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Wiring Diagram for Solar Modules in Series

*Warning: Incorrect wiring configuration can cause controller damage*

NOTE: Your system may have 2 or more modules in series.
Do not exceed controller VOC rating.
For wattages above 500W a DC Isolator or Circuit Breaker must be used.

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L1, L2, L3 to Pump

24-48 V Controller has an open circuit max of 100 V DC
110 V Controller has an open circuit max of 200 V DC

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Summary of Contents for Waterboy

Page 1: ...Installation Manual ...

Page 2: ...NS 11 Wiring Diagram for Controller 11 Wiring Diagram for Solar Modules in Series 12 Wiring Diagram for Solar Modules in Series Parallel 2x2 13 Wiring Diagram for Solar Modules in Series Parallel on Single Array 4x2 13 REMOTE SWITCHING 14 Waterboy Tank Float Switch 14 Wiring 14 Waterboy Pressure Switch 15 Wiring 15 Setting 16 TROUBLESHOOTING 17 Running Indicators and Malfunction Information 17 Con...

Page 3: ... p8 Do not set the pump on the bottom of the bore or in near mud and debris Do not exceed a maximum submersion depth of 40m at any time Make sure there is a non return valve included in the line Do not allow the pump to run dry at any time Always use the stainless steel cable to raise or lower the pump assembly p4 The low water sensor when used must be installed a minimum of 300mm above the water ...

Page 4: ...ble to the delivery pipe every 2 meters with a strong tape such as duct tape to prevent snarling of cable Be sure to leave some slack between each section of tape as this will allow for the pipe to stretch Bore when installing in a bore or suspending in a well you will need to use a strainer or suspension wire for hanging the pump we supply a 3mm 316 stainless steel cable with all our bore systems...

Page 5: ... following system is often used with a conventional AC pump so a generator can be used for backup The AC pump is placed immediately below the cylinder and connected to the cylinder s threaded intake When power is applied to the AC pump it pushes water up through the cylinder pushing its valves open When the windmill draws water it sucks it up through the AC pump with little resistance The centrifu...

Page 6: ...rizon more of the sun s rays will strike the surface of the array and provide more power to the pump In the summer months the angle of the array can be reduced to take advantage of the sun s higher position in the sky This adjustment improves total output whether the solar array is a fixed or a single axis tracking type Wiring the Array When connecting the panels together you need to be aware of t...

Page 7: ...e than 30m from the controller to the bore head or to the float switch Lightning rods surge arrestors and additional lightning protection devices may be obtained from a local supplier Float switch cable A long run of control cable to a float switch in the storage tank can pick up damaging surges from nearby lightning The best protection is to use shielded cable Shielded cable has a metallic foil o...

Page 8: ...appropriate waterproof cable splice jointing kit includes crimp connectors to join the copper wires adhesive heat shrink tubing and instructions Always ensure the connectors are firmly crimped onto the electrical wire and no insulation is caught inside Allow at least 10 15 minutes before moving the join to ensure the heat shrink is set hard Splicing the Submersible Cable onto the Low Water Probe T...

Page 9: ...t the low water cable through the smaller gland in the bottom of the controller box being careful not to damage any components on the board 6 Connect the two wires to the terminals COM1 and WH 7 The tank full circuit uses the normally open NO terminals COM2 and TH If no tank full pressure switch is used leave open 8 Insert the tank full pressure switch cable through the smaller gland in the bottom...

Page 10: ...etween the shut offs Continue reducing the speed in small stages until you are satisfied with the compromise between the flow rate and the amount of time that the pump shuts off on low level NOTE It is recommended that the speed not be reduced below 50 as this can cause low power issues for the controller if less flow is required then revise your system needs or bleed off some flow back to the sou...

Page 11: ...d follow labeling for correct wiring Low water and tank pressure switch wires have no polarity for connection Pump cable wires must Be connected by number 1 2 3 SYS Pump MPPT ERR_1 Low Pwr Tank F Well L Timer Control Speed Control P P B B 1 2 3 COM2 TH COM1 WH SOLAR BAT Tank Float Or pressure switch with N O contacts Low Water Sensor Pump Controller ON OFF Switch may be in a different position and...

Page 12: ...r damage NOTE Your system may have 2 or more modules in series Do not exceed controller VOC rating For wattages above 500W a DC Isolator or Circuit Breaker must be used Solar Solar L1 L2 L3 to Pump 24 48 V Controller has an open circuit max of 100 V DC 110 V Controller has an open circuit max of 200 V DC ...

Page 13: ...4 panels is balanced before connecting to DC Isolator Incorrect connection could damage controller DC Isolator or Circuit Breaker 24 48 V Controller has an open circuit max of 100 V DC 110 V Controller has an open circuit max of 200 V DC Solar Solar L1 L2 L3 to Pump NOTE Branch plug has one ve output Branch socket has one ve output Branch plug Branch socket DC Isolator or Circuit Breaker Solar Sol...

Page 14: ...ing vertically when the tank is full The float switch comes with 20m of cable making it the perfect way to remote switch over a short distance Selecting 2 of the 3 wires available BLUE BLACK BROWN are all that is needed for N O normally open or N C normally Closed terminal contacts based on float up or down position see below Filling a tank Emptying a tank Closed Open Pump off Pump on Open Closed ...

Page 15: ...this valve is shut building up pressure in the pipeline At the desired pressure the switch opens and the controller stops the pump The pump will start up again when the pressure in the pipeline is released as the tank empties Always install the pressure switch with the pressure gauge in the upright position Wiring As a standard BW Solar Pressure Switches operate in the Normally Open N O configurat...

Page 16: ...crew at the top of the switch On the side window are markings from 4 to 12 10x number shown for meters of head pressure to show where the pressure is set a red tab inside moves up or down as the top screw is adjusted A right turn on the screw raises the pressure a left turn lowers the pressure The pressure switch must be set between 5 and 10 meters above your operating head pressure TDH ...

Page 17: ...I light Indicates current error Examples are when power cables are too small fix this by using larger wire cross section such as 4mm or a locked rotor in the pump fix this by cleaning out any debris from the pump or drying the pump end out if in water lock 5 LOW POWER light Indicates low power input to the controller Check for shading or bad panel connections Can also occur if the speed dial is tu...

Page 18: ...ump submerged too deep Raise the pump to within 30m of the maximum water level Low Power light illuminated Sunlight not strong enough Wait until sunlight level increases or remove items shading array Loose connection in solar array or damaged panel Check all connections between panels and to the controller Replace damaged panel s Pump cable splice connection bad pump water locked or blocked Repair...

Page 19: ... and tank volume Broken or damaged cable Check entire length of cable for damage Short at terminal Ensure there is no stray wires or insects connecting the terminals COM2 and TH Blocked diaphragm Check and remove any dirt or blockages from the inlet at the bottom of the pressure gauge ...

Page 20: ...all check the following Carefully check the Electric Cable to the Motor Especially check any underwater cable splice Check the Pressure Switch Float Switch is operating Disable the Pressure Switch Float Switch and retry starting the Motor Use care when disabling ensure that the Controller is turned off Examine pump for a blockage sand tree roots snakes algae etc Check the Bore has an adequate wate...

Page 21: ...of helical rotor pumps and can be easily avoided All HR pumps should be run every day or removed from the water when not used Solar array The solar array will require no maintenance beyond a visual inspection especially after a storm or strong winds over an extended period Tighten any loose bolts and ensure the footing remains sturdy and no erosion has undermined the frame Solar Tracker If the sys...

Page 22: ...he 4 inch pumps have 4 bolts Always ensure the solar panels are disconnected from the controller prior to any work being carried out Dismantling the worn pump assembly Procedure Remove the bolts from the top of the pump housing and set aside Lift the top end off the pump and slide along the cable out of the way Remove the stator Remove the bolts from the body and slide up off the rotor out of the ...

Page 23: ...set aside The motor shaft flexi coupling and rotor utilise a Left Hand Thread Using a spanner to hold the motor output shaft unscrew clockwise the rotor and flexi shaft from the motor Inspection of parts Inspect the rotor and stator for wear and tear and note any scoring on the rotor that may indicate excessive solids in your water ...

Page 24: ...ump has been running for some time it must be running with the correct rotation or it would not have been pumping You can reuse your existing grub screws if available Procedure Screw anti clockwise the flexi shaft onto the motor shaft and hand tighten Insert the grub screw into the bottom thread and tighten Ensure the rotor is tightened into the flexi shaft Insert the grub screw into the top threa...

Page 25: ...25 NOTES ...

Page 26: ...fits resulting from any cause whatsoever arising out of or relating to the installation or commissioning of any product sold This warranty does not cover products altered or modified in ANY WAY not authorized in writing by BW Solar 2 Warranty Performance This limited warranty is applicable only to Customers who have purchased the above products directly from BW Solar or from an authorized agent of...

Page 27: ... s expense NO EXCEPTIONS 3 Costs All costs incurred in obtaining warranty are the responsibility of the customer or Agent including but not limited to shipping and handling travel expense lost time lost production or pickup and delivery and return shipment 4 Agents Responsibility The Agent must supply their customer with all documentation relating to installation and warranty and if installing mus...

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