern, lake, or stream. If used in
conjunction with a pressure switch and tank, they may be used to pressurize a
water system.
The SDS-D series pump's light weight, only 14 pounds, and small size 3.8”
outside diameter and 10.75” length allows easy installation by hand into a 4”
inside diameter well. The SDS-Q series pump, weighing 16.5 pounds and with a
4.3” outside diameter, also allows easy installation by hand into a 5” inside
diameter well.
Their stand-alone, pollution free and low noise operation makes them an ideal
solution for remote home, wildlife, and stock watering problems, without
violating the environment.
Simplicity is the key feature of the SDS series pump line. They require no
lubrication, they run on 12 volts or 24 volts DC and are completely serviceable.
A variety of power sources may be used including solar panels, wind generator,
batteries, or any combination of the three. (A SOLARJACK PC or PB series
controller must be used as an interface between the power source and the pump on
all systems).
All new generation SDS series pumps are designed to meet the National Electric
Code. The necessary changes have been made to all SOLARJACK pumps and
controllers to meet this code.
Section 2
INSTALLATION INSTRUCTIONS
2.1 PUMP
2.la Before installing the pump, measure the depth and static water level of the
well. The static water level is the distance from the top of the casing to the
water level in the well. This information is necessary in determining where to
set the pump and the low water cut-off electrodes, if used.

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2.lb Connect the drop pipe, safety rope, and sand shroud (if used) to the pump.
Splice the drop wire to the motor lead and stretch it all out on the ground. See
the wire splicing instructions in section 2.3 (Be careful not to get any dirt
inside the drop pipe when stretching it out on the ground). If a saw is used to
cut the drop pipe, make sure to clean the saw cuttings out of the pipe before
Installation). Make the length of the pipe assembly a minimum of two feet longer
than that of the static water level plus the anticipated draw down of the water
level in the well. Never install the pump deeper than necessary.
2.lc Tie the drop pipe, drop wire, and safety rope together every ten feet with
the wire ties or a high quality black electrical tape. (If the low water cut-off
circuit- is used, attach the E-lS electrodes at the proper set points at this
time also). Slide the well seal over the discharge end of the pipe, connect the
discharge fitting, pull the drop wire through the seal, and connect the safety
rope to the I-Bolt.
2.ld Lower the pump and pipe assembly into the well positioning the well seal
over the top of the casing.
2.le Connect the discharge pipe to the fitting on top of the well seal and
attach the pump wires and electrode wires (if used) to the controller.
2.2 PANEL SUPPORT STRUCTURE
2.2a The panel support structure should be located as close to the well as
possible. This keeps the length of the drop wire and thus the voltage drop to a
minimum. It must also be mounted in a good sunlight location away from trees,
buildings, or anything that could cast a shadow on the panels.
2.2b Dig an 8” to 10” diameter hole to a depth of at least 24 inches. (This is
for a 2-module support structure.)
2.2c Install the support structure pipe into the hole making sure that the pipe
is plumb and then fill the hole with concrete. Allow 24 hours for the concrete
to cure before installing the panels.
2.2d After the concrete has cured, install the panel support head (B) on the
support structure pipe (E). Attach the upright (C) onto the head using the 5/8”
bolt tabs (A). Attach the cross pieces (D) onto the upright using the 3/8”
bolts. Attach the panels onto the cross pieces using the 1/4” bolts. (See
separate instructions for other types of support structures and trackers.)
2.2e Cover the panels with a blanket or opaque material before wiring the panels
to the controller and pump. CAUTION: PV PANELS GENERATE DC ELECTRICITY WHEN
EXPOSED TO SUNLIGHT.
2.2-f Connect the panels and controller as illustrated in the wiring diagrams in
the controller manual.

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2.2g Remove the blanket from the panels and turn the switch on. If there is good
sunlight the pump will start operating.
2.3 WIRE SPLICING
2.3a Prepare the cable by stripping the outer jacket insulation back 1-1/2” on
the pump end and 2-1/2” on the incoming power end. (The insulation on the outer
jacket of the long side is stripped back just enough to allow the smaller shrink
tube to fit over the inner wire and allow the compression sleeve to be
installed).
2.3b Prepare the inner wire ends by stripping the insulation to expose about
1/4” of each conductor.
2.3c Slip the large length of tubing over the entire cable and the smaller
tubing over each wire on the long side. Splice the wires to the motor pigtail
using the proper crimping tool and compression sleeves. Observe the color-
coding.
2.3d Position the small shrink tubing over each joint, making sure it is
centered. Apply heat to the shrink tubing with a flame from a lighter or a
propane torch. If using a torch, keep the flame moving to prevent burning the
tubing. Proper shrinkage is reached when the tubing does not show any further
reduction in size and the sealant has started to ooze at the ends.
2.3e Position the large shrink tubing over the entire joint making sure it is
positioned over each side of the outer wire jacket. Apply heat until the proper
shrinkage is reached.
2.3f To check proper sealing of the splice and wire installation immerse the
splice and wire in a container of water for ten minutes and then take a
resistance reading between the water and each of the cable conductors. Connect
one ohmmeter lead to the conductor and the other lead to a piece of metal
immersed- in the same water. Set the ohmmeter on the R x IOOK scale. The
resistance should be two megohms (2 million ohms) or higher. A lower resistance
indicates an insulation leak that must be corrected.
2.4 CONTROLLER ADJUSTING PROCEDURE
NOTE: It is usually not necessary to adjust the controller since it has been
pre-adjusted at the factory.
2.4a This procedure should be performed with the panels at their normal
operating temperature at mid-day. To maintain peak output throughout the year,
readjust the controller in very hot and very cold weather or as necessary.
2.4b With the system installed and pumping water, turn the panels away from the
sun or cover the panels until the pump flow rate is reduced by approximately
50%.
2.4c Connect a DC volt-meter to the pump side of the controller. (LD+ and LD-)
2.4d Turn the "panel voltage adjusting pot", located on the upper left side of
the controller, until the highest possible voltage is obtained. (This will also
be the highest flow rate).

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2.4e Return the panels to their normal position. The pump will then operate at
its maximum output.
2.5 ELECTRODE INSTALLATION (OPTION)
2.5a With the pump and pipe stretched out on the ground and before installation
into the well, (refer to step 2.1b) cut the electrode wire to the desired
lengths and install all three E1-S electrodes in the proper locations.
2.5b The "ground electrode", terminal 3, must be in the water at all times and
should be placed approximately two inches above the top of the pump. The "low
water level electrode" terminal 1, is placed at the desired cut off point and is
usually placed two to six inches above the ground electrode. The "high water
level electrode", terminal 2, is placed at the desired turn-on level, but must
be placed below the static water level and should be located no more than 20
feet from the low water electrode.
NOTE: Wells with a high mineral content in the water and/or with cascading water
above the electrodes may not be suitable for use with the low water cut-off
circuit. Mineral deposits may collect on the electrodes insulating the circuits
from the water.
Section 3
FOR PROPER PUMP PERFORMANCE
(Do not disassemble the pump during the warranty period. Any tampering will void
your warranty). WARNING: IF THE PUMP IS DISASSEMBLED, USE EXTREME CAUTION AS THE
MOTOR HOUSING MAY BE UNDER HIGH PRESSURE.
3.la For optimum pump performance make sure that the wire is sized properly for
the length of run between the pump and the panels. Wire sized too small will
cause a decreased output from the pump. Keep the distance from the PV panels to
the pump as short as possible. For depths over 150 feet, higher wattage panels
will help compensate for the additional losses in the longer wire lengths as
well as the higher current requirements.
3.lb Make sure that the discharge pipe is sized properly for the length of run.
Friction loss in a pipeline, especially over a long distance, will add head to
the pump and thus reduce the flow rate. (Consult your SOLARJACK dealer for
correct sizing for your system).
3.lc Never rest the pump on the bottom of the well, lake, cistern, etc. This can
cause the pump to fill with mud and damage the diaphragm as well as reduce the
flow of water past the motor and may cause overheating problems. Suspend the
pump five feet or more above the bottom of the well.
3. 1d Use no larger than 1/2” drop pipe on SDS-D series pumps and 3/4” on SDS-Q
series pumps. Because of the low flow rates the velocity of the water in larger
pipes is not fast enough to carry small particles to the surface. These
particles may settle inside the pump as well as the drop pipe causing pump
damage as well as restricting the flow of water. If there is a known sand
problem, a sand shroud or a screen is required. (Please note that the minimum
well casing diameter for the SDS-D series shroud is 5” and the SDS-Q series
shroud is 6”). Damage to the pump caused by sand will void your warranty. It is

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highly recommended that all pumps be installed with sand shrouds for maximum
pump protection.
3.le Due to the aggressive action of DC power, it is essential that the wire
splice at the pump be made correctly. This splice must be watertight. Improper
sealing of this splice will cause poor pump performance and may cause damage to
the controller. SOLARJACK’S splice kit #S-703 is recommended for this watertight
connection.
3.lf Never install the pump over 60 feet below the static water level. Excessive
water pressure on the pump may cause seal damage and allow water to enter the
motor housing.
3. 1g Never chlorinate a well while the pump is installed. Heavy concentrations
of chlorine will damage the diaphragm and seals.
3.lh Never install the pump in a well that has or has had an oil lubricated line
shaft turbine in it. Any drip oil remaining in the well will damage the
diaphragm and seals.
3.li If the pump is used in a well over l00 feet deep, install a poppet type
check valve on top of the pump. This will help relieve some of the pressure on
the internal check valves and will keep any sediments from falling back into the
pump.
Section 4
TROUBLESHOOTING
4.1 PUMP DOES NOT RUN
4.la Check wiring diagrams for proper connections.
4.lb Check for proper panel, controller, and/or battery voltage
with a volt meter. If our pump controller is being used, a quick look at the
indicator lights will verify power coming from the panels going to the
controller and power coming from the controller going to the pump. If the red
light is on and the green light is not, connect a jumper wire across terminals 6
(PV-) and 7 (LD-). This will bypass the controller and will allow the pump to
run panel direct.
4.lc Check the splice above the pump for proper connections.

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4.ld Check for a broken wire leading to the pump.
4.le Check to see if the water level is above the top electrode, if the low
water cut-off circuit is being used. (Turn dip switch #5 off and switch #6 on to
bypass the low water cut-off circuit.)
4.lf Check for an open motor winding. (With an ohmmeter set on the R x 1 scale
check between the two pump wires. Meter reading should be between .5 and 50
ohms. If the resistance is higher than this, disconnect the pump at the splice
above the pump and check again).
4.lg Check the controller for proper adjustment. If the controller is adjusted
wrong the pump flow rate will be low. If the voltage setting is higher than the
input voltage, the controller will not turn on. (See section 2.4)
4.lh Check to see if the float switch, if used, is functioning properly.
(Disconnect wires from terminals 4 & 5 to bypass the float circuit).
4.2 PUMP RUNS BUT DOES NOT PUMP WATER
4.2a Check to see if the pump is below the surface of the water. 4.2b Check for
holes in the drop pipe.
4.2c Check for a plugged suction screen or pump full of mud, sand, or pipe
cuttings. (If the pump is full of mud or sand, hold the pump upside down in a
bucket of water and allow it to pump until all the mud clears).
4.2d Check for a plugged drop pipe or discharge pipe.
4.2e Check to see if the controller is adjusted properly. (See controller
adjusting procedure section 2.4)
4.3 EXCESSIVE CURRENT DRAW (Over the normal amperage rating of the pump).
4.3a Check wiring diagrams for proper connections.
4.3b Check for skinned wires or faulty underwater splice. (See section. 2. 3d)
4.3c Check for a locked motor armature. (With the pump out of the well, bypass
the controller and connect power directly to the motor leads. If the pump still
does not run and the current is over 1.5 amps, the pump is in a locked or loaded
rotor condition and must be repaired).
NOTE: New pumps will draw slightly higher current for approximately 30 days.
With the new heavy duty bearings and long life brushes the pump goes through a
longer break-in period.

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4.4 DECREASED PUMP OUTPUT
4.4a Check for a plugged suction screen. (Pull the pump and clean the screen).
4.4b Check for holes in the drop pipe.
4.4c Check for a restriction in the drop pipe.
4.4d Check to see if the water level in the well has dropped lower than normal
or below the pump.
4.4e Check for mud or sand packed inside the pump or drop pipe. (If the pump is
full of mud or sand, hold the pump upside down in a bucket of water and allow it
to pump until all the mud clears. If the pipe is plugged with sand, clean the
sand out of the pipe and install a SOLARJACK sand shroud around your pump).
4.4f Check the controller for proper adjustment. A controller being out of
adjustment will cause decreased flow rates. (See section 2.4)
4.4g Check for the correct pump motor polarity. The black motor lead is always
negative and the red motor lead is always positive. If these leads are reversed
increased motor current and decreased pump flow rates will occur.
4.4h Check for dirt on the array or partial shadowing of the array.
4.5 PUMP RAPID CYCLING
4.5a If the low water cut-off circuit or high water cut-off circuit is being
used, check to see if the high and low electrodes have been reversed.
4.5b If a pressure switch is being used, make sure a pressure tank is installed.
4.5c If a pressure tank is being used, make sure the tank is not water logged.
4.5d If a diaphragm pressure tank is being used, make sure the air pressure in
the tank is 2 pounds less than the cut-in pressure, with the tank empty.
WARNING: IF THE PUMP IS DISASSEMBLED USE EXTREME CAUTION AS THE MOTOR HOUSING
MAY BE UNDER HIGH PRESSURE. REMEMBER, THIS VOIDS All WARRANTY.

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