Backwoods Solar P-BW-4AC-7-640 Submersible Pump With Controller Solar Pump User Manual

P-BW-4AC-7-640 Submersible Pump With Controller Solar Pump

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Specifications

AC/DC Pumps

– Multistage centrifugal type pump with radial impellers
– Stainless steel impellers and components
– Maximum permitted amount of sand: 120 g/m3

Helical Pumps

– High efficiency for low flow and high head applications
– Special wear-resistant screw and rubber stator
– Not recommended for use in dirty/sandy water
– Recommended for water temperatures up to 86 degrees
Fahrenheit

Pump Motor

– Innovative design for AC/DC power sources
– Maximum input power: 2,800W
– Motor speed range: 0 rpm to 3600 rpm
– Rare earth permanent magnets
– Built-in electronic control via frequency converter

Product Usage Instructions

AC/DC Pumps

– Ensure the pump and motor are directly connected with a rigid
coupling
– Check that all components are made of stainless steel for
durability
– Do not exceed the maximum permitted amount of sand (120
g/m3)

Helical Pumps

– Use in applications requiring high efficiency for low flow and
high head
– Avoid using in water containing sand or impurities
– Operate in water temperatures up to 86 degrees
Fahrenheit

Pump Motor

– Connect the motor to both AC and DC power sources as
needed
– Ensure maximum input power does not exceed 2,800W
– Use the built-in electronic control for optimal pump
performance

FAQ

Q: Can the AC/DC pumps be used with both AC and DC power

sources simultaneously?

A: Yes, the innovative design allows the pumps to be powered by
both AC and DC sources depending on availability.

Q: What is the maximum permitted amount of sand for the AC/DC

pumps?

A: The maximum permitted amount of sand is 120 g/m3.

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1

CONTENTS
AC/DC Pumps Introduction…………………………………………………………………………4
Construction Features of Centrifugal Pumps…………………………….5 Construction Features of Helical Pumps……………………………………..6 Construction Features of the Pump Motor…………………………………….7 Controller Functions and Features…………………………………………………….. 8 Controller Installation……………………………………………………………….9 Controller Operating Instructions………………………………………….10 Technical Specifications……………………………………………………11 Flow Meter and Generator Dry Contact………………………………….11 System Installation Options……………………………………………..12-14 Electrical Connections……………………………………………………15-16 Dimensions (controller & motor)…………………………………………. 17 Solar Panels………………………………………………………………………18 Solar Panel Installation ………………………………………………….. 19 Solar Panel Wiring ………………………………………………………… 20 Solar Pumps Installation Notes……………………………………………….21 Water Source and Pump Installation Options……………………………21 Important Precautions…………………………………………………….. 22 Wiring………………………………………………………………………..23 Troubleshooting……………………………………………………………..24
DC Only Pumps Introduction……………………………………………………………………….25
Features and Protections………………………………………………….25 Pump End…………………………………………………………………..26 Motor…………………………………………………………………………26 Controller…………………………………………………………………………..27 LED Lamp Instructions In Panel…………………………………………….27 Electrical Connections For Centrifugal Pump…………………………….27 Electrical Connections For Helical Pump…………………………………28 Direction Of Motor Rotation…………………………………………………28 Alarm and Fault Codes………………………………………………………..29 System Installation Diagram…………………………………………………….30
2

System Installation …………………………………………………………………………………. 31 Water Source…………………………………………………………………………. 31 Pump Installation ……………………………………………………………………. 31 Heat Dissipation Requirements For Pump Installation………………….. 31 Installation Of Float Switches……………………………………………………. 32 Pressure Switch And Mechanical Floats…………………………………….. 32 SPD (Surge Protection Device) ………………………………………………… 32 Controller Installation ………………………………………………………………. 33 Distance Between Controller and Pump …………………………………….. 33 Check Valves …………………………………………………………………………. 33 Wire Splicing ………………………………………………………………………….. 34
Solar Array Installation ………………………………………………………………………… 35 Warning ………………………………………………………………………………… 35 Solar Panel Glossary of Electrical Terms……………………………………. 35 Solar Panel Wiring ………………………………………………………………….. 35 Motor and Controller Input Energy Limitations:……………………………. 36 Solar Array Installation Considerations: ……………………………………… 36
3

AC/DC Pumps Introduction
The Backwoods Solar line of solar pumps provide a supply of clean water based on the most widely available renewable energy, the Sun. With electric power supplied by a series of photovoltaic panels and a Centrifugal or Helical Submersible Pump with a built-in inverter type controller, the system can ensure a continuous draw of water from a suitable source even when solar irradiation conditions may vary. The permanent-magnet motor’s high efficiency means a smaller number of solar panels are needed in order to work. Backwoods Solar pumps are designed for easy use and require no maintenance. They are the ideal solution for supplying water in remote areas where grid power is inconsistent or completely unavailable. Centrifugal pumps feature dry-run protection so no additional protection is needed. When the pump runs dry for 10 seconds it will stop and then try again after 1 minute. If it does not sense water again it will stop and attempt to run again after another 30 minutes. Helical pumps feature a run dry protection sensor that has been integrated in the power cable. During installation, the water surface must be above the sensor. When the water surface drops below the sensor position, the pump stops immediately. The pump will resume operation 10 minutes after the water level covers the sensor again. .
4

Construction Features of Centrifugal Pumps
Multistage centrifugal type pump with radial impellers. Pump and motor directly connected with a rigid coupling. Stainless steel impellers fitted on floating clearance rings made of synthetic low abrasion material, and polymer diffusers that impart significant wear resistance to the pump.
The pump liner, shaft and coupling, strainer, and cable sheath are made of stainless steel. Base support and upper head is microcast AISI 304 stainless steel. Check valve incorporated in the head.
The innovative wet end design gives the pump superior sand handling capabilities and provides maintenance free operation. Maximum permitted amount of sand: 120 g/m3.
Materials

NO PART*

1

Discharge chamber

2

Non-return valve

3

Guide vanes

4

Pump Shaft

5

Impeller

6

Impeller fastener

7

cable cover

8

Inlet part

9

Shaft coupling

10 Upper Bearing Housing

11

Upper Bearing

12

PM Rotor

13

Stator

14

Pump Housing

15

Thrust bearing

16

Lower Bearing

17 Lower Bearing Housing

18

PCBA

19

Controller Housing

20

Radiator

21

Inductor

22

Base

MATERIALS
Stainless steel Stainless steel PC/Stainless steel Stainless steel POM/Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Silicon Carbide
– – Stainless steel Graphite Silicon Carbide Stainless steel – Stainless steel Aluminum – Stainless steel

5

Construction Features of Helical Pumps
Helical pumps provide high efficiency for low flow and high head applications. These pumps feature a special wear-resistant screw and rubber stator for long service life. However, due to this construction design, performance and service life of the pump will be seriously reduced in water containing sand or other impurities. Do not use Helical pumps in dirty/sandy water! Backwoods Solar will not warranty Helical pumps used in these conditions.
Water temperature will affect pump performance. Pumps are recommended for use in water temperatures up to 86 degrees Fahrenheit.

Materials

NO
1

PART*
Floating ball

2

Non-return valve

3

Rubber stator

4

Screw shaft

5

Transition Festival

6

Supporting tube

7

Intake section

8 Upper Bearing Housing

9

Upper Bearing

10

PM Rotor

11

Stator

12

Pump Housing

13

Thrust bearing

14

Lower Bearing

15 Lower Bearing Housing

16

PCBA

17

Controller Housing

18

Radiator

19

Inductor

20

Base

MATERIALS
Stainless steel/PC Stainless steel
Rubber /Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel Silicon Carbide – – Stainless steel Graphite Silicon Carbide Stainless steel – Stainless steel Aluminum – Stainless steel

6

Construction Features of The Pump Motor
Innovative design allows the AC/DC pumps to powered by both AC and DC power sources. All AC/DC pumps with a maximum of 2,800W input (P1) use the same motor. Motor speed range is 0 rpm to 3600 rpm depending on the power input and load.
Motors uses rare earth permanent magnets and feature built-in electronic control via a frequency converter and motor controller. Vector control and MPPT are used to select the best operating point for the pump based on the energy available from the input source. The motor can be supplied with either AC or DC power. (see below) Note: Maximum axial thrust 3000N. Maximum Input power (P1) 2.8 kW.
The motor is sealed by welding and uses an encapsulated water filled design, ensuring high efficiency, clean and pollution-free operation. Maximum submersion depth is 150m.
The Solar Motor is capable of the following functions: 1. Powered by AC/DC 2. MPPT High Efficiency 3. Run Dry protection 4. Reverse Polarity protection 5. Over-Pressure protection 6. Over-load protection 7. Over-current protection 8. Missing-Phase protection 9. Low voltage protection 10. Over power protection

Motor Energy Input Capabilities

Voltage 60 ­ 380Vmp/440VOC 90 ­ 240V AC

Current 12A DC (ISC) 10A AC

Energy DC ­ Solar or Battery AC ­ Grid, Generator, or Inverter

7

Controller

The controller is not a mandatory part of the pump system but it provides more functions and protections for the pump, making the system more convenient and intelligent. Functions include intelligent switching of AC/DC power supply, float switch terminals, and power display. The controller is suitable for outdoor installation and is weather-proof but installing it in direct sunlight should be avoided.

Functions and Features

The Controller is capable of the following functions:

1. Display input power AC / DC

2. Tank full / tank empty display

3. Intelligent Modes (Three modes can be selected)

AC MODE – The incoming power can be from the grid, generator, or inverter

DC MODE – The power supply can be from either Solar Panels or Battery

AUTO MODE – Intelligent switching between AC and DC power supply, DC first

4. Manual Pump ON / OFF switch

Dead-head/no flow conditions protection (with Flow Meter)

6. Lightning and surge protection

7. Over-voltage protection 8. Automatic start and stop of generator

Controller features:
· The controller has inputs for two float switches · The “TWL” signal tells the controller that the reservoir/tank is full and at this point
the controller stops the pump. When the water level of the storage tank drops, the float drops and the pump returns to operation after 10 minutes. Within the 10 minutes, the “TANK FULL” signal light remains on and the display starts counting down from “600” to “0.” When the countdown ends the “TANK FULL” indicator goes off and the pump restarts. · The “WWL” signal tells the controller that the reservoir/tank is empty and the controller starts the pump. When the water source runs low on water, the float drops and the “TANK EMPTY” indicator light illuminates and the pump system immediately shuts down. When the water level rises, the float rises and the pump returns to operation after 10 minutes. Within the 10 minutes, the “TANK EMPTY” signal light remains on and the display counts down from “600” to “0”. The “tank full” indicator goes off and the pump system restarts when the countdown is over.
6. AUTOMODE
7. AC MODE

1. Display Input power
2. Power AC 3. Power DC

11. Button to switch between AUTO MODE, AC mode, DC mode
8. DC MODE

12. Button to switch between PUMP ON,
PUMP OFF

4. Tank Full

5. Tank Empty 9. Pump Off 10. Pump On

8

Controller Installation
WARNING · The power supply from any DC or AC supply can cause serious harm or death from electrocution. · Apply appropriate safety procedures when working on or with any system component. · Only suitably qualified personal should be involved in the electrical connection /
disconnection and handling of the equipment. Electrical equipment is subject to applicable state, national and country electrical standards. · The Solar Motor contains capacitors that must be allowed to discharge before handling · Allow a minimum of 1 MINUTE for stored energy to dissipate before handling the motor. · The Solar panels will create electrical energy when exposed to light. Assume all cables are “live” at all times, and handle with appropriate safety equipment and procedures.
Caution Disconnect all electrical sources before installation, servicing or repair of any components in the system. The controller is used to switch AC and DC power supplies and can automatically start a connected generator, or switch between DC or AC power sources at ANY time. Ensure all energy sources and generator starting circuit are properly locked-out before working on the system.
Electrical Component Selection When using DC power all electrical components (wires, fuses, breakers, etc) MUST BE selected according to the input power available, and rated for DC POWER.
Controller Installation The controller is IP65 rated, however it is recommended that the controller is not mounted in direct sunlight. Mounting the controller behind the solar panel array is a good way to protect the controller. Grounding As most solar installations are off-grid, particular attention must be paid to grounding the controller and pump motor. Follow the instructions in the controller manual and electrical requirements for your area.
Switching Between DC and AC Power The controller allows you to manually switch between DC power supply and AC supply, or the controller will auto-select when in AUTO mode. During the switch over, the internal controller in the pump motor runs through an automatic discharge process to dissipate the electrical charge contained in the capacitors in the motor. This process takes approximately one minute and cannot be sped up. If the pump is not running when there is a suitable input power supply, check the display panel to see if the changeover is taking place before further investigation.
The controller is biased to DC supply when in Auto mode.
9

Controller Operating Instructions

1. 2. 3. 4. 5. 6. 7.
i.
ii.
iii.
8.
i. ii. iii.
9. 10.

Before operating the system perform a visual inspection of the installation for damage from weather events, livestock, pests, or human interference. Solar panels should be clean and not in shade. All wiring must be terminated, with no bare wires exposed. Check the pump is completely submersed, and below the surface of the water source. Turn any isolator switches to the ON position. Open all valves. AC supply present (if connected) is indicated by LED light on controller1
DC Supply present (solar/battery if connected) is indicated by LED light on controller2
Make sure the generator (if connected) is topped up with fuel, generator starts and runs on demand. and is connected to controller via the “GEN Signal” wire.
Select the controller mode. Press the top button on the right-hand side of the controller to cycle through the operating modes. Modes are indicated by the LED light on the display panel. AUTO MODE3 ­ Controller selects the power source to run the pump depending on
AC or DC availability. DC power is primary when available. When the system is using
AC power, the AC LED light pulses in 30 sec intervals. When the system is using DC
power, the DC led light pulses in 30 sec intervals.
AC MODE 4- Controller only uses AC power to run the pump, provided power is available. Only one AC power supply can be connected at a time! Either grid, generator or inverter. DC MODE5 – Controller only uses DC power source to run the pump, provided power is available. CAUTION ­ When switching between modes, the motor needs to dissipate the
energy stored within its internal capacitors. This process takes 1 minute. Repeated switching between modes will restart the dissipation cycle, causing extended delays before the pump will run. Push the PUMP ON button on the bottom left-hand side of the controller. LED6light
indicates the pump is on. The controller starts counting down and after 120 seconds it
will start pump using selected power supply, provided the following conditions are met:
The input energy is sufficient to run the motor Motor has finished power dissipation cycle, if required The input signals indicate the unit should run. These include: a. WWL ­ Well Water Level is “open” indicating sufficient water around pump (when
installed) b. TWL ­ Tank Water Level indicates tank requires filling (when installed) c. TWL ­ Pressure switch indicates system pressure is low (when installed) d. TWL is bridged, meaning pump runs when input energy sufficient. To stop pumping, push the PUMP OFF button on the bottom right-hand side of the controller. LED7 light indicates pump is off.
When finished using the system, turn all electrical isolating switches and valves to the off position.

10

Controller Technical Specifications
· The controller is designed for simultaneous AC and DC incoming power supplies and is manually switchable between AC and DC power, or automatically switchable depending on solar irradiation.
· IP65 weatherproof enclosure. · Suitable for up to 2.2 kW (3 HP) pumps. · AC voltage input 120 or 240 VAC. Terminals L N & GND · DC voltage input range 60­380Vmp / 440Voc. Terminals + – & GND · Input connections for 1 or 2 float switches. TWL & WWL
· Input connection for pressure switch. TWL
· Input connection for flow meter. FLOW SIGNAL -> REF. Setting flow meter function (on this page)
· Power on, input power, pump on, pump off, water tank full or tank empty indicator LEDs · Auto operation via 1 or 2 float switches. · Auto operation via pressure switch. · Auto off via flow meter. · Auto starting of generator (if generator supports auto gen start). GEN SIGNAL · Manual operation. · Auto switching from AC to DC supply with DC bias. DC switching point is 40V.

Note: Faulty wiring can cause serious damage or death. Please refer to page 10 for wiring.

Flow Meter and Generator Dry Contact switch and knob settings
Flow Meter Water flow of solar pumps will change with solar input power. When sunlight is weak and the power is insufficient, the pump may run continuously but not have enough power to push water to the desired output. It can also happen if there is a blockage in the output pipe. This is called a “dead-head” and water temperature in the pump and pipe can rise, reducing the service life of most pumps. Backwoods Solar pumps are designed to withstand dead-heading with no effect on their service life, but there are times when someone may want to avoid dead-heading. Installation of a flow meter will help prevent this. When there is no water flow in the flow meter, the controller will stop the pump and then resume operation after a specified time. The delay time is adjustable via a knob in the controller. Generator Dry Contact The controller can auto start and stop a generator. It can turn the generator on based on solar input, and minimum run time can be set via an adjustment knob in the controller.

Controller Switches

Optional Flow Meter

Switches: Set switch 1 to “OFF” if a flow meter IS NOT installed. Set switch 1 to “ON” if a flow meter IS installed.
Set switch 2 to “ON” to turn on the generator automatic start/stop function. Set switch 2 to “OFF” if not using the automatic generator start/stop function.

Flow Meter Terminal wiring: The wiring order for the flow meter is redyellowblack. Incorrect wiring may cause system malfunction.
Adjustment Knobs: The upper knob adjusts the dead-head recovery time, in 10-minute increments. The 0 setting disables shutdown. The lower knob is the minimum run time of the generator, in 10-minute increments. The 0 setting runs for 3 minutes.

Dead-Head Recovery and Generator Run Time Adjustment Knobs

Flow Meter Terminal

11

System Installation Options
1. Float Switch without Controller
Note: 1The above Solar panel power supply can be directly replaced by battery or AC
power. When AC power is selected, the input power can be utility power grid, generator, or inverter. 2Panel Max Voltage: 380Vmp/440Voc DC Voltage: 60-380VDC AC Voltage:120/240VAC
12

System Installation Options
2 With Controller and Electronic Float Switch
Controller
.
13

System Installation Options
3 With Controller, Mechanical Float Switch and Pressure Tank
Controller
Note: The mechanical float in this system must be used with the pressure switch, and the pressure switch must be adjusted to the appropriate pressure range. If not installed correctly it may cause the pump to stop abnormally and may cause the pipe to burst.
14

Electrical Connections
1. With One Float Switch.
TWL = TARGET TANK WATER LEVEL WWL = WELL WATER LEVEL
2. With Two Float Switches
TWL = TARGET TANK WATER LEVEL WWL = WELL WATER LEVEL FOR ALL WIRING OPTIONS ONLY ONE AC INPUT SOURCE CAN BE USED BY THE CONTROLLER ­ USE GRID/INVERTER or GENERATOR unless the Generator has an Auto Transfer Switch (ATS) to manage the switch over. Consult your Generator manual.
15

Electrical Connections
3. With Pressure Switch
4. No Switches
GENERAL NOTES FOR ALL SET UP CONFIGURTIONS NORMAL PRESSURE SWITCH CONNECTS TO TWL REVERSE ACTING PRESSURE SWITCH GOES ON WWL WITH A JUMPER ON TWL GENERATOR CONTACT WILL CLOSE IF NO AC INPUT AND DC INPUT DROPS BELOW 90V.
FOR ALL WIRING OPTIONS ONLY ONE AC INPUT SOURCE CAN BE USED BY THE CONTROLLER ­ USE GRID/INVERTER or GENERATOR unless the Generator has an Auto Transfer Switch (ATS) to manage the switch over. Consult your Generator manual.
16

Dimensions
Controller
Dimensions: 267mm (H) x 180mm (W) x 86mm (D); Weight 1.4 kg Motor
Dimensions: 662mm (H) x 99mm (Dia); Weight 12 kg 17

Solar Panels
For DC operation, power supplied by solar panels is required: Motor is rated for 60 ­ 380Vmp / 440Voc, 12A.

WARNING:

Panel combinations must NOT exceed the Solar Motor input limits

DC Volts Max: 380Vmp/ 440Voc

DC Amps Max:12A Isc

AC Volts Max: 240V

AC Amps Max:10A

Exceeding these limits may cause serious harm or irreparable damage to

the motor and Controller, as well as voiding the warranty.

Recommended solar panel power for the Backwoods Solar Pumps:

Motor
Power(kW) 0.37 0.55 0.75 1.1 1.5 1.8 2.2

Motor Power(kW)
0.5 0.75
1 1.5
2 2.5 3

Recommend Photovoltaic.
Power(kW) 0.6 0.75 1 1.5 2 2.5 3

Connection
In Series In Series In Series In Series In Series In Series In Series

. .

18

Solar Panel Installation
WARNING ­The power from Solar Panels can cause SERIOUS HARM or DEATH from electrocution. – Use appropriate safety procedures when working on or with any system component. -Only suitably qualified personal should be involved in the electrical connection / disconnection and handling of the equipment. – Electrical equipment is subject to applicable state, national and country electrical standards. -Solar panels will generate electrical energy when exposed to light. Assume all panel cables are always “live” and handle with appropriate safety equipment and procedures. General Notes: In North America (and all northern hemisphere locations) mount the solar panel(s) facing due South. The solar panel’s angle from horizontal should match the location’s latitude. For example, Sandpoint, Idaho’s latitude is 48.3 degrees North. Solar panels in Sandpoint should be mounted approximately 48 degrees up from horizontal.
Solar availability As a general rule-of-thumb panels will receive approximately 3.5 hours of solar irradiation during winter months. Actual average sun hours for geographic regions are available from NASA or your local weather service. If using your pump year-round, base your pump calculations on minimum WINTER energy availability.
19

Solar Panel Wiring
Series Wiring
To wire solar panels in series, the positive of one solar panel is wired to the negative of the next solar panel. In this case: Sample panels are 300W, 8.64Isc, 44Voc and 37.6Vmp each.
· Output voltage is multiplied by the number of panels. 4 x 44Voc = 176Voc · Output voltage multiplies by the number of panels. 4 x 37.6Vmp = 150.4Vmp · Output watts are multiplied by the number of panels. 4 x 300W = 1200W · Output amps remain the same as a single panel. 8.64 Isc (A)
A group of panels wired in series as above is called a string. Note: in any combination, output Volts and Amps must not exceed stated limits.
20

Solar Pump Installation Notes

Water Source and Pump Installations Options

For Helical pumps the water source must be clean water, free from contaminates such as, dirt, dust, loose rocks, decaying organic matter, and other foreign bodies that could block the intake screen or foul the impeller stack. For Centrifugal pumps, sand content cannot exceed 120g/m3 of water pumped.

Pumps can be installed in any orientation vertically to horizontally. In all installation positions the motor must be fully submerged with a minimum water flow across the motor during operation of 8cm/sec before entering the pump intake.

To induce the correct water flow across the motor, use of a flow inducing sleeve

should be used when:

·

Well diameter is too large relative to motor diameter to induce correct flow.

·

Motor and Pump are in open water

·

Motor and Pump are in a rock well or below casing

·

The Bore is top feeding (water enters intake without passing over motor)

·

Motor and Pump are set in screens

WARNING – The power from any DC or AC supply can cause serious harm or death from
electrocution. Apply appropriate safety procedures when working on or with any system component. – Only suitably qualified personal should be involved in the electrical connection, disconnection, and handling of the equipment. – The pump motor contains capacitors that must be allowed to discharge before handling. Allow a minimum of 1 MINUTE for stored energy to dissipate before handling the motor. – Solar panels generate electrical energy when exposed to light. Assume all panel cables are always “live” and handle with appropriate safety equipment and procedures.
Caution
Isolate all electrical sources before commencing any installation, servicing, or repair of any component in the installation. The Controller is used to switch AC and DC power supplies and can automatically start a connected generator or switch between DC (Solar) or AC (Generator/Grid) power sources at ANY time. Ensure all energy sources and the generator starting circuit are properly locked-out
before working on the system.

21

WARRANTY The following Warranty conditions shall apply to the solar pump installation. Backwoods Solar shall not be held responsible for damage caused by improper installation, use Controller or level controls which are not approved. 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.
Important Precautions
1. Damage to pump or motor caused by abrasive or corrosive water is not covered by the Warranty. Verify your water source before installing any pump to ensure pump suitability.
2. The water source must be clean before pump installation. The pump must not be used to bail a new bore.
3. Be sure voltage and frequency as shown on the nameplate of the Controller and motor are the same as the voltage and frequency on the line to which the motor is to be connected. Voltage at the motor must be 60 to 380Vmp/440Voc or 120/240VAC.
4. In addition to the check valve built into the pump, it may be necessary to install an additional check valve. This is mandatory for heads greater than 80 meters, or on pressure systems. This will reduce water hammer shocks to the pump.
5. Know the total depth of the bore and ensure that the pump does not rest on the bottom or in sand. Ensure 1.5 meters (5 feet) clear below the pump to the bottom of the bore.
6. Know the water level of the bore and ensure that the pump remains submerged at all times. Use of a level controller is recommended. If probe type is used, the probe should be located to switch the pump off when the bore water level drops within 1 meter of the pump suction.
7. A Flow Inducer Sleeve or shroud which ensures that the water is drawn into the pump from below the motor is required when the pump is in open water (i.e. water tank, river, or dam), is in a rock well, below casing or set in screens, or well diameter is too large.
8. Do not install pumps in a crooked bore without measuring first. Lower a gauge of 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.
9. Never support the weight of the pump by the power cable or by the safety rope.
22

Wiring Wiring should conform to the requirements of local and national electrical codes. If in any doubt, contact your Electrical Authority. Caution The use of smaller gauge wiring than recommended may cause premature motor failure and will void the pump warranty. Larger sized wires may be used. Contact Backwoods Solar for correct wire gauge and maximum length. Grounding The pump motor is equipped with a ground lead which must be connected to the ground of the control module. If testing or used outside a well, the motor must be connected to the power supply ground to prevent a lethal shock hazard. Electrical Check List It is recommended that where possible, all electrical connections be carried out before delivery to site. Always check that the motor gland is tight. Check that motors and pumps are as ordered and correctly matched. If possible, it is good to test run the pump briefly in a water (water must be over the suction inlet) to verify correct operation before installation in the bore. Drop cable should be affixed at 3m intervals by a suitable underwater tape with the cable having some slack between each interval to compensate for the expansion of the outflow pipe when under load.
23

Troubleshooting
PROBLEM Pump doesn’t start
No water delivery
Low water delivery
Pump doesn’t shut off Pump starts and stops too often. (more than 5 cycles per hour)

WHAT TO LOOK FOR
Faulty pressure switch Control box in sun or near heat source Wrong control box being used Defective control box Hydraulic overload Water logged pressure tank Low voltage supply to motor (low solar irradiation)
Controller is switching between energy sources Low solar irradiation Broken pump shaft or coupling Check valve installed backwards Check valve stuck closed Inlet screen clogged Water level too low in well Hole in delivery pipe below top of bore
Water level too low in well Discharge pipe clogged, corroded, or ruptured Pump installed too low in well and covered with sand or other solids Inlet screen partially clogged Worn pump Leak in outlet pipe below top of bore Check valve stuck partially closed
Pipe ruptured Defective or improperly adjusted pressure switch Water level too deep for pump. Pump is air locked Worn pump Pipe is blocked Pump needs adjusting
Incorrect pressure switch, see pressure system installation
Defective air valve or tank diaphragm Pressure switch differential adjustment Pressure tank is too small

Electric shock from water pipe Note: A motor down to earth or defective cable will not cause a shock. Pressure gauge oscillates, flow surges
(snoring)
Electrolysis on motor and pump

Defective (grounded) incoming power leads Defective control box Ground wire connected to wrong control box terminal
Water level too low in the well. (Flow through pump greater than flow into well) Insufficient ground / ground leakage Broken ground wire

24

DC Pumps Introduction
The Backwoods Solar line of solar pumps provide a supply of clean water based on the most widely available renewable energy, the Sun.
With electric power supplied by a series of photovoltaic panels and a Centrifugal or Helical Submersible Pump with controller, the system can ensure a continuous draw of water from a suitable source even when solar irradiation conditions may vary.
The permanent-magnet motor’s high efficiency means a smaller number of solar panels are needed in order to work. Backwoods Solar pumps are designed for easy use and require no maintenance. They are the ideal solution for supplying water in remote areas where grid power is inconsistent or completely unavailable. Centrifugal pumps feature dry-run protection so no additional protection is needed. When the pump runs dry for 10 seconds it will stop and then try again after 1 minute. If it does not sense water again it will stop and attempt to run again after another 30 minutes. Helical pumps feature a run dry protection sensor that has been integrated in the power cable. During installation, the water surface must be above the sensor. When the water surface drops below the sensor position, the pump stops immediately. The pump will resume operation 10 minutes after the water level covers the sensor again.
Features and Protections
High efficiency BLDC motor High efficiency MPPT and Vector control External controller included Display of voltage, current, power, etc Water filled motor Thrust Bearing system Run Dry protection Over-load protection Over-voltage protection Low-voltage protection Lost Phase protection Stall protection Error display
25

Pump End
Plastic impeller centrifugal pump end or helical pump. Pump and motor are directly connected with a rigid coupling.
Impellers are fitted on floating clearance rings made of synthetic low abrasion material, and polymer diffusers impart significant wear resistance to the pump.
Pump liner, shaft and coupling, strainer and cable sheath are stainless steel. Base support and upper head are microcast AISI 304 stainless steel. Check valve is incorporated in the pump head.
The innovative wet end design gives the pump superior sand handling capabilities and provides maintenance free operation. The Helical pump adopts special wear-resistant rubber and a hardened shaft to increase wear resistance and prolong service life. However, in general, Helical pumps must not be used in water containing sand or sediment.
Motor
This series of motors are high efficiency BLDC motors specially designed for solar pumping systems. The shielding structure, all stainless-steel construction, and welding process, ensure long-term high reliability of the motor, free from maintenance. Thrust bearing system with water filled housing ensures more stable operation and longer service life. Water filled for clean, pollution free operation.
The centrifugal pump motor operates at 1000 rpm to 4000 rpm depending on the power input and load.
Installation parameters: Maximum submergence depth is 150m The sediment content of water source shall not exceed 120g/m³ Recommended water temperature of 0 to 40 Maximum axial thrust 1500N.
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LED Lamp Instructions In Panel
LED Power: Lit when power is supplied. LED MPPT : Lit when the pump is in MPPT mode.
LED Well Alarm for pump dry protection, Associated with WWL
terminals or Alarm for various faults
LED Tank Alarm for full water tank protection , Associated with TL
/ TH / COM terminals
LED V When this indicator light is on Voltage is displayed LED A When this indicator light is on Current is displayed LED W When this indicator light is on Power (Watts) is shown LEDRPM When this indicator light is on pump Speed is displayed
Press switchto cycle through V, A, W, RPM
Electrical Connections For Centrifugal Pump
If the maximum VOC voltage is exceeded, the controller will be damaged irreparably.
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Electrical Connections For Helical Pump
If the maximum VOC voltage is exceeded, the controller will be damaged irreparably.
Direction Of Motor Rotation
When the W/V/U wiring sequence is incorrect, the motor may rotate in the opposite direction, and the flow and head of the pump will decrease. Screw pumps may be damaged. You must install W/V/U correctly! For centrifugal pumps, the motor rotates counterclockwise when viewed from the top. For helical pumps, the direction is clockwise.
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Alarm and Fault Codes

Table 2

Code
P50 P51 P48 P0
P43
P49
P46
P60 PL E8 Beep alarm

Interpretation

Causes and Solutions

Low voltage protection High voltage protection Dry protection Hardware over current
Phase Missing Protection
Over current
Stall Protection
Controller High Temperature Low Power PCB component failure Reverse connection of positive and negative poles

The Voltage is below the requirement
The voltage exceeds the requirement Water shortage in well, low power WWL “closed”. Short circuit of cable or terminal between motor and controller; Motor and controller model mismatch; Phase loss of controller output; The wiring between the motor and the controller is loose. The cable is damaged and needs to be replaced. The motor may be damaged. Please check the motor resistance between every 2 items of UVW, exceed 15% is not allowed Dry run, very small current. Put the pump in water and retest. Short circuit of cable or terminal between motor and controller; Motor and controller model mismatch; The pump is blocked or jammed; remove the jam check whether the connection between the pump body and the motor is smooth motor bearing damage, need to replace the bearing Motor and controller model mismatch Keep good ventilation and heat dissipation near the controller Input power too low; The pump is blocked or jammed; remove the jam. PCB damaged, need to return to factory for inspection Pay attention to the ± pole of the power supply

Automatic recovery time
Error reporting of “P48” 2 times, automatic recovery occurs after 30 minutes.
Error reporting “PL” 5 times, automatic recovery occurs after 30 minutes.
The automatic recovery time of other faults is 30s after the fault is removed.

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System Installation Diagram
– 1. Solar Panel Array – 2. SPD(DC), Surge Protection Device – 3. Check valve – 4. Wiring waterproof splice – 5. Low-Level Float – 6. Sacrificial Anode – 7. Water Pump head and BLDC Motor – 8. Safety rope – 9. The High-Level Float – 10. External controller – 11. Grounding Rod
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System Installation
Water Source For Helical pumps the water source must be clean water, free from contaminates such as, dirt, dust, loose rocks, decaying organic matter, and other foreign bodies that could block the intake screen or foul the impeller stack. For Centrifugal pumps, sand content cannot exceed 120g/m3 of water pumped. The new 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.
Pump Installation Before the pump is put into the well, test pump for function to ensure that the pump works normally Make sure the pump is completely submerged in water When the pump is installed, it must stay off the bottom of the water source. Prevent sand from burying and damaging the pump.
In a well, keep the pump 5 feet off the bottom In open water such as river, keep 1 foot off bottom Allowable installation angle of pump is 0-90° Allowable operating temperature 0-40
Heat Dissipation Requirements For Pump Installation In all installation positions, the pump motor must be fully submerged and a minimum water flow across the motor during operation of 8cm / sec before entering the pump intake. To induce the correct water flow across the motor, use of a flow inducing sleeve should be used when: Well diameter is too large relative to motor diameter to induce correct flow. Motor and Pump are in open water. Motor and Pump are in a rock well or below casing. The Bore is top feeding (water enters intake without passing over motor). Motor and Pump are set in screens.
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Installation of Float Switches Low-Level Float A low-level float can be wired to the WEL/COM terminal to prevent dry running.
A low-level float is optional for centrifugal pumps but must be
installed with helical pumps to prevent dry running. The low-level float must be installed a minimum of 6 inches above the pump outlet.
High-Level Float A high-level float can be wired to the TL/TH/COM terminal to stop the pump when the tank is full. To prevent the pump from starting and stopping frequently, adjust the float to a suitable swing range. When the float is “closed” the pump will restart
Pressure Switch and Mechanical Floats When the pipeline is very long and float switches are not feasible due to long
wire runs, a pressure switch and mechanical floating ball valve are an alternative to a high-level float.
The mechanical floating ball valve is installed at the outlet of the pipeline. When the water tank is full, the floating ball valve closes and the pipeline pressure increases. When the pressure switch trips it stops the pump by changing the TWL or WWL status. When the water level of the water tank drops, pumping resumes.
Normally closed pressure switch connected to TWL terminal Normally open pressure switch connected to WWL terminal
SPD (Surge Protection Device) Surge Protection Devices protect the system from lightning. Where lightning is likely to occur, SPD’s must be properly installed and grounded.
Select an SPD with a voltage rating greater than the maximum voltage of the system. Call Backwoods Solar for help with proper sizing of the SPD.
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Controller Installation The controller is IP65 rated, however it is recommended that the controller is
not mounted in direct sunlight. Mounting the controller behind the solar panel array is a good way to protect the controller.
Distance Between Controller and Pump The maximum allowable distance between the controller and pump is 120m.
Extending this distance may lead to controller failure. Extended distances will also will cause power loss (voltage drop) at the pump. For long distance runs use lower gauge (thicker) wire. Call Backwoods Solar for recommendations. Do not use the cable to carry the weight of the pump or make the cable bear any tension. The cable should be kept in a relaxed state. Drop cable should be affixed at three meter intervals by a suitable underwater tape with the cable having some slackness between each interval .
Check Valves Check valves can effectively prevent damage caused by water hammer on the pump. It is recommended to install a check valve every 70m of the vertical height of the pipeline. In areas where water freezes in winter, make sure to install pipeline drainage or pipeline freeze protection.
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Wire Splicing Effective electrical contact and waterproofing of the cable splice are required for the pump to operate. Poor waterproofing can lead to electric leakage and cause the pump to corrode or stop working entirely, and can cause personal injury. Proper waterproofing procedure is shown below.
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Solar Array Installation

Warning
· The power supply from a DC power sources such as solar panels can cause SERIOUS HARM or DEATH from electrocution · Use appropriate safety procedures when working on any system components · Only suitable qualified personnel should carry out electrical connection/disconnection · Always treat solar panel wiring as LIVE and handle with care · Use correctly rated electrical wires and connectors

Solar Panel Glossary of Electrical Terms

Term Voc(V) Vmp(V) Isc(A) Imp or Impp(A)
Solar Panel Wiring

Definition Volts open circuit, nothing connected Volts maximum power point, under load Amps short circuit Amps maximum power point

Table 4

It is recommended to install the solar panels in series.

To wire solar panels in series, the positive of one solar panel is wired to the negative of the next solar panel. In this case: Sample panels are 300W, 8.64Isc, 44Voc and 37.6Vmp each.
· Output voltage is multiplied by the number of panels. 4 x 44Voc = 176Voc · Output voltage multiplies by the number of panels. 4 x 37.6Vmp = 150.4Vmp · Output watts are multiplied by the number of panels. 4 x 300W = 1200W · Output amps remain the same as a single panel. 8.64 Isc (A)
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Motor and Controller Input Energy Limitations:

Table 5

Motor&Controller Vmp

0.3HP-24V 0.5HP-48V 0.75HP-72V 1HP-96V

20-40 40-76 65-110 80-150

Max. VOC
48 96 150 180

Max. Current
15A 15A 15A 15A

Recommended solar panels
300W x 1 300W x 2 300W x 3 300W x 4

Do not exceed the maximum VOC voltage or pump and controller damage will occur. Damage caused by incorrect voltage is not covered under warranty.

Solar Array Installation Considerations:
· In North America (and all northern hemisphere locations) mount the solar panel(s) facing due South. The solar panel’s angle from horizontal should match the location’s latitude. For example, Sandpoint, Idaho’s latitude is 48.3 degrees North. Solar panels in Sandpoint should be mounted approximately 48 degrees up from horizontal.
· Any shading on the solar array will drastically reduce the solar panel(s) performance
· Dust or bird droppings will impair the array energy output. Keep panels clean.
· The array must be grounded to help prevent damage from lightning strikes.

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