Installation Manual - Dankoff Solar Pumps
Contents
1.2. tt tt Low voltage systems require larger wire than 115v See Dankoff Universal Wire Sizing Chart for assistance Failure to install a fuse or breaker equal or less than the motor s Max Amp rating will void your warranty The manual contains important maintenance information and is the property of the pump owner Please give it to them when you are finished A STEADY BUZZING SOUND indicates EXCESSIVE SUCTION An UNSTEADY BUZZING SOUND indicates a LEAK IN THE SUCTION LINE See Page 14 for troubleshooting tips Dankoff LCB PV Load Load Float Switch Module wiring detail is for illustration purposes ONLY Your array wiring will be different Consult with your dealer for details Storage The Dankoff LCB uses Reverse Action Float switch logic Close on Rise or Pump Down 30 Filter amp Foot Valve DSP 11035 3 pack 30 Filters DSP 11036 4 Solar SlowPump a EZ Install Diagram Solar www dankoffsolar com Priming Port if pump is above water source i Note 10 Inline Filter DSP 11033 may be used in place of the 30 submerged filter Debris Screen Optional Dry Run Protection DSP 02526 for 1300 1400 Series DSP 02527 for 2500 2600 Series Foot Valve Innovative Solar Solutions e 2725 Westinghouse Blvd Suite 100 e Charlotte NC 28273 e 866 856 9819 e www innovativesolar com
3. carbon filter for this purpose 30 INTAKE FILTER WARNING Cartridges vary slightly in outside diameter If replacement fits loosely into end caps wrap ends with cloth or tape to make a snug fit If cartridge is too large to fit peel away some fibers using a knife End caps MUST fit snugly or dirt will enter Pack of 3 cartridges Dankoff Solar Item 20237 MOTOR BRUSHES After a year or two inspect your motor brushes and measure their length remove one or both of the black plastic screw heads near the rear of the motor Motor brushes on most models measure 3 4 inch long not including the rounded end If you have a 1 2 HP model 1400 or 2600 series or any motor larger than 5 diameter they begin life measuring about 1 1 4 After they show some wear you may calculate how many more years they have left before they are too short After inspecting a brush replace it in the EXACT SAME POSITION and tighten the plastic screw GENTLY Most brushes last at least 5 YEARS of daily running Brush wear will not effect motor performance until contact is suddenly lost MOTOR BRUSHES for 12V pumps Dankoff Solar Item 20301 MOTOR BRUSHES for 24V pumps Dankoff Solar Item 20302 For 1400 and 2600 series pumps large blue motor and for AC models please ask your Dankoff dealer 13 TROUBLESHOOTING BEFORE YOU CALL FOR HELP TRY TO LOCATE YOUR PROBLEM HERE Please note the terms Front and Rear See P 1 illustration PUMP
4. WILL NOT FIT INTO YOUR 6 DRILLED WELL CASING Close Elbow fittings are required Dankoff Solar Item 20308 PUMP DOESN T TURN ON NO POWER 1 CHECK DRY RUN SWITCH on front of pump if present Press red button to reset Correct the cause of dry run 2 CHECK FUSE or BREAKER and any control or wiring devices in line 3 MOTOR STARTS WHEN YOU HIT IT Sticking brushes Motor Brush Problems 4 Remove rear cover of motor to check connections there Check for voltage present at motor If voltage is present see next entry 5 CHECK THERMAL OVERLOAD SWITCH on rear of motor Bypass it by holding a piece of wire across its terminals If motor runs and is not hot replace thermal switch DRY RUN SWITCH may be tested the same way PUMP SPINS BUT DOESN T PUMP WATER 1 CHECK DIRECTION of rotation If not clockwise viewed from brass front end reverse polarity 2 CHECK PRIME Open priming plug or valve see instructions Pour water in LOSS OF PRIME INTAKE PIPE LEAKAGE CHECK ALL FITTINGS a pinhole leak in suction pipe will cause loss FOOT VALVE may leak Inspect pressure test clean or replace Debris may be stuck in foot valve causing leak if not protected by fine screen or intake filter REGARDING POLYTHYLENE PIPE FITTINGS If pipe does not stretch tightly over fittings it may leak Gently heat with torch or hot water and retighten hose clamp WITH WRENCH Replace stripped clamps Use ALL STAINLESS clamps NOISY PUMP NOISE CAVITATI
5. for removal PUMP FROZEN BY LOW TEMPERATURE It should blow fuse or breaker Allow it to thaw Observe test performance If damaged replace or rebuild Check all plumbing for damage and leaks and protect from future freezing RUBBER SHAFT COUPLER FAILURE MISALIGNMENT between pump and motor shaft due to removal of pump plate from motor and reassembly without readjustment See CHANGING PUMP HEAD POSITION on p 5 Replace rubber spider Inspect metal coupler halves for damage and replace if worn These are common parts available from any electric motor shop machine shop or heating air conditioning supply or from factory Coupler parts will last forever if alignment is correct MOTOR BRUSH PROBLEMS Motor brushes are carbon rods that make electrical contact with the spinning copper commutator on the motor shaft The two brushes are accessible by the plastic screws near the rear of motor They MUST slide in and out very easily a spring pushes them in as they wear Brushes must be at least 3 8 long longer on motor larger than 5 diameter They generally last about 5 years unless motor has been wet inside see WATER DAMAGE Retighten plastic screws gently 1 WORN BRUSHES Call dealer or factory for replacements 2 STICKING BRUSHES Inspect inside each brush holder with flashlight Clean if corroded or dirty If brushes still don t slide in out without friction sand down two of the long sides of brush VERY slightly 3 BR
6. in pressure OO Pressure Switch I i pex ra Tank Tee Z Supply to House Turn CW to raise CUT ON amp OFF a oO oe pressure Eg Turn CW to EZ Install Kit Flex hose raise OFF pressure DSP 11012 A STEADY BUZZING SOUND indicates EXCESSIVE SUCTION An UNSTEADY BUZZING SOUND indicates a LEAK IN THE SUCTION LINE See Page 14 for troubleshooting tips FlowLight Booster Pump EZ Install Diagram www dankoffsolar com R 1 1 2 2005 Copyright Dankoff Solar 2004 My Priming Port if pump is above water source Qo Ball Valve C1 10 Filter Capsule DSP 11033 k with 10 micron KI ky Filter set KA DSP 11034 SA RA KB Debris Screen Optional Dry Run Protection DSP 02527 for Booster Pumps Notes to Installer This pump pulls water in by suction The inlet plumbing must offer a very free flow like a drain pipe in reverse The pump will be very noisy if intake is restricted or blocked by air pockets or being undersized See Page 3 NOISE CAVITATION RAPID PUMP WEAR FIX THE PROBLEM See Page 14 This pump tolerates NO solid debris A disposable cartridge filter is required at the intake NEVER run this pump without a filter See Page 2 Do not omit the intake screen After the first test run check the screen and remove any plumbing debris See Page 6
7. inline Filter intake Filter maintenance Float Switch Freeze protection Fuse protection Grounding Linear Current Booster Maintenance Motor brushes Mounting pump Mounting suspended in well Noise problems Piping intake sizing amp layout Piping material Piping outlet Pressure relief valve Booster Pressure Switch Pressure switch adjustment Pressure switch installation Pressure tank Priming Pump Controller Pump models amp specifications Rebuild Exchange pump head Repairs amp troubleshooting Repairs factory service Slowpump non battery wiring Screen intake Thermal switch Troubleshooting amp repair Warnings Warranty Water level controls Water tank Water usage conservation 12 Wiring INDEX Page Diagrams 8 9 8 9 4 7 3 10 18 2 2 4 2 2 13 15 3 8 12 6 11 7 11 13 13 17 18 5 20 20 5 6 20 20 4 14 15 3 20 8 9 20 2 6 4 10 3 20 20 10 20 9 20 9 4 11 after p 20 18 14 18 18 11 11 13 7 14 18 back cover 18 8 8 6 7 11 21 WARNINGS TO INSTALLER 1 This pump pulls water in by suction The suction pipe must offer a very free flow like a drain pipe in reverse The pump will be very noisy if intake is restricted or blocked by air pockets See Page 3 2 This pump tolerates NO solid debris A disposable cartridge filter is required at the intake NEVER run the pump without a filter See Page 2 3 Low voltage systems requir
8. ordinary 10 fiber filters not paper from local source Glue them end to end with epoxy and install 3 TRY BACK WASHING filter by blasting it with pressure from the inside For 30 intake filter remove check valve and attach garden hose adapter Back washing is effective on coarse sandy material but is NOT effective with clay rust very fine or sticky deposits PURCHASE SPARE FILTERS NEVER RUN PUMP WITHOUT A FILTER LOW FLOW RATE PUMP TURNS FAST DRAWS LOW CURRENT Pump is worn out from dirt rust or other abrasive particles in water or from cavitation from running dry or just from age REPLACE PUMP HEAD See Rebuild Exchange Service BOOSTER PUMP TAKES LONG TIME TO REACH CUT OFF PRESSURE 1 If pump spins fast see above entry 2 If pump rotation slows way down as pressure builds wire is too small Consult low voltage wire size chart or ask your dealer for correct wire size LOW FLOW RATE PUMP TURNS SLOW DRAWS HIGH CURRENT may run hot may blow fuses Pump is hard to turn due to 1 EXCESSIVE VERTICAL LIFT beyond system s capacity Trade pump head for lower volume model or increase size of solar array if it will not overpower the motor see Specifications Chart 2 MISALIGNMENT Pump plate was removed from motor and not readjusted after assembly See CHANGING PUMP HEAD POSITION p 5 Check rubber shaft coupler for damage 3 MINERAL DEPOSITS Turn shaft with two fingers Will be hard to turn Use vinegar or whate
9. storage parts may lock up Grab shaft coupler lightly with pliers and try turning it backwards 2 Debris jammed in pump Disconnect plumbing pour water into outlet and run pump IN REVERSE by reversing polarity Watch for debris exiting inlet Check performance damage is likely 3 See Pump Frozen PUMP JAMS MAKES CRUNCHING NOISES black material in outlet Internal parts are broken either by debris in pump severe freezing external shock or just bad luck See Rebuild Exchange Service WATER DAMAGE MOTOR SUBMERGED OR DRIPPED ON Inspect brushes and commutator If in very poor condition motor may be beyond repair Contact factory If motor was not run wet for very long it may need only new bearings available from factory or from any 16 motor repair shop or bearing supplier Rough commutator must be turned resurfaced on a lathe This may be done by a machine shop or electric motor shop CORRECT THE CAUSE of damage If your water level is too unstable contact your dealer or factory about a submersible pump RUSTY BEARINGS 1 PUMP HEAD Steel ball bearing is visible at pump head shaft Rust caused by water drip or submersion Pump head must be rebuilt to replace the bearing see Rebuild Exchange 2 MOTOR Replace with DOUBLE SEALED R8 bearing front and R6 rear These are common bearings available from automotive or electric motor suppliers or factory Any mechanic can do this A puller tool or a press is needed
10. the plate around so it settles into the position where there is NO VIBRATION then tighten the bolts firmly HANDLE YOUR PUMP CAREFULLY Never hammer on it clamp it in a vice or drop it Pump motor alignment is critical DO NOT DISTURB THE ALLEN HEAD BOLTS holding the mounting plate to the motor UNLESS you wish to rotate the pump head to a different position The shaft coupler between the motor and pump should turn easily using two fingers Sometimes after a period of dry storage the pump will stick If you can t turn the coupler put a bit of water in the pump intake and turn the coupler with pliers to crack it loose Do this by turning it BACKWARDS If it sticks again see Troubleshooting IF YOU ARE NOT EXPERIENCED WITH WATER SUPPLY INSTALLATION PLEASE CONSULT LOCAL SOURCES regarding 1 Freeze protection 2 Choice and sizing of pipe 3 Plumbing design in general INSTALLATION IN A DRILLED WELL CASING INSIDE A 6 INCH WELL CASING SPECIAL ELBOWS ADAPTERS are required The elbows fit 1 2 polyethylene black flex pipe MEASURE CAREFULLY to determine the length of pipe you need SUBTRACT 1 5 TO ALLOW FOR PIPE AND ROPE STRETCH Assemble according to diagram A priming plug is not needed Before lowering the pump place the intake into a bucket of clean water and run the pump until water exits Now it is primed A pitless adapter may be optimum for freeze protection Check with your local well supplier for details POLYE
11. when outlet pipe is blocked Order the valve from your dealer or any electric or plumbing supplier Grainger s part number 1X624 or equivalent about 15 To adjust be sure water has reached the highest point in your system Loosen the valve til it leaks water then tighten it gradually JUST PAST the point where it stops Be sure water will not drip onto the motor pump To PREVENT freezing of exposed pipes S owpump system you might consider the primitive method of drilling a small weep hole in the outlet pipe below ground level The pipe will drain when pumping stops but a small amount of water will be wasted during pumping Set the outlet pipe to spill into the top of the tank so that the tank will not drain or install a check valve and vacuum breaker to allow pipe to drain Water WILL drain back through the pump if allowed to but it will do so slowly If this is desired do not use any check valves or foot valve Pump must have suction draw of no more than a few feet however If pump drainage is required position pump vertically head downward or horizontally with intake and outlet facing downward see Changing Pump Head Position p 5 Take every precaution to PREVENT pump freezing The forged brass pump head will survive most light freezes but a hard freeze may damage it If you insulate your pump for freeze protection keep the motor exposed so it won t overheat 12 MAINTENANCE INTERNAL INTAKE SCREEN The pump has an int
12. BOOSTER PUMP requires a BATTERY SYSTEM NOT A PV ARRAY DIRECT installation PV ARRAY voltage may exceed 15V and overspeed the pump 10 SOLAR SLOWPUMP POWER CONTROL for ARRAY DIRECT NON BATTERY OPERATION When working against a constant head vertical lift Solar Slowpump requires nearly constant current regardless of the voltage speed When low light conditions are present the PV array cannot supply full current The voltage will drop to nearly zero and the pump will stall like a truck trying to start in 4th gear The remedy is either to add a PUMP CONTROLLER also called LINEAR CURRENT BOOSTER LCB to your system This device will match the power source to the load by transforming the voltage down while increasing the current delivered to the motor like an automatic transmission If you are not using a controller in your non battery system contact your dealer It will greatly improve low light performance System Wiring for Typical Slowpump Installation Non battery System Series Wiring is shown for nominal 24V system Voltage from panels will read 40V when disconnected open circuit and about 30V while pumping For 12 Volts use a single panel or wire panels in parallel to to Installing a Solar Tracker Use stranded wire for flexibility Secure the wires to tracker with plenty of tape Make a long slack loop to allow free motion of tracker The proper fuse must be Cont
13. Flowlight Booster Pump and Solar Slowpump Installation amp Service Manual 2003 by Dankoff Solar Products IMPROPER INSTALLATION WILL DAMAGE YOUR PUMP AND VOID YOUR WARRANTY This manual is based on 20 years of experience with over 5000 pumps sold We are pleased to observe how few problems arise when our pumps are properly installed and maintained Please read and save this manual RECORD your MODEL __ SERIAL Verify your purchase Please check Specification Sheet at the end of this manual to verify that the pump you received is the best model for your application If it is not please contact your dealer or the factory for correction BEFORE installing your pump This manual covers two similar product lines e Solar Slowpump for water lift powered by battery or solar direct power and e Flowlight Booster Pump for water pressurizing powered by battery system only Rear Brush Holders Shaft Coupler Front one on each side Rear Cap of Motor Pump Head y Electrical Cable Mounting Foot Dry Run Switch Note Slowpumps of the1400 and Round optional 2600 Series and 115 Volt AC Plate clamps here have different mounting structure _ INDEX IS INSIDE BACK COVER 1 BASIC CONSTRAINTS l PUMP MUST NOT BE SUBMERSED ll WATER MUST BE FILTERED ABSOLUTELY CLEAN lll PUMP MUST NOT RUN DRY I NON SUBMERSIBLE PUMPS Your pump must NOT be submerged in water or rained or dripped on If it is
14. ON RAPID PUMP WEAR FIX THE PROBLEM STEADY BUZZING SOUND Indicates EXCESSIVE SUCTION due to any combination of 1 HIGH SUCTION LIFT mount pump as low as possible 2 UNDERSIZED SUCTION PIPE 3 CLOGGED FILTER NOTE Fiber filter cartridges may be clogged and LOOK CLEAN fine silt is hidden within the fibers 4 CLOGGED INTERNAL INTAKE SCREEN See next two entries 5 SOFT FLEXIBLE HOSE used on intake line may be crushed or kinked by suction replace with more rigid pipe material UNSTEADY BUZZING SOUND Indicates LEAK IN SUCTION LINE allowing AIR to enter 1 Check for bubbles in in line transparent filter or air in outlet water 2 See LOSS OF PRIME in above entry 3 If you have IN LINE FILTER with red Pressure Relief Valve red button on top and it is mounted several feet above water source air may be drawing in around the valve SEAL AROUND THE VALVE with silicone sealant or epoxy glue OR unscrew the red button and replace it with a nut tightened 4 If no source of air leakage is present water may have high concentration of DISSOLVED GASSES which release as bubbles in suction pipe Reduce suction lift if possible Install air chamber in intake line with valve on top Pour water in to replace air when problem reappears 5 Turn filter to a horizontal position This allows bubbles 14 to get out of the way of flow Do NOT turn it upside down or dirt may fall in when filter is changed NOISE AND VIBRATION IN PIPES p
15. PUMP TO FACTORY FOR REPAIR Please call us before shipping anything 505 473 3800 FAX 505 473 3830 Email pumps dankoffsolar com PLEASE tell us your MODEL amp SERIAL NUMBERS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk WARRANTY kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Your pump is warranted to be free from defects in material and workmanship for ONE 1 YEAR from date of purchase Failure to provide correct installation operation or care for the product in accordance with instructions will void the warranty Product liability except where mandated by law is limited to repair or replacement at the manufacturer s discretion No specific claim of merchantability shall be assumed or implied beyond what is printed on the manufacturer s printed literature No liability shall exist from circumstances arising from the inability to use the product or its inappropriateness for any specific purpose It is the user s responsibility to determine the suitability of the product for any particular use In all cases it shall be the responsibility of the customer to insure a safe installation in compliance with local state and national electrical codes 18 DRILLED WELL 6 INCH CASING Typical Groundwater Pump Installations pump box DEVELOPED SPRING check valve g spring box overflow pipe maximum water level gt gt gt minimum water level gt
16. THYLENE PIPE comes in rolls and is inexpensive and quite freeze tolerant Use with plastic adapters and secure with ALL STAINLESS hose clamps obtain such clamps from a pipe supplier rather than automotive supplier If pipe does not stretch tightly over fittings warm it with a torch or hot water then tighten clamps firmly with a wrench Use two clamps at each joint Keep extra clamps handy in case you strip one ELECTRICAL WIRING WIRE SIZING DON T CHEAT YOURSELF with undersized wire Your pump is wired with a short length of 14 or 12 cable This size is sufficient for short lengths only Splice it to a larger size of wire if your wire run is longer than 15 feet Consult a low voltage wire size chart or call your dealer or the factory for recommendations Excessive voltage drop will slow the pump down but if it is unavoidable don t worry It will NOT cause any harm to the motor BLACK WIRE POSITIVE WHITE WIRE NEGATIVE GREEN WIRE GROUND 1400 amp 2600 Series Slowpumps Red Positive Black Negative Reverse polarity will cause reverse rotation This will not cause damage if done for a short time Reverse the wires if necessary so pump turns CLOCKWISE looking at the red face of the pump FUSE OR CIRCUIT BREAKER PROTECTION FAILURE TO INSTALL A FUSE OR BREAKER equal to or less than the motor s Max Amps rating WILL VOID YOUR WARRANTY If water flow becomes blocked or if the pump jams or freezes and cannot turn freely the m
17. This is for non battery systems only 3 Float valve in tank restricts flow Pressure builds up and actuates pressure switch at pump Small captive air pressure tank is necessary at pump to prevent switch chatter Contact your dealer or the factory for further advice FLOW RESTRICTION MUST NOT BE USED as a method to reduce your pump s flow rate It may result in excessive pressure build up and current draw Flowlight Booster Pump Installation For Pressurizing Systems A PRESSURE TANK IS REQUIRED with a Booster Pump system PRESSURE TANKS are available from local water supply dealers Use the largest tank that you are willing to buy 40 gallon size is typical it allows you about 12 gallons of water between pump cycles Those 12 gallons may be drawn ata higher flow rate than the pump produces A large pressure tank will minimize on off cycling of the pump In a typical household of more than four people a tank of at least 60 gallons is recommended The bigger the better More than one tank may be connected They need not be the same size A PRE CHARGED CAPTIVE AIR TANK is recommended Cheaper galvanized tanks require periodic recharging store less water between cycles and don t last as long PROPER PRE CHARGE IS ESSENTIAL Follow the instructions that come with your pressure tank With presure discharged from the tank adjust pre charge to 2 3 PSI below cut in pressure This will assure that you get the best performance from your sy
18. USH SPRINGS WEAK wire looks overheated Motor overheated severe overload lack of fuse protection Replace motor and correct the cause 4 BROKEN BRUSH HOLDER Repair with epoxy or replace contact factory Glue it to motor shell with EPOXY PUTTY carefully mixed To insure proper position remove rear plate of motor to see that brush sets into perfect position as glue sets Glue must be hard and strong 5 COMMUTATOR PROBLEMS may be caused by poor brush contact overheating or water damage Com is visible thru brush holders or Booster Pump cooling slots The wearing surface should be smooth with a uniform brown color If it looks good DO NOT sand it or do anything to it Commutator damage may require resurfacing on a lathe A local electric motor repair shop or automotive electric shop can perform these repairs 17 FACTORY REPAIRS WHEN CALLING FACTORY OR DEALER FOR HELP PLEASE tell us your MODEL and SERIAL NUMBERS Most failures involve the pump head not the motor This is the brass part that the pipes connect to The pump head may be replaced with simple hand tools a 7 16 wrench and a 1 8 Allen wrench hex key YOUR PUMP HEAD IS NOT USER SERVICEABLE It is delicate and difficult to re assemble Disassembly of your pump head will void your warranty Individual parts are not available If the pump head is faulty it must be replaced with a new one WARRANTY CLAIMS must include receipt to prove date of purchase TO SHIP
19. YSTEM DESIGN If you are not experienced in water supply design and installation you may wish to seek professional assistance Many people are surprised to find how complex water system design can be See diagrams on p 20 for typical groundwater installations MINIMIZE SUCTION LIFT to just a few feet if possible The practical suction limit for any pump is 20 vertical feet at sea level subtract 1 ft for every 1000 ft of elevation The more you minimize suction lift the more reliable and quiet your pump will be Just be sure the motor will not be submerged if the water level rises or it will be ruined Your pump may be placed DOWNHILL from your water source if feasible YOUR INTAKE PIPE may run any reasonable horizontal distance although it is BEST TO KEEP IT SHORT We know of installations where the pump is placed 200 feet from the water source using 1 1 2 pipe USE LARGE PIPE for the intake 1 to 1 1 2 for larger Slowpumps or Booster Pump Slope the intake line from the water source UP toward the pump AVOID HUMPS in the intake line They trap air pockets which can block the flow AVOID LEAKS IN SUCTION LINE They are hard to locate and will cause constant problems 3 INTAKE PIPE MUST BE SIZED GENEROUSLY to allow no more than a slight pressure drop at peak flow rate or pump will be noisey and will wear rapidly USE PIPE REDUCER FITTINGS to adapt your pump s inlet or outlet to larger pipe size where necessary Excessive pi
20. and suction line completely with water This must be done if the pump is mounted higher than the water source A removable plug or a valve must be installed at the highest point is in the suction plumbing Prime the pump and intake line by pouring water into the opening until it is completely full Your foot valve prevents loss of prime by not allowing water to flow back into the water source Your pump will create enough vacuum to SELF PRIME to around 10 feet less at high elevations but only when it is in new condition and wet inside A priming plug is always recommended if the pump is to be located higher than the water source EXCEPTION see Installation in Deep Well Casings You may use a good quality ball valve instead of a plug if frequent priming is expected A CHECK VALVE AT THE PUMP OUTLET is required if there is more than a 30 foot lift above the pump or in any pressurizing system This allows the pump to start easier It also prevents back flow when changing filter cartridges PIPE UNIONS If you run rigid piping copper or PVC directly to the pump unions are required Unions make pump replacement easy without the need to cut and re solder or re glue the pipe Copper Flex Connectors commonly used for water heaters may be used instead However Do NOT use them for the larger Slowpumps 2507 2607 or Booster Pump They are too restrictive MOUNTING YOUR PUMP Locate your pump in a cool place Do not allow direct exposure t
21. e larger wire than 115V See Page 6 4 Do not omit the intake screen After the first test run check the screen and remove any plumbing debris 5 This manual contains maintenance information and is the property of the pump owner Please give it to the owner when you are finished Thank You 22 Notes to Installer This pump pulls water in by suction The inlet plumbing must offer a very free flow like a drain pipe in reverse The pump will be very noisy if intake is restricted or blocked by air pockets or being undersized See Page 3 NOISE CAVITATION RAPID PUMP WEAR FIX THE PROBLEM This pump tolerates NO solid debris A disposable cartridge filter is required at the intake NEVER run this pump without a filter See Page 2 Do not omit the intake screen After the first test run check the screen and remove any plumbing debris See Page 6 See Page 14 Low voltage systems require larger wire than 115v See Dankoff Universal Wire Sizing Chart for assistance Failure to install a fuse or breaker equal or less than the motor s Max Amp rating will void your warranty The manual contains important maintenance information and is the property of the pump owner Please give it to them when you are finished AS AN JE Foot Valve required if tank is below pump ED CO Storage Tank Pressure Tank 40 Gallon Minimum recommended size Adjust pre charge to 2 3 psi below cut
22. ernal metal intake screen It s purpose is to catch solids accidently introduced during installation or filter servicing dirt stuck inside your intake pipe before installation or mineral deposits that may accumulate and flake off of the intake piping 1300 SERIES SLOWPUMP has an angled extension with a large brass nut on the end Remove the nut to inspect and empty screen 2500 SERIES SLOWPUMPS amp FLOWLIGHT BOOSTER PUMP have a strainer pushed into the intake fitting EXTERNAL FILTRATION IS STILL REQUIRED If you notice signs of intake blockage inspect your screen If solids keep accumulating improve your filtration See Page 2 for details about filters and cartridges PUMP HEAD Except for the internal screen your pump head is maintenance free DO NOT remove its front plate or otherwise tamper with it unless you are intending to get it rebuilt The pump head is NOT USER SERVICEABLE It is easy to dissemble but difficult to reassemble without special tools WATER FILTER The best way to determine when a cartridge is becoming clogged is to listen for an increasingly loud buzzing noise cavitation It is difficult to determine the condition by the appearance of the cartridge KEEP SPARE CARTRIDGES You can buy cartridges locally but the best ones are thick body polypropylene fiber construction not the type that looks like twisted string or paper We recommend 10 micron cartridges pack of two Dankoff Solar Item 20236 Do not use a
23. gt gt FB 30 intake H filter foot H valve Pressure Switch Wiring for Flowlight Booster Pump Ground Ground green white black Source First Tall Screw Adjust this one to set both cut in amp cut out pressure Set it for the cut in that Second Short Screw you desire This one adjusts Counterclockwise will cut out pressure only lower the setting Explanation The National Electrical Code specifies that switches not disconnect the grounded conductor which is the negative So we are switching only the positive Using both sets of contacts as shown in series will extinguish the arc spark that forms when the contacts break This greatly increases switch reliability 19 Other solar and DC water pumps SUBMERSIBLE PUMPS FOR SURFACE AND DEEP WATER LIFT AND PRESSURIZING ETAPUMP SOLAR SUBMERSIBLE 32 GPM at 25 FEET 1 7 GPM at 650 FEET High tech maintenance free SURFACE PUMPS FOR LIFT AND PRESSURIZING SOLAR FORCE PISTON PUMP 5 9 GPM to 230 FEET or to 100 PSI Extremely rugged and dirt tolerant SUNCENTRIC CENTRIFUGAL 5 70 GPM to 90 FEET Also for circulation for swimming pools pond management solar heating and more SOLARAM SURFACE PUMP 3 9 GPM to 960 FEET Ask your Dankoff dealer or go to www www innovativesolar com 20 Topic Booster Pump system Check valve Circuit breaker Dry Run Switch Easy installation kit Factory service Filter cartridges Filter
24. installed outdoors supply some weather protection such as a sheet metal shield or even a dog house something to keep it dry and also to protect it from the sun s heat ll FILTRATION REQUIREMENT Your pump is a PRECISION MACHINE Traces of sand clay rust or other solids will cause rapid wear or immediate damage just as they would in your automobile engine If your water is CRYSTAL CLEAR ALL THE TIME our Fine Intake Strainer will provide sufficient protection If you have an intake strainer already it is probably not fine enough openings must be no more than several hairs wide or additional filtration is required Since water conditions are subject to change it is good insurance to use a filter regardless Many dealers refuse to sell our pumps without a filter since it minimizes call backs Our 30 INCH INTAKE FILTER FOOT VALVE is necessary for pumps lowered into wells Otherwise our INLINE FILTER is best installed close to the pump s intake If filters are expected to clog often maintainance may be minimized by plumbing two or more filters in parallel The INLINE FILTER has a clear bowl so its condition may be observed KEEP SPARE CARTRIDGES HANDY FILTER CARTRIDGES are available from your dealer or the factory 9 7 8 inch cartridges for the INLINE filter may also be obtained from local water system suppliers The 5 or 10 micron spun polypropylene type is best Paper filters have less capacity The kind that look like string has mo
25. ngs determine the pressure range of your system To conserve energy set the pressure as LOW as feasible This will also prevent the motor from overheating if you run it for long periods sprinkling for example Low pressure even 15 20 PSI may deliver excellent water flow IF your plumbing and hoses are sized larger than minimum If not yet plumbed use at least one size larger pipe than conventional and avoid restrictive connections such as 3 8 tubing often used to feed sinks Adjustment Start with the standard setting usually 30 50 PSI Reduce the pressure according to your requirements if you wish It is wise to measure the current used by your pump with an amp meter in series with the line your system metering Current draw will rise in direct proportion to outlet pressure Pressure should NOT be set beyond 50 PSI MAXIMUM 65 PSI with 2910 Model or loss of efficiency and motor over heating will result IMPORTANT After any change to your cut in pressure you need to readjust the pressure tank pre charge 9 If you are raising water vertically AND pressurizing note the relationship 2 31 ft 1 PSI Example A pump that lifts 23 vertical feet and pressurizes to 30 PSI must pump a total of 40 PSI Total lift vertical distance from water surface to pressure tank WARNING INSTALL THE PRESSURE RELIEF VALVE INCLUDED WITH YOUR PUMP Flowlight Booster Pumps are supplied with a 75 PSI Pressure Relief Valve as a safety feature If your p
26. o sunshine during operation or the motor may overheat Allow free flow of air around the motor for cooling SHELTER IT FROM RAIN AND SUN or it will be a mess in a few years The pump may be mounted horizontally or vertically If vertically FACE THE PUMP HEAD DOWNWARD RIGID MOUNTING IS NOT required in most installations In a non battery system starting is gradual and the pump does not jerk with the start In a battery system it will jerk slightly but simply mounting it to a small wooden board is sufficient to stabilize it The pump may be hung vertically on a rope Observe the pump and see that it is not likely to overstress or loosen pipes as it starts DO NOT mount the pump directly to a wall or wood floor in your home It will increase the noise CHANGING PUMP HEAD POSITION If you wish to face the pump s fittings sideways or downward you may rotate pump head to a different position by removing the four bolts that secure the pump to the motor If your pump looks like the picture on P 1 do this Remove the four hex head bolts from the round plate then rotate pump head to new position REALIGN THE PUMP AND MOTOR SHAFTS or the coupler will bind and wear This is simple When you remove the round plate notice that the bolt holes are oversized for alignment adjustment Reposition as desired but leave the bolts loose BEFORE installing the pump drop a teaspoon of water into the inlet and run the pump on 12 volts is OK for the 24v pumps Slide
27. otor will draw excessive current A fuse or circuit breaker will then break the circuit Without such a safety valve a minor fault can burn your motor and wiring Install a fuse or breaker with an AMP RATING close to the MAX AMPS rating of your motor OR LESS but not more higher If a Linear Current Booster is being used for array direct Slowpumps install the fuse between the booster and the pump Use the rating recommended for the booster or for the pump WHICHEVER IS LESS This fuse will protect the booster as well as the motor and wiring from overload FUSES Use a time delay type The 3 paper cartridge type is good and may be installed into a raintight disconnect switch available at any electric supplier An automotive in line fuse holder is fine for 12 or 24V systems Automotive blade fuses type ATC are prefered over glass fuses They have sufficient time delay Time delay glass fuses are available from ELECTRONIC suppliers only not automotive Use good quality fuse holders protected from weather Keep spare fuses handy Never substitute a larger fuse CIRCUIT BREAKERS Most AC breakers cannot be used for low voltage DC circuits We recommend only the SQUARE D QO or QB series which been rated safe up to 48 volts DC A 10 amp size is available but not in most stores It may be ordered from your PV dealer or from an electric supplier Install the fuse or breaker at the power source to protect the wiring as well as the mo
28. pe sizing will do no harm INTAKE MUST NOT BE RESTRICTED by undersized pipe excessive suction lift or a CLOGGED FILTER Excessive suction at the pump intake causes CAVITATION formation and implosion of vapor bubbles This causes very loud buzzing noise and RAPID PUMP WEAR A slight buzzing noise is acceptable if it cannot be avoided DO NOT USE THIN WALL HOSE or soft tubing on the pump s intake It may collapse under suction and restrict the flow Do not use polyethylene pipe black flexible for the suction either It is prone to slight leakage at the fittings INLINE FILTER should be mounted HORIZONTALLY and as low as possible This prevents any air trapped in it from blocking the water flow Be sure to leave some space below it for a pan to catch water when replacing the filter cartridge FOOT VALVE is a check valve installed at the water intake It is required in any case where the pump is located higher than the low water level in the source We recommend a high quality spring loaded type to avoid loss of prime A check valve allows water to flow one way and not the other Be sure to install it the right way Our 30 Intake Filter or Fine Intake Strainer Foot Valve accessory is recommended These prevent debris from catching in the foot valve and causing loss of prime REMOVE FOAM PLUGS BEFORE CONNECTING PIPES New pumps are packed with foam plugs to prevent contamination PRIMING YOUR PUMP Priming a pump means filling its intake
29. r wire radiating out in two or more directions from the PV array Try to contact moist earth as much as possible Use only the copper or bronze electrical connectors designed for grounding application and BE SURE ALL CONNECTIONS ARE TIGHT Connect your ground system to the METALLIC FRAME of your PV array via min 8 copper wire Also ground metallic support structures and electrical enclosures For non battery pumps we have observed the least lightning damage where only the mechanical structure is grounded NOT an electrical conductor This may vary from electrical codes Call the manufacturer of your controller if you have questions WATER LEVEL amp FLOW CONTROL FLOAT SWITCHES WATER LEVEL SENSORS These are devices that sense high or low water level and switch your pump on and off Ask your dealer or factory about these Most switches rated for 15 AMPS at 230 VAC are fine for your DC pump FLOAT CONTROL IN WATER SOURCE may be used if dropping water level is causing dry run or excessive suction noise due to cavitation FLOAT CONTROL IN STORAGE TANK may be used to turn pump off when tank fills This eliminates tank overflow and reduces pump wear and filter changing REMOTE FLOAT CONTROL when tank is aLONG DISTANCE from pump may be done in three ways 1 Small wire buried from tank float switch to pump actuates a relay at the pump 2 Very small wire from sensor in tank actuates Water Level Sensor option in your pump controller LCB
30. re restance to flow Carbon taste and odor cartridges have less capacity for dirt more resistance to flow and cost more Use them only if you have taste and odor problems A filter cartridge may look clean and still be clogged due to fine silt embedded in the fibers If the pump becomes increasingly noisey over time it is usually due to a clogging filter cartridge On the other hand a cartridge that looks discolored may not be clogged As long as your pump runs quietly the filter is OK Use pump noise to indicate the need to change cartridges IRON PIPE OR FITTINGS will introduce abrasive rust particles if installed on the intake side of the pump they rust even if galvanized Pipe that is dirty inside even new pipe or has mineral deposits in it will also introduce dirt Dirt is introduced as pipe joints are assembled especially in a trench Therefore make sure inlet lines and fittings are FLUSHED CLEAN before hooking up to pump The INLINE FILTER may have a red push button valve to release pressure for maintenance If filter is placed more than a few feet higher than water source at lowest level the suction may pull the valve open and introduce air Prevent this by sealing around the push button with silicone sealant or epoxy or replace the button with a nut tightened down 2 lll PUMP MUST NOT RUN DRY Water is the lubricant for your pump If it runs completely dry it will overheat and fail DRY RUN SWITCH is an optional accesso
31. ressure gauge vibrates extremely One of four vanes in the pump is broken Pump head must be rebuilt See Rebuild Exchange Service There should be almost no vibration of pressure gauge needle FILTER CLOGS FREQUENTLY 1 INTAKE TOO CLOSE to bottom of well stream tank etc Raise it as high as feasible to reduce intake of dirt 2 IMPROVE THE DEVELOPMENT of the water source channel water into a settling tank clean tank periodically 3 Install a larger filter or plumb two filters parallel to each other CLOGGED INTAKE SCREEN Safety screen is located at the pump intake Remove large nut 1300 series or intake fitting 2500 series or Booster Pump to inspect and clean screen 1 IF YOU DON T HAVE A CARTRIDGE TYPE FILTER INSTALL ONE NOW 2 If screen is clogged with fibers from filter cartridge use higher quality cartridges 3 If screen is clogged with rust deposits replace iron pipe or fittings with plastic copper or brass 4 If mineral or corrosion deposits are clogging screen install filter as close as possible to pump intake Ask local water professionals what type of pipe is least susceptible to mineral accumulation and corrosion in your area FILTER IS CLOGGED AND YOU DON T HAVE REPLACEMENT 1 IN LINE FILTER Purchase common Rust and Sediment fiber wound cartridge at local hardware store or pump well supplier 2 30 INTAKE FILTER Obtain spares from your dealer factory or industrial suppliers In emergency purchase 3
32. ressure switch fails EXCESSIVE PRESSURE may cause your tank or piping to burst and flood your home A properly sized fuse or circuit breaker should shut pump off before relief valve opens BUT many breakers are not accurate and the proper fuse may not always be present INSTALL THE PRESSURE RELIEF VALVE near your pressure tank at the Accessory Tee shown in diagram Run a pipe or hose from its outlet to a drain or drain pipe or to the outdoors where water can drain away safely A GATE VALVE and DRAIN VALVE are recommended see diagram for convenience during system shut down The drain valve is simply a garden hose outlet which allows easy draining of the system It also allows water delivery by hose while water is shut off to the house during installation or repairs to plumbing EASY INSTALLATION KIT IS AVAILABLE If you have not yet purchased the small parts you need to install your Booster Pump you can save time and confusion by purchasing our convenient Easy Installation Kit Pipe components are brass to resist corrosion The kit includes pressure switch pressure gauge tank tee shutoff ball valve and hose bib drain valve plus the necessary pipe nipples Order Dankoff Solar Item 20200 VENTILATION SLOTS are located on bottom of motor for cooling Standard Model Booster Pump only If you are concerned with insects building nests inside your motor glue some screen over the slots Silicone sealant works best for this FLOWLIGHT
33. roller inserted inside the LCB to LCB protect the pump from overload for backup power or testing using a battery hook jumper wires here not to controller input Remote Tank Float Switch See your controller instructions Float switch must MAKE contact on rise to turn the pump OFF This is opposite of normal action so your float switch may be labeled pump down to empty Earth Ground 11 WATER USAGE WATER CONSERVATION ENERGY CONSERVATION LESS FILTER MAINTENANCE TOILETS A 1 6 gallon flush toilet may reduce total domestic water consumption by 50 compared with typical 4 5 gallon toilets They are now standard in U S A IRRIGATION SYSTEMS Many drip trickle or flood irrigation systems will function on LOW PRESSURE It is wasteful of energy to supply pressurized water where it is not required You may wish to arrange separate gravity flow from your water source or storage tank if possible Or if a small amount of lift pressure is required consider a low pressure DC pump such as a marine bilge or circulator pump LOW FLOW SHOWER HEADS are recommended IF you are running 30 50 PSI pressure range At lower pressures they may not provide adequate flow FREEZE PROTECTION If freezing of your outlet pipe is to be expected you may avoid the frequent necessity of replacing fuses or resetting your breaker by installing an ADJUSTABLE PRESSURE RELIEF VALVE at the pump outlet This will allow water to flow back into the well
34. ry to prevent damage from dry run It is a small device with two wires that attaches to the front of the pump It senses temperature and switches the pump off before it gets too hot If you are pumping from a tank cistern or any water source that can run low accidentally a Dry Run Switch should be used If it saves a failure once in 10 years it s worthwhile WARNING The dry run switch must be clamped tightly to the front red plate of the pump Its round metal surface MUST press firmly against the red plate or it will not function If you can slip a piece of paper between the switch and the red plate it is not making sufficient contact Loosen the clamp and press the brackets further onto the pump so the contact is tight OPERATION The red push button pops out if the pump runs dry Push it in to reset the switch after water is restored A FLOAT SWITCH placed in the supply tank is an alternative to the Dry Run Switch The advantage is that it will reset itself wnen water rises and will not allow the pump to lose prime The disadvantage is the need to run a power cable to the switch OK if distance is short Please call your dealer or the factory if you have questions WARNING Do NOT use a LOSS OF PRIME PRESSURE SWITCH for dry run protection This is a pressure switch with an automatic shut off lever It will NOT function with this type of pump Your pump will push sufficient air to maintain pressure holding the switch on PLUMBING S
35. stem Installation from cistern or storage tank where pump is higher than the water source Q Air vent amp Dipstick access n _ Vv Buried Plastic Storage Tank Ground level pe P Float switch Feed pipe from well Fill Dirt 6 pump NOTE It is preferable to place the pump LOWER than the water level in the tank This illustrates an alternative not an ideal Note the upward rise of the suction pipe the high position of the priming plug and the horizontal position of the filter These measures help prevent air entrapment that restricts flow and causes pump noise Follow your pressure switch instructions for wiring Use the flexible hose that comes with your Booster Pump cut it into two sections Our Easy Installation Kit contains the tee fitting at the tank a DC rated pressure switch and all of the small parts shown between the pump and the house plumbing See PRESSURE SWITCH DIAGRAM on PAGE 20 Dry Run Switch a si optional S E clamps to pump face r RAE l faa j House plumbing Pressure relief valve Hose bib Flexible Hose Kit included allows easy installation and service and smooth flow If you do not use it install unions so that the pump can be removed for service without sawing pipes No iron piping between filter and pump Typical Flowlight Booster Pump installation Illustration by Home Power Magazine PRESSURE SWITCH ADJUSTMENT Switch setti
36. tor If the circuit is protected by a breaker then any additional fuse may be installed at the motor THERMAL OVERLOAD If your pump resembles the illustration on P 1 a THERMAL SWITCH is mounted on the rear of the motor inside the white cap to shut off the motor if it approaches an overheat condition If this happens it will turn back on after a cooling period of about 20 minutes If overheating occurs during normal operation of the pump it may be because it is working beyond it s capacity See Troubleshooting The Flowlight Booster Pump Standard Model may overheat if it is running for more than 20 minutes at a pressure exceeding 50 PSI It will cool and reset automatically GROUNDING and LIGHTNING PROTECTION A long wire run may act like an antenna receiving induced surges of high voltage when lightning is present Proper grounding will greatly reduce risk of lightning damage to your power system A proper ground system consists of a minimum of one 8 ft copper plated ground rod driven into the ground preferably in a moist spot close to the PV array Or if you have a steel well casing drill and tap a bolt hold to make good contact to it In a dry lightning prone location use more than one ground rod at least 10 ft apart Bury bare copper wire between them Use min 8 ground wire larger for distances exceeding 20 ft In a rocky location where ground rods can t be driven bury as much as feasible 150 feet total of bare coppe
37. tting pre charge Modern captive air tank will not need pre charging again GALVANIZED TANK without air bladder MUST BE RECHARGED with air about once per year as air dissolves into water Use tire pump or compressor BOOSTER PUMP TURNS ON PERIODICALLY WHEN NO WATER IS BEING USED 1 Water is leaking somewhere after the check valve check valve must be installed at pump outlet 2 Check valve leaks internally Foot valve if present also leaks LOW FLOW RATE PUMP TURNS SLOW MOTOR COOL 1 Voltage at motor measures lower than voltage at source WIRE IS UNDERSIZED Consult wire size chart or ask your dealer 2 See next entry SLOWPUMP RUNS TOO SLOW OR STALLS IN LOW LIGHT Array Direct Non Battery System 1 Solar array or wire is undersized 2 Linear current booster or similar matching devices needed to prevent stalling when array current is less than pump requires Contact dealer or factory 3 Current booster not tuned properly if it has an adjustment Set screwdriver adjustment for peak performance in LOW LIGHT conditions See current booster instructions 4 Pump may be drawing too much current Test Connect pump to battery s of proper voltage Measure current draw amps and flow rate Check against chart Watts Volts X Amps See Low Flow Rate Slow High Current above if not close to specifications PUMP WON T TURN shaft coupler can t be turned by hand Should blow fuse or breaker 1 After a period of disuse or
38. ver solution works to dissolve the mineral deposits in your plumbing Remove pipes from pump and allow solution to circulate through pump by turning it backwards If this doesn t work or if pump has been damaged replace or rebuild 15 PUMP CYCLES ON AND OFF ABOUT EVERY 20 MINUTES MOTOR IS OVERHEATING Thermal switch on back of motor is working 1 HIGH CURRENT DRAW See above 2 NO VENTILATION Motor must have FREE AIR FLOW to prevent overheating Do not wrap with insulation 4 Motor is exposed to sun or other heat source keep it cool 5 BAD THERMAL SWITCH Motor should shut off at approximately 140 degrees F If motor smells or is too hot to hold your hand on for 3 seconds replace thermal switch and check for overheat damage If motor is not getting so hot you can hold your hand on it for 5 seconds replace thermal switch NOTE ON BOOSTER PUMP STANDARD MODEL may overheat if run continuously periods over 20 minutes at pressures exceeding 50 PSI This may happen while running irrigation Observe pressure gauge and open valve s for higher flow so that pressure drops below 50 PSI or reduce your pressure switch setting The thermal switch protects the motor from damage BOOSTER PUMP CYCLES ON AND OFF EVERY FEW SECONDS PRESSURIZING SYSTEM PRESSURE TANK MUST be used with system Pre charge tank via air fitting to 2 PSI less than cut in pressure that s 28 PSI air in a 30 50 system Turn power off and release water pressure before se
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