Installation & Service Manual
Contents
1. a cushion or spring In order to function the air pressure MUST be set properly for your system as follows 1 Be sure that there is NO water pressure at the tank s pipe fitting The tank can be detached from the pump to do this 2 Measure and note the existing air pressure in the tank using a tire gauge 3 Calculate the pumping pressure by noting the vertical lift feet from the pump to the outlet or storage tank This number divided by 2 31 PSI 4 Adjust the air pressure by letting some air out or pumping more in to approximately Page 4 ONE HALF of the pumping pressure PSI This setting does not need to be exact If it is too high the air bladder will be too hard and will not act like a cushion 5 Screw the Surge Tank in to the port marked Prime on top of the pump water box Priming If pump intake is higher than the water source Remove the plug or surge tank from the port called prime and pour water in while pump is running then reinstall the plug This is an outlet port but water will seep through the outlet valves when they are not under pressure and fill the cylinder If any point on the intake line is higher than the top of the pump s water box install a pipe tee and plug at that point Remove that plug to prime the pump You must displace any air that may get trapped in the high point on the intake line Install a check or foot valve at the base of the intake line so that it holds prime S2. draw less current and pump less water Order them from your dealer or factory or other pump supplier They are similar to those used in windmill and hand pump cylinders Do NOT use rubber seals They cause excessive friction and may cause sand particles to scratch the cylinder wall When replacing leathers on Model 3040 use your spare brass cylinder as an insertion guide See Starting the Pump amp Servicing the Leathers 4 CHECK OIL LEVEL Keep oil filled ONLY to the bottom of the inspection window 5 CHANGE OIL every 2 to 5 years depending on use Use 8 oz 240 cc SAE 30 weight ISO 100 oil The best oil is hydraulic oil with good water resistance You can also use air compressor oil or motor oil If the oil develops an opaque light brown milky color it is contaminated with water and must be changed immediately Wipe out the crank case to remove water and leave it open to dry out before you refill it 6 CHECK ROD WIPER see diagram part 57 This is a rubber disk on the piston rod It prevents water from leaking into the crank case and displacing the oil It MUST FIT TIGHTLY on the piston rod so it MOVES WITH THE ROD If it is loose on the rod GLUE it to the rod using silicone sealant or similar rubber adhesive 7 CHECK MOTOR BRUSHES These are small blocks of carbon graphite that make the contact to the spinning part of your motor When they wear out the motor will stop completely as the circuit is broken Remove the
3. two curved plates on the rear of the motor The brushes are held in with clips that are easy to remove with your finger New brushes measure 1 1 4 3 cm long When your brushes are worn half way replace them Brushes should last 5 10 years After a few years you can measure the wear and predict life expectancy Storing and Restarting Your Pump If you will not be using your pump for periods of 2 months or more please drain it This will allow the leathers to dry so that they don t grow mold or mildew and will prevent heavy accumulation of rust Remove one of the plugs under the water box Remove the round cover plate on front of the water box and then remove the piston assembly using a 3 4 socket wrench Replace the cover plate loosely to keep rodents out To restart the pump soak the piston assembly stretch the leathers out then replace it in the cylinder See Startup Proceedure Long Term Care Crankcase Oil If your pump runs all day please change the oil during the first year After that change oil at 2 year intervals Check for contamination See 5 and 6 under Maintenance above Cup Leathers Leathers may last for 5 10 years However we recommend changing them periodically to protect your cylinder Leather is used because it can absorb particles of dirt that would otherwise scratch the cylinder If the leather becomes saturated with abrasive material it acts like sandoaper We have a customer who pumps water that
4. Solar Force Installation amp Service Manual PV Models for Solar Direct Application Please record your MODEL PV Serial Your shipment may arrive with the motor pump and surge tank in three separate parcels We no longer include oil with the shipment due to safety regulations imposed by our freight carriers Please obtain your own oil see page 3 Assembly of Motor and Gearbelt Drive Install the motor pulley on the motor shaft with the square shaft key inserted Oil the shaft first to make future removal easier If the pulley does not push on easily file the edges of the shaft slot or file off two sides of the square key slightly Do not tighten the screws yet Bolt the motor to the motor mounting blocks Hold a straight edge against the motor face to check that it is parallel to the large pulley Adjust belt tension for about 1 4 inch deflection Turn the large pulley by hand Be sure the belt runs nearly centered on the large pulley and tighten the motor pulley Handle gearbelts carefully Do not force pry or bend them Sharply Locating and Mounting the Pump See Diagram If the pump is to be located higher than the water source mount the pump as low as possible without risk of flooding It is desirable to minimize suction lift for greatest reliability See the attached specification sheet for suction lift limitations Allow easy access to the round plate on the front of the water box You may need to r
5. e that we had to look to the past to utilize the energy source of the future We have sold our Solar Force pumps since 1989 with terrific results It is rare for any of them to need any more than the inexpensive parts included in our parts kits KEEP THESE INSTRUCTIONS IN A DRY SAFE PLACE You will want to refer to them years from now Copyright 1996 by Dankoff Solar Products All Rights Reserved Page 7 Innovative Solar Solutions e 2725 Westinghouse Blvd Suite 100 e Charlotte NC 28273 e 866 856 9819 e www innovativesolar com
6. emove it to replace piston seals leathers occasionally If your water is very dirty you will need more frequent maintenance so leave plenty of work space Pagel Solar Force Piston Pump System Layout Observe these minimum clearances for inspection and maintenance Corner Clearance Top View Mirror may be used to inspect oil ney 6 in Leave space open here for servicing rod Belt Guard seal oil belt requires 12 in drive and motor clearance above brushes it for removal Check Valve Union Water Box Leave clearance above and below Leave space to service pump open here for Surge Tank valves servicing cup Mounts onto fitting marked leathers Prime Leave 15 clearance above Water Box Bolt the pump directly to a strong firm surface Do not mount on rubber pads Expect traces of water and oil leakage at the rod packing Pipe from Pressure Relief Valve not shown must lead to safe drainage Avoid humps in the intake line to eliminate air pockets Store spare parts and Instruction Manual in a clearly marked box nearby The pump and the belt guard must be screwed or bolted down to a base of wood concrete or steel Be sure that your mounting structure will be able to support the weight of the pump and water in whatever pipes the pump will support Your mounting structure should be able to hold up for 20 years or more in damp conditions If it is not strong the pump will shake i
7. he water supply Model 3040 Your intake pipe must be no smaller than 1 1 4 inch size the size of the intake port on the pump Models 3010 amp 3020 You may reduce down to 1 inch pipe if you wish If intake pipe is more than 25 feet 8m long and yours Is the higher flow model 3040 then go one size larger Do not restrict intake with undersized pipe or suction lift beyond specified limits Doing so will cause cavitation formation of vapor bubbles A slapping sound is evidence of cavitation which will cause excessive wear and loss of performance Do not use flexible hose that crushes or kinks easily Do not allow intake to draw sediment from the bottom of water source Avoid humps in the intake pipe They can cause air pockets that will obstruct the flow of water A gradual incline is best If your pump is placed higher than high water level in your water source you will need a foot valve available from any pump supplier You will also need to prime the pump by pouring water into the port marked prime on the pump You must completely fill the intake pipe so that the pump does not draw air in order to draw up the water Shutoff Valve If your pump is placed lower than your water source install a shutoff valve to stop water flow when you are working on the pump Screening Debris If your water contains sand consider the addition of a sand screen If your water contains various debris use a foot valve with a large inta
8. hould now be little or no accumulation of water Pressure Relief Valve A Pressure Relief Valve is supplied This is an important safety device that must be installed on the front of your water box above the round plate If your pump s outlet is ever blocked excessive pressure will build and water will escape from this valve Fit a pipe or hose to the valve to conduct water safely away to prevent water damage should the valve open Position the valve so that its outlet does not block access to the round cover plate The valve is factory pre set for 80 PSI 180 feet 55 m If you are pushing more pressure total lift turn its adjustment screw clockwise until water leakage stops no further To reach the adjustment screw remove the flat front cover screw stamped 100 psi You will see the adjustment screw inside MAINTENANCE Parts of your pump will wear with normal use Your pump came with a box of spare parts Keep it labeled and stored in a safe place so it can be found years from now Page 5 1 TIGHTEN THE PACKING NUT around the piston rod when water leaks too much Tighten it LIGHTLY while the pump is running Do not overtighten it or more power will be consumed It will always leak slightly 2 CHECK BELT TENSION Belt should deflect no more than about 1 4 6mm Slide the motor to adjust the tension 3 PUMP LEATHERS are the seals that form the heart of the pump When they are worn the pump will turn faster
9. ke screen This will keep out large particles and sticks that can catch in your foot valve Near the pump s intake you can add in line screen or disc filter to catch finer debris where it may be cleaned out easily Contact pump or irrigation suppliers for these items Outlet Plumbing A check valve must be installed at the pump outlet This will make the system more efficient and easier to service and will prevent continuous leakage at the rod packing Use a spring loaded check valve with a rubber seat Page 3 If your outlet pipe is long you will need to increase the size to larger than 1 inch Look at a pipe sizing chart or ask your dealer or a pipe supplier for advice Electrical Wiring Low voltage power requires larger wire than conventional 115 Volt power Consult a low voltage wire size chart or ask your dealer for wire size recommendations Undersized wire will reduce pump speed and may be hazardous Always follow the National Electrical Code If you are not experienced with electrical installation hire a qualified electrician Motor Wiring Red Positive Black Negative Direction of Rotation Clockwise If motor turns in the wrong direction reverse the wiring Protection from Electrical Overload A mechanical or hydraulic fault in your system can cause motor overload If protection is not provided this can cause damage to your motor or other parts of your power system including fire hazard A circuit breaker
10. looks like creamed coffee After about 2000 hours with the original leathers the flow began to diminish due to grooves worn in the cylinder Even clear water may contain occasional particles of sand or traces of clay You can easily inspect your cylinder by removing the round plate from the water box Turn the pulley to draw the piston inward then feel the cylinder wall with your finger If it is not very smooth then replace your cup leathers at more frequent intervals Page 6 Valve Parts The rubber valve discs will wear if the water is dirty but will generally last for 5000 10 000 hours Replace them if they develop any cracks Replace the valve springs at the same time Tools Keep these tools at hand for inspection and maintenance Wrenches Packing Nut Wrench included with pump or substitute 1 1 8 open end 7 16 1 2 and 9 16 box end wrenches Socket wrench with 3 4 deep socket or shallow socket with short extension Pliers Common straight slipjoint type Screwdriver phillips head 1 2 HP models or flat head 1 4 HP models to fit motor brush covers Pipe Wrenches as appropriate Operating Solar Force by Hand You may operate your pump by means of any mechanical power source that will turn the pump pulley To work it by hand attach a lever to the pulley You need only to work it back and forth within a 90 arc Make a handle of wood or metal Square or angle stock Drill two pairs of holes and use
11. or fuse is the electrical safety valve that prevents such damage Failure to install a proper fuse or circuit breaker will void your warranty If you are using a non battery solar direct system with a current booster controller LCB wire your breaker or fuse in the circuit between the current booster and the pump not between the array and the booster Place the fuse or breaker at the controller not at the motor A circuit breaker is better than a fuse Most AC breakers cannot be used for DC circuits We recommend only Square D QO or QB Series breakers They are commonly available at electric supply stores and are UL listed for low voltage DC up to 48V If you use a fuse use either a plastic plug type automotive fuse 24V 30 Amp Max or a cartridge type time delay fuse the same as used for AC power Do not use the small glass tyoe of fuse Keep spare fuses nearby DO NOT substitute a larger fuse if there is a problem Amp Rating of fuse or breaker The breaker of fuse must be rated NO MORE than 10 higher than the Amps rating on the motor label Surge Tank A piston pump produces a pulsating flow It stops and starts with every cycle A surge tank is a tank of air that takes water in and out and completely smoothes the pulsating flow This greatly increases the efficiency of your system The tank we provide contains an air bladder much like a balloon inside with a tire type air fitting on top The air bladder acts like
12. small U bolts or bolts with a metal plate to mount the handle to the pulley Position the lever so that its motion causes the the piston rod to move through its full stroke If your pump is operating in a range that requires less than about 200 watts you may not need a long lever to work it You can try this Drill a hole near the edge of the pulley and attach a long bolt that can act as a handle This will allow full rotary cranking motion If the motor remains belted to the pump it will spin as a flywheel and help the pump to turn smoothly Warning The motor will act as a generator Disconnect it from any power source insulate the motor leads and beware of shock hazard History Brass cylinders with leather cups have been used to pump water since the dawn of the industrial revolution Double acting piston pumps similar to ours were very popular for pumping shallow wells and for pressurizing from the 1920 s to the 60 s Old folks have told us that they had piston pumps like this that lasted 30 years Cheaper submersible and jet pumps took over the market by the 1960 s The modern pumps have one moving part and require no maintenance The problem is they consume twice as much energy The piston pump has two other advantages One is that we can use our choice of DC motors Another is that it can develop full pressure even when turning very slowly This is an essential characteristic for solar direct pumping systems It is curious to not
13. t loose Level the mounting base to insure proper oil distribution Expect some water to drip from the rod packing Traces of oil may also leak from the Page 2 crankcase around the shaft and window Mount the pump so that it cannot leak into your water supply If that is not practical place some rags under it to absorb oil and water that may drip Place the belt guard over the belt drive assembly Position it so that the pulleys turn freely then screw it down to your mounting surface WARNING DO NOT OPERATE PUMP WITHOUT BELT GUARD IN PLACE Catching a finger or loose clothing or hair in the mechanism can lead to serious injury Shelter your pump from rain dirt and hot sun as well as from children and other wildlife If it is outdoors provide a good cover Leave some air space around the motor for cooling If you insulate the pump for freeze protection do not wrap insulation around the motor Adding Crankcase Oil Do not run your pump until you have added 8 oz 240 cc SAE 30 weight ISO 100 oil to the crankcase The best oil is hydraulic oil with good water resistance You can also use air compressor oil or motor oil To add oil either remove the brass plug above the clear sight window or remove the sight window Bring the oil up only to the bottom edge of the window Any more will leak out Intake Plumbing lt is most important to minimize resistance to flow on the intake side Place the pump as near as possible to t
14. tartup Proceedure amp Servicing the Leather Cup Seals DO NOT RUN THE PUMP DRY If it does not work after priming it may be because the leather seals are dry They need to soak up water and expand If it still doesn t work remove the piston and stretch the leathers with your fingers then replace them in the cylinder 3040 Models Use your spare brass cylinder as an installation guide If pump is pushing only 1 2 capacity and pulsating one leather is not sealing It will usually seat itself in a short time If not remove the piston and stretch leathers again You will need a 3 4 INCH SOCKET WRENCH and straight pliers to service the leathers When unscrewing the piston the piston rod may turn and come out with it no problem When replacing the piston assembly screw it in firmly WARNING DO NOT tighten the piston very much or the piston follower part 19 will crack Run in Your new pump may be stiff at first causing higher current draw than anticipated This will correct itself as parts wear in Adjusting the Packing Nut The piston rod enters the water box through a packing seal When you first start your pump it will leak While the pump is running tighten the packing nut You may use the wrench supplied with your pump Tighten it until the pump slows down substantially This will compress the packing Now loosen the nut slightly until the pump runs faster and is Slowed only very slightly by the packing pressure There s
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