Waterboy MAXI ARRAY User manual

Array Frame Installation
-MAXI ARRAY -

2
Contents
INTRODUCTION.......................................................................................................................................3
Tools required.....................................................................................................................................3
COMPONENT LIST ...................................................................................................................................4
INSTALLATION.........................................................................................................................................7
Footings...............................................................................................................................................7
Set Footing ......................................................................................................................................7
Fastened Footing.............................................................................................................................8
ARRAY BUILD...........................................................................................................................................9
Tube Cap .............................................................................................................................................9
Beam .................................................................................................................................................10
Angle Adjusters .................................................................................................................................10
Rails...................................................................................................................................................12
Sub Frame .....................................................................................................................................12
Upper Frame .................................................................................................................................13
SOLAR PANELS.......................................................................................................................................15
Placing the solar panels on the array................................................................................................15
Solar Module Cable Clips ......................................................................................................................17
Appendix ...............................................................................................................................................18
WARRANTY STATEMENT.......................................................................................................................19

3
INTRODUCTION
Thank you for choosing a Waterboy Pole Mounted Solar Array for your application.
The Waterboy range of pole mounted solar arrays provide a strong, durable and reliable support
frame for your solar modules, with an assembly method that is fast, simple and secure.
Utilising a strong galvanised steel base with a lightweight aluminium support frame, we can offer
strength and flexibility under even the most extreme conditions.
Tools required
•Concrete for footings (Cement, sand, aggregate), shovels, mixer, form work etc..
•Spirit level
•Tek drill
•General spanner set
•6mm Allen key

4
COMPONENT LIST
PRODUCT
NAME
PICTURE
COMMENTS
6x
Aluminium
Rail
1650mm Lengths
8x
Aluminium
Rail
2100mm Lengths
8x
End Clamp
Includes：
M8 Hexagon screw
and fixing nut
12x
Mid Clamp
Includes：
M8 Hexagon screw
and fixing nut

5
24x
Joiner
clamps
Includes：M8
Hexagon screw and
fixing nut
1x
Tube Cap
2x
Angle
adjustment
arm
1x
Beam
1x
Post top
1x
Post Base

6
7x
Aluminium
Rail extender
6x
Square
Bracket
3x
M16 All
Thread
Includes：6x M16
Hexagon nuts
6x
M8x12 Key
bolts
12x
M8x30 Hex
bolt
Includes：M8
Hexagon nuts And
washers
56x
25mm Tech
Screw
PLEASE NOTE –STAINLESS STEEL BOLTS WILL BIND UP OCCASIONALLY
APPLY GREASE ONTO BOLT BEFORE TIGHTENING TO STOP THIS OCCURING

7
INSTALLATION
Footings
There are two common types of array footing, Set and Fastened.
Set Footing
A Set Footing is the most common method for installing the Post Base. It involves setting the large
square base into the concrete footing.
Prepare a posthole min 600mm wide (A), to a depth (B) of 600 –800mm (double the width
measurements for soft sandy ground) and pre pour a thick layer of concrete into the bottom of the hole,
and place the post base onto this.
Ensure post is straight and level before continuing the concrete.
To avoid water sitting around the post base, finish with a tapered water shed (D).
Allow concrete to set.
Once the concrete is set, attach post top to post base with 4 bolts/nuts/washers provided.
Continue to Array Build
B: 600mm –800mm
A: 600mm
C: Pre post
concrete
D: Tapered
water shed

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Fastened Footing
The array post base is designed with the option to be bolted to pre-set bolts in a concrete floor or
block if desired.
Position post over bolts and tighten down.
Attach post top to post base with 4 bolts/nuts/washers provided.
Continue to Array Build
200mm pre-set
anchor bolts, or
sleeve anchor
bolts
or(minimum)

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ARRAY BUILD
Place the Tube Cap on the Pole and position with the two adjuster mounting holes facing south.
Tighten the six M8 key bolts to maintain the correct position, so panels will face towards true North.
Tube Cap
North Facing side
South Facing side

10
Beam
Place the Beam in the Tube Cap flanges and fasten with M16 All Thread and nut.
Angle Adjusters
Place the 2 x angle adjustment tubes between the beam and the tube cap, on the outside of each.
Fasten with the M16 All Thread and nuts once you select the angle desired (see next page). It is
recommended positioning the beam flat for assembly and adjusting for angle once complete.

11
Adjust the angle of elevation by attaching the Adjustment Tubes to the hole positions required
corresponding to the required angle. Please refer to the illustration below.

12
Rails
Sub Frame
Place the 3x sub frame rails (2600mm) across the flanges on the Beam, ensure the mid- point of the
rail is centre to the beam.
Lightly fasten the brackets with M8 bolts, leaving loose at first, then tightening once all 3 are square.

13
Upper Frame
Rail Joiners
The Upper Frame assembly is made up of 4 long rails comprised of 2x 1700mm lengths joined
together as outlined below.
•Mark a centre line on the small joiners
•Slide one end into one length of rail
•Fix Tek screws through the rail and into the joiner (make sure to avoid the screws protruding
into any mounting channels)
•Slide the second rail onto the joiner and repeat as above
•Repeat Tek screws on the reverse side

14
Rail placement
Place the joined rails on top of the sub frame in 4 x places, evenly spaced, and no closer than 10mm
from any edge. Align the centre of the join with the mid-point of the middle Sub Frame rail and
clamp BOTH SIDES with the joiner clamps.
Ensure ALL edges are square and evenly placed before tightening all clamps.
Check and tighten ALL frame bolts and clamps before proceeding.

15
SOLAR PANELS
Placing the solar panels on the array.
Use end and mid clamps to attach solar panels to the rails. Clamps are inserted from above (see
below).
With the array at an angle of 0˚(flat) place the first two panels centre and then place the mid clamps
in position but do not tighten.

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Place the second row of panels and tighten Mid Clamps once everything is square.
Continue with subsequent rows
Fix end clamps on outside of final modules.
Once fitted with the required number of solar modules, be sure to double check tightness of all
mechanical fixings.
Adjust array for optimal angle when complete (see pg. 11)
WATERBOY solar array installation is now complete.

17
Solar Module Cable Clips
For your convenience, the Waterboy range of Solar Array Frames come with cable fastening clips to
secure the solar panel power cables to the modules.
The clips are made from high quality stainless steel and offer a long lasting solution to untidy cables.
They clip directly to the module frame underside edge and are simple to install and remove or
relocate.
Clip to module frame insert cable done!
Clip to the underside of the modules and anywhere suitable on the Array Frame.
Keeps the cables safely tucked up and away.

18
Appendix
Our designs are compliant with the following standards:
GB50009-2001
GB50011-2001
GB/T 13912-92
GBT 14846-2008
GB-T 6892-2006
GB50429-2007
GB50017-2003
AS NZS 1170
ASCE/SEI 7-05
ASCE/SEI 7-010
2007 California Administrative Code
IBC 2006
Euro Code 8
DIN1055
EN 1991-1-3 - Snow Load
EN 1991-1-4 - Wind Actions

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WARRANTY STATEMENT
BW Solar warrants that, subject to the limitations outlined below, the product will, with normal use,
and within the original operating specifications, be free from faulty parts, manufacture or
workmanship during the warranty periods relevant to the products stated below
•Waterboy Solar Water Pump Range - no more than 24 months
•Waterboy Solar Module Array Frame Range - no more than 24 months
•All other Products, including actuators, A/C water pumps and controllers - no more than 12
months
* PLEASE NOTE: ANY DISASSEMBLY or MODIFICATION WHATSOEVER OF THE PRODUCT VOIDS ALL
WARRANTY. *
1. Warranty Limitations
This warranty is limited to the quality and performance of the products provided, BW Solar shall have
no responsibility or liability whatsoever for damages or injury to persons or property, initial or
consequential, or for any other losses (including lost profits) resulting from any cause whatsoever
arising out of or relating to the installation or commissioning of any product sold.
This warranty does not cover products altered, modified or used in ANY WAY not authorized in
writing by BW Solar.
2. Warranty Performance
This limited warranty is applicable only to Customers who have purchased the above products directly
from BW Solar or from an authorized agent of BW Solar. To qualify for this warranty adequate
documentation must be presented to prove that the product was purchased from BW Solar or their
authorized Agent.
For any claims relating to the WATERBOY Solar Pump range, a SYSTEM REPORT FORM must be
returned to BW Solar within 1 Month of the products installation, failure to do so will void this
warranty.
Returned products shall become the property of BW Solar. BW Solar shall have the right to deliver a
different type of product (performing to the same or better operational functionality as the returned
product) if an identical replacement is deemed no longer available or suitable.

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Pumps - All wearing parts of the Pump that are in contact with the pumped liquid, such as rotor,
stator, impeller, guide wheel, valves, vanes, bearings, seals etc., are not covered by this warranty.
BW Solar Pumps are designed for pumping water potable for humans and animals, not containing
solid or long fibred particles larger than sand grains. Max sand content: 50 g/m3, max salt content:
300-500 ppm at max. 30° C. Defects due to pumping other liquids are not covered by this warranty.
Negative head on the pressure side of any BW Solar submersible pump will void warranty of pump
and motor. Pumps with a centrifugal pump end require a minimum positive head as specified in the
product information sheets.
Any alteration, damaging, removal, or other changes leaving the serial number or identification plate
illegible or obscuring the identity and date of production of the product, will void this warranty.
If product has been modified, remanufactured or tampered with in any way the claim will be rejected
and sent back at the customer’s / Agents expense. (NO EXCEPTIONS)
Array Frames –All Array frames, built or sold by BW Solar are compliant with current structural
and loading ratings and are only to be used and installed as per instruction manuals provided. ANY
alteration on design or installation voids all warranty. Any overloading of array structure and/or
components are NOT covered under this warranty.
3. Costs
All costs incurred in obtaining warranty are the responsibility of the customer or Agent, including but
not limited to, shipping and handling, travel expense, lost time, lost production, or pickup and
delivery and return shipment.
4. Agents Responsibility
•The Agent must supply their customer with all documentation relating to installation and warranty
and, if installing, must complete and submit the SYSTEM REPORT FORM on behalf of their customer.
•The Agent shall maintain a sufficient inventory of replacement parts to promptly satisfy their after
sales service and customer needs.
•The Agent is responsible for any warranty requirements of their customers.
•The Agent must not make any unauthorized modifications or alterations to the product.
•The Agent may not make any warranties on behalf of BW Solar which have not been authorized in
writing.
5. Validity
This limited warranty shall be valid from 1 September 2015 and shall apply to the above mentioned
BW Solar Products sold to the Customer or Agent from this date, replacing and making void all
previous warranties issued by BW Solar.