SHERVEY SOLAR PUMP PMP5040 Mk2 – Complete Bundle with 600watts of Solar User Manual

SHERVEY SOLAR PUMP PMP5040 Mk2 – Complete Bundle with 600watts of Solar

Parts List:

• Pump
•  Controller
• 40m pump cable
• Solar array to suit pump model purchased
• low good sensor with 40m cable
• Solar fly lead
• Solar Combination 3m lead for 72V pumps only
• User manual and installation guide

Optional Extras:
Ground mount frames for the solar array
Bore Cap – ¼” or ½”
Additional submersible cable in 10m lengths
Pressure switch kit
Dam float kit
Recommended extra items for installation:
6mm silver rope with a clip as a pump safety rope
Duct Tape, 4.5 x 200mm UV stable cable ties, poly fittings
How it works:
The solar pump controller uses the energy from the solar panel to directly drive the pump. This allows the pump to continuously pump water during daylight hours. Both the controller and pump motor are optimized for solar power and will even run the pump when the weather is cloudy.

Benefits and Features

• MPPT solar pump controller, to get the maximum power from the available sunlight
• Highly efficient DC brushless motor
• Stainless steel construction
• Very low maintenance
• Variable speed control to adjust the water output
• Extra-low voltage for safe and easy DIY installation
• No Electricity or fuel costs
• Local service and support for your pumps
• Environmentally friendly

Safety Precautions

• Do not disconnect the solar cable while the pump is running

• Do not short circuit panels as damage may occur to the panels

• Do not short circuit solar leads when panels are connected, as this may cause arcing and melting of the terminals

• Do not short circuit controller output leads as this may cause damage to the controller and or pump
  Do not attempt to touch any exposed moving parts, as this may result in severe injury

• Make sure that the panels are disconnected before attempting to work on your pump

Before You Begin

• Read this manual thoroughly
• Open the box and make sure all parts are present
• Make sure you have the tools you will need
• Have a clear space to work in

Setting Up Your Pump

• Make sure that the poly fitting is the correct thread size for your pump
• Use plumbers thread tape when inserting your poly fitting for a good seal
• Screw the fitting into the pump outlet and attach the poly pipe
• Do not overtighten the fitting into the pump
• Make sure that the well low sensor is between 500mm and 1 meter above the pump then duct tape the sensor body to the poly pipe with the cable exiting upwards
• Lay the poly pipe, pump cable, and well low sensor cable straight along the ground
• Duct tape them in a neat bundle every meter making sure that there is no tension on the pump cable at the pump end
• Terminate your poly pipe at the bore cap (if you are using one) and make sure the cables are in the slot of the bore cap
• Attach your safety rope to the stainless-steel eye bolt and lay along the pipe and cable but not attached to it
• Lower the pump into the water and commence wiring the controller

Wiring the Controller

1. Remove the front cover being careful not to pull on the cable to the indicator lights.
2. Look carefully at the picture of the controller mainboard and take note of the lettering. (on next page)
3. Set the speed control (A) to the ‘Full’ speed position.
4. Feed the PV (Solar) Fly lead through the solar cable entry (F) making sure the solar panels are not connected yet.
5. Connect the solar positive cable to the terminal marked P+, and the negative to P- (B) and tighten the screws.
6. Feed the 3 pump wires through the cable entry marked (G).
7. The pump cable wires are marked U, V and W. Make sure they are connected to their corresponding terminal. i.e.: Wire U to Terminal U as per (C) and tighten the screws
8. If using a Pressure Switch, remove the red bridging wire at the terminals marked TC and TH (D)
9. Feed the Pressure Switch cable through the entry marked (G) and connect the two wires to the two terminals (D) polarity is not important for the sensor.
10. If using a Low well Sensor (recommended) Remove the red bridging wire at the terminals marked WC and WH (E)
11. Feed the Low Well Sensor cable through the entry marked (H) and connect the two-wire to the two terminals (E) polarity is not important for the sensor

Please Note! The pump Controller must be installed in a vertical position and at a height that will prevent inundation or submersion in water or other liquids. The controller must have adequate ventilation airflow. Incorrect installation may cause failure and as such is not covered under warranty. Ensure that the cable entries (F), (G), and (H) are well sealed to prevent ants and other insects from entering the controller.

Wiring your Solar Panels:

• (FAILURE TO FOLLOW PROCEDURE MAY CAUSE TERMINAL DAMAGE AND VOID WARRANTY)

PMP5020 (24V)

• 1 x 300w panels are recommended. Wire them in series as shown.

PMP5040 (48V)

• 2 x 300w panels are recommended. Wire them in series as shown.

PMP5080, PMP5100, PMP6070 & PMP6090 (72V)

• For a 72V Pump: 6 x 300w panels are recommended.

3 IN SERIES .2 IN PARALLEL

• Technical parameters for controllers 72V Controller Maximum open circuit voltage is 150V DC

(MULTIMETER RECOMMENDED)

24V controller Maximum open circuit voltage is 63V DC

Operating the Pump

• Ensure that the pump has been submerged in water for at least 15 minutes prior to start-up
•  Make sure the panels are in full sun with no shading
•  Make sure the main switch inside the pump is in the Solar position and the switch under the controller body is in the on position
• The Power Available light and Motor Running Light should be on. The Optimising Solar light will flash intermittently
• The pump has a soft start function and will start after 6 seconds, it will then spin up to speed over the following 6 seconds
• If everything is set up correctly you should see water coming out of the delivery pipe soon.
• If there is no water output, please see the troubleshooting guide
• The Low Well Sensor will be on if there is insufficient water in the bore. Once the water level rises above the sensor the light will start blinking. This continues for 30 minutes and then the pump will restart. This allows the bore to recharge.
• Take careful note of the dos and Don’ts below Make sure that water can flow over the motor for cooling. If you are unsure mount the pump in a pump shroud to guarantee proper motor cooling

Do’s and Don’ts:

• Do keep the pump underwater at all times when running
• Do be careful with the wiring
• Do remove the pump from the water if it will be unused for a long period. Wipe the screw and the pump body down with vegetable oil for storage
• Do Install the pump in a vertical position
• Do Keep your pump 1 to 1.5 meters off the bottom of the bore if possible.
• Do Periodically inspect your pump and wiring
• Do Keep your pump running as long periods of inactivity can be detrimental to the rotor and stator
• Do make sure to keep the controller free from insects such as ants and wasps
• Do Keep your solar panels clean
• Don’t run the pump out of the water even for a second as it will cause permanent damage and void your warranty.
• Don’t submerge the pump any deeper than 35 meters from the surface of the water
• Don’t bypass the well low sensor except for troubleshooting.
• Don’t use the pump in excessively dirty water as it will cause premature rotor wear which is not covered by the warranty. The maximum suspended particle size is 0.1mm and only up to 1% concentration of total water volume
• Don’t use the pump in excessively salty or acidic water. Recommended PH is 6.5 – 8.5
• Don’t disassemble the controller as there are no user-serviceable parts inside.
• Don’t open the bottom of the pump
• Don’t attempt to disassemble the pump body
• Don’t Remove the drain plug on the top of the pump body, doing so will void your warranty

Trouble Shooting

• Please use the following guide to assess and solve any problems you may have, that were not previously discussed in this manual.

external switch are on Make sure solar panels are correctly connected

Make sure that the cable from the LED strip in the lid is plugged into the mainboard

Check that you have the correct voltage from the solar panels

The lights are on but the pump does not run| Check that the pump cable wires are connected correctly and screwed down tight

Make sure that the speed control is on Full speed

The first three lights are green and Tank Full light is on and the pump does not run| If there is a tank full sensor or pressure switch the tank may be full.

Make sure the external switch is turned on

The first three lights are green and Low Well light is on and the pump does not run| The low good sensor has been activated and turned the pump off due to insufficient water in the bore

Check that the Low Well Sensor wires are correctly connected, and terminals are tight

Foreign matter may have entered the Low Well Sensor, pull up the pump and low good sensor and clean the sensor

The first three lights are green and Low Well light is blinking and pump

does not run

| The Low Well Sensor has been activated and now the water is back above the sensor. The light will blink for 30 minutes and then the pump will restart.
The pump is running but no water comes out| If the pump appears to be sucking water down, open the controller and switch the U and V wires

The rotor and stator may be worn, pull up a pump and replace the rotor and stator with the correct replacement parts (the rotor and stator are wearable parts and the service life of the rotor and stator is heavily dependent on water quality)

The pump is working but the output is decreased or not lifting water as high as previously| Make sure that the solar panels are not shaded at all Make sure the solar panels are clean

Check the rotor and stator, if they are worn, replace them

The first three lights are green and Low PV light is on and the pump does not run| Very heavy cloud cover will cause low power Check that the speed controller is set to Full speed

Make sure that the panels are not shaded even by a single branch

Check rotor and stator. Sometimes the rubber of the stator can swell from long periods of inactivity or if the water is acidic.

You have checked the pump manually and are still not able to get the pump working| Contact Survey Pumps for further information

Limited 12 Month Warranty or 3 Years with Online Registration

1. Shervey Solar Pumps extends only to original consumer purchase, a limited warranty against defects in material and workmanship for a period of 12months from the date of purchase. This warranty covers the pump, controller, and sensors. Warranty can be upgraded to a longer period, free of charge with the completion of our online warranty registration. This free upgrade must be submitted within 30 days of purchase. Proof of purchase will be required for all warranty claims and a copy must be submitted with the item.
2. Shervey Solar Pumps or an authorized factory representative will repair, or at its option replace any defective part or parts of the product free of charge. In the event of a malfunction, the purchaser must return the product to Shervey Solar Pumps at their expense. The warranty is limited to the repair or replacement of the product and the manufacturer or its dealers disclaim all liability for indirect and or consequential damages including any installation charges.
3. The warranty does not apply when the equipment has not been installed as per the instructions or damage has occurred through abuse, carelessness, improper voltage or it has been serviced by anyone other than an authorized factory representative.
4. A purchase receipt or invoice for proof of purchase must be presented to claim the warranty.
5. All repairs not covered by warranty or outside the warranty period will be charged at normal rates.
6. Corrosion due to salty/acidic water supplies, or microbial-induced corrosion is not covered under warranty.6a. All corrosion claims must be accompanied by a water sample of at least a liter from the bore in question. Testing of the sample is at the owners’ expense and at the present time costs approximately $350. If you wish to have independent testing done contact us for a list of things that must be tested for.
7. Helical screw rotors are considered a wearable part and are not covered under warranty.
8. Please contact Shervey Solar Pumps at www.sherveysolarpumps.com for a return authorization before sending any goods.

References

• Shervey Solar Pumps – Shervey Solar Pumps
• Shervey Solar Pumps – Shervey Solar Pumps

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>