T.E.(Terry) Manning Schoener 50 1771 ED Wieringerwerf The Netherlands Tel/fax 0031-227-604128 Homepage: http://www.flowman.nl E-mail:pumps@flowman.nl

FLOWMAN

ADVANCED PUMP TECHNOLOGIES

Edition 11: 27 January, 2002

SOLAR SPRING SOLAR PUMPS

INSTALLATION

The following pages are about the Sunprimer controller and how to mount the Sunprimer controller on the support structure. If you are more interested in other aspects concerning installation, please return to INSTALLATION INDEX

Fitting Sunprimer Mk I/d or Mk I/e or MK II controller on the panel support

HIGH HAZARDOUS VOLTAGE WARNING

WARNING! If your PV array is left disconnected in the full sun in open circuit condition, voltage may rise to anything up to 100V even in cloudy weather, enough for a nasty shock. When working on the array output wiring you may leave one wire disconnected between two of the modules to break the circuit, or shade the array by turning it out of the sun or by covering it.

ARRAY DISCONNECT SWITCH

An array on/off switch may be placed between the array and the controller, NEVER between the controller and the pump. Any good quality water-tight 30 amps single phase switch will do the job. This switch will always be left in "ON" mode, and will be switched off only during installation and maintenance. If there is no array disconnect switch, then BEFORE TOUCHING ANY WIRES make sure your array is turned away from the sun or that it is covered so as to reduce all risk of serious shock.

DIFFERENCE BETWEEN SUNPRIMER CONTROLLERS AND "BOOSTERS"

Simple controllers called "boosters" are available in commerce for use with PV panels. They are valid and useful for most applications. They are essentially voltage or current transformers or inverters and serve to improve the coupling ratio between PV panels and the devices being used. HOWEVER THEY ARE NOT SUITABLE FOR USE WITH HIGH PERFORMANCE SUBMERSIBLE HORIZONTAL AXIS PISTON PUMPS which have to be able to start under load. For this purpose more complex devices such as the Sunprimer units are required, with devices capable of starting the pump under and protecting the motor when the pump is not working.

FUNCTIONS OF THE SUNPRIMER CONTROLLER

The Sunprimer electronics unit incorporates five functions:

1) To interrupt current connection between the PV panels and the pump when insolation (and, with MK I/e or MK II, the battery charge) is such that voltage is so low (with the Mk I/D and Mk I/E Sunprimers this is about 20V, with the MK II unit it is about 22V) that the pump slows down to the point where it stops. This stops the motor from being put under continuous load when stopped.
2) To start your Solar Spring pump as early as possible in the morning and keep it going as long as possible into the evening (thus extending running time), provided insolation or battery charge is sufficient to keep the pump running. If the pump cannot start, or is turning too slowly, function 1 enters into operation. If insolation is reasonable, function 2) will make another attempt to start the pump. A secondary timer unit attempts to start the pump at intervals of approximately three minutes (Mk I/d and Mk I/e) and two (Mk II). This timer also operates on initial starting up, so that the pump will start operating APPROXIMATELY THREE MINUTES (Mk I/d and Mk I/e) OR TWO MINUTES (Mk II) AFTER ELECTRICAL CONTACT HAS BEEN MADE.
3) To switch nominal voltage between 48V and 24V in relation to the available power from the PV panels and pump load, so as to optimise amperage absorbed by the pump motor and adjust motor speed as required to optimise pump capacity. This function works with the MK I/D controller only where four panels are used, by automatically connecting all the panels in series or in two sets each of two panels in parallel, according to insolation and the load on the pump. This enables the pump to operate better in slightly cloudy conditions and/or earlier in the morning and later in the evening. This device performs some of the functions of traditional "boosters". The Mk I/E controller performs the same tasks where two panels or 24V battery systems are used. The MK II controller combines the features of both the Mk I/d and the Mk I/e units and always charges the capacitor to 60V even in 24V and battery applications. The Mk I controllers start in 48V mode, then switch to 24V mode where current supply is limited. The Mk II controllers start in 24V mode, then switch to 48V if sufficient current supply is available.
4) To connect the Solar Spring pump to GOOD QUALITY external float switches and/or other devices such as presostates. This is the smallest cable which comes out of the Sunprimer. It has two wires which, when placed in contact with one another or in an electrical circuit, interrupt the electricity supply. When the two wires are not in contact with one another or in an electrical circuit, the controller feeds current to the pump motor and, assuming insolation is sufficient, the pump will start again after about three minutes. The external controls or switches used should be of high quality and such that on and off contacts be made cleanly, precisely and quickly. Uncertain or irregular contacts may damage the controller.
5) To save pump motor and system components where specifications are not complied with during installation and/or in the presence of particular extreme or unforeseen environmental events (including freezing or blocking of the feed pipe system for any other reason or excessive draw-down of water in the borehole) where a fail-safe system is needed. For instance this function intervenes to cut current where current is greater than 4.5 amps for more than half a second. Normal starting procedures will then be activated, so the pump will attempt to start again after approximately three minutes (Mk I/d and MK I/e) or two minutes (Mk II).
6)Another device will act to cut current to the contoller by putting the PV panels into short circuit when for any reason the main transistor in the controller is damaged so that the controller can no longer work properly. The pump will automatically start again once the damaged transistor has been repaired.
7) Neither the Mk I nor the Mk II controller has a minimum current control to switch the pump off where it is running dry. The pump can run dry for days or even weeks without suffering undue harm. It has been assumed that where dry running is not immediately obvious to users, those interested will carry out periodic checks to make sure the pump is in fact pumping water.

MOUNTING THE CONTROLLER

The Sunprimer unit is to be mounted VERTICALLY with CABLE OUTLETS TOWARDS THE BOTTOM on to the rear side of the lower panel support. Although the controller is hermetically sealed against water, sand, and weather conditions generally, it is good practice to place it in as protected an environment as possible, sheltered so far as possible against rain and the direct rays of the sun. Although the Sunprimer is equipped with internal protection mechanisms tending to avoid momentary faulty connections and inversions of polarity, electrical connections should be made very carefully. SHORT CIRCUITING SHOULD BE AVOIDED. NEVER put wires in short circuit to see whether they produce sparks as is sometimes done with motor vehicle batteries. Where the array is placed a long way away from the water source, it is preferable to site the controller separately, appropriately sheltered from heat and the sun's rays, closer to the water source. In case of doubt, please consult your supplier.

WARNING! DO NOT MOUNT THE CONTROLLER DIRECTLY AGAINST PV PANELS. PV panels become hot when exposed to the sun. If the controller is mounted in direct contact with PV panels, the heat from the panels can be transferred through the controller box to the electronics environment of the controller. This may damage the controller. Where the controller is to be placed next to PV panels suitable heat insulation material must be inserted between the PV panel and the controller to avoid passage of heat from the PV panel to the controller.

SELF DIAGNOSTIC CIRCUIT WITH LED LIGHTS - SUNPRIMER MK II

The controller incorporates a self-diagnostic circuit which helps detect faults during installation and maintenance. The LED lights can be seen when the back of the controller box is removed by undoing the four controller box screws.

The LED lights are numbered in LOGICAL CIRCUIT ORDER, in order from the top 4,2,1,3

The LED at the top (marked no. 4 on the diagram) lights up when solar voltage greater than about 10V reaches the controller from the panels.
The second LED (marked no. 2 on the diagram) lights up when the main capacitor is charging. This phase lasts about three minutes (Mk I/d or Mk I/e) or two minutes (Mk II).
The third LED (no. 3 on the diagram) lights up when the controller sends output voltage greater than about 10V to the pump motor.
The fourth LED (no. 4 on the diagram) lights up when the pump motor stops because the external (float) switch is in OFF mode.
For more information on the LED lights refer toUSE OF CONTROLLER DIAGNOSTICS

WARNINGS !

Despite the presence of defence mechanisms built into the Sunprimer units, the manufacturer's guarantee is voided where voltages higher than those prescribed are used, even if such voltages are applied for a very short period of time. Nor does the manufacturer's warranty cover the use of the Sunprimer with power generators not being photovoltaic generators or, with Mk I/e and Mk II units for batteries, nor does it cover infiltration of water or external overheating whether of solar or other origin. Consult your supplier BEFORE carrying out laboratory testing, for which instructions will be given to interested parties.

THE CONTROLLER ITSELF MAY BE DAMAGED IF VOLTAGES HIGHER THAN THOSE PRESCRIBED ARE USED.

THE PUMP MOTOR WILL BE DAMAGED IF CURRENT IS NOT CUT WHEN THE PUMP IS NOT WORKING.
The product guarantee for Solar Spring pumps and/or Sunprimer controllers does not cover use with generators, even for a very short time, other than PV panels and batteries, whether for testing purposes or otherwise. Nor does the warranty extend to use of the products with voltages and/or currents greater than those specified for normal conditions of use with 24V PV or battery systems or with 48V PV panels systems using 4 panels each of 12V nominal voltage as prescribed. Nor does the warranty cover loss or damage directly or indirectly caused by lightning, water infiltration or externally caused overheating whether of solar or other origin.

For information on lightning protection please return to INSTALLATION INDEX

AVOID leaving coils of surplus electric cable on-line at the well-head or elsewhere, as these have been known to cause secondary inductive current and on rare occasions confuse controller components.

INITIAL PRIMING OF THE PUMP

It is good practice to run the pump with an open head in a recipient for a few minutes to make sure the valves are not stuck, BEFORE proceeding with the installation of the pump. For a drawing, refer to:
ILLUSTRATION OF INITIAL PRIMING PROCEDURE.
Please refer to WHAT TO DO IF THE VALVES ARE STUCK for a description of the procedure to follow.

HOW TO CONNECT THE SUNPRIMER TO PUMP AND PANELS

The diagram for making electrical connections is on the top of the box of the Sunprimer unit being used.

1) The Mk II Sunprimer works without adjustment with 48V and 24V arrays and 24V battery installations. If you are using a new Mk I/e or Mk I/e Sunprimer, the small black switch visible situated UNDER the supplementary circuit card is already in the position "four panels". If you are using a two panel system with a Mk I/d controller then the switch must be moved to "two panels", so the Sunprimer box must be opened and the contact switched to "two panel" mode. This is NOT necessary with the Mk I/e controller, which remains in the pre-set "four panels" mode even when used with two panels or with 24V battery sets.
If you are using a Mk I/d Sunprimer which is not new, or if you do not know whether it is currently switched on "four panel" mode or on "two panel" mode, then it is necessary TO CHECK THE POSITION OF THE BLACK SWITCH.
2) When closing the Sunprimer box make sure the box sealing ring is correctly in place.
3) If you are using a Mk I/d or Mk I/e Sunprimer, look at the circuit on the outside of the Sunprimer Mk I/d box. This circuit applies when you are connecting FOUR PANELS. If you are connecting TWO PANELS with a Mk I/d controller, details are given later in this section. The MK 1/E circuit for 24V systems is to be found on the front of the Mk I/e boxes.

Three electric cables come out of the lower part of the Sunprimer unit.

The SMALLEST is to be connected to eventual external switches such as float-switches, pre-sostate or pressure control groups etc.; the MIDDLE-SIZED cable (or outlet cable), which is to be connected to the pump, the LARGEST (or inlet cable) which is to be connected to the panels. If the smallest cable is not used, the ends of each of its two wires must be separately carefully insulated.

CABLE INDENTIFICATION SUNPRIMER TO PUMP

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII

The Sunprimer outlet cable has two wires, one BROWN (POSITIVE) and one BLUE (NEGATIVE). This has to be connected to the PUMP.

With all 4" diameter pumps the cable from the pump has three wires, brown, black, and blue.

1)THE BROWN OF THE SUNPRIMER IS CONNECTED WITH THE BROWN OF THE PUMP. Since the pump motor can run in either direction, the BROWN of the Sunprimer can also be connected to the BLACK of the pump.
2)THE BLUE OF THE SUNPRIMER IS CONNECTED WITH THE BLACK OF THE PUMP, Since the pump motor can run in either direction, the Blue of the Sunprimer can also be connected with the Brown of the pump.
3)THE BLUE OF THE PUMP IS THE EARTH WIRE AND IS TO BE CONNECTED TO EARTH OR WELL INSULATED AND NOT USED, ACCORDING TO APPLICABLE ELECTRICAL NORMS. The blue wire is supplied only to meet the requirements of eventually applicable electrical safety standards. We recommend the earth be used ONLY WHERE it's use cannot be avoided. We believe it INCREASES risk of damage and that it can cause electrogalvanic corrosion phenomena.

Note that with very early 6" diameter pumps, the cable from the pump has three wires : black is positive as with the 4" units; blue is negative; and yellow-green is earth.

HOW TO CONNECT THE SUNPRIMER TO THE PANELS

FIRST, TO AVOID RISK OF SHOCK MAKE SURE YOUR ARRAY IS NOT IN OPEN CIRCUIT! Turn it away from the sun, and/or cover it and/or disconnect one wire between two modules.

THEN CONNECT THE SUNPRIMER TO THE MOTOR AS ALREADY DESCRIBED ABOVE.

CABLE IDENTIFICATION SUNPRIMER TO PANELS

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII

The larger cable coming out of the bottom of the Sunprimer unit is the inlet cable and it has to be connected to the photovoltaic panels.

It has FOUR WIRES, brown, black, blue, and green-yellow.

WHERE YOU ARE USING FOUR STANDARD PANELS EACH WITH 36 CELLS WITH 12V NOMINAL VOLTAGE AND A WORKING VOLTAGE FROM 14-17V AND AN OPEN CIRCUIT VOLTAGE FROM 18V-21V open circuit voltages can reach 100V.

Panels with 72 cells are now commercialy available. These are usually made by mounting two standard panels each with its own electrical clips in the same frame. Extra attention should in such case be paid to the electrical contacts because of the risk of getting the electrical contacts of each of the two single panels mixed up.
Panels with a nominal voltage of 6V can of course also be used provided they are grouped in lots of 24V as prescribed.

SOLAR SPRING IS A 48V NOMINAL SYSTEM!

The four photovoltaic panels are ideally divided into two pairs and the panels of each pair are connected in series with 24V nominal voltage.

Four panel 48V applications with Mk I/d or MK II controller

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII

The POSITIVE of the first pair of panels is connected to the BROWN wire of the Sunprimer. The NEGATIVE of the first pair of panels is connected to the BLACK wire of the Sunprimer.
The POSITIVE of the second pair of panels is connected to the BLUE wire of the Sunprimer unit. The NEGATIVE of the second pair of panels is connected to the YELLOW-GREEN wire of the Sunprimer.

Four panel 48V applications with Mk I/e controller

If the Mk I/e model Sunprimer is used with four panels, the wiring is the same as for the Mk I/d unit, but the controller box must be opened. The panel mode switch remains on "4 panels" The switch on the side of the box near the float switch wire, which is always in "ON" position when it leaves the factory, must be changed to "OFF" position.

Comments valid for Mk I/d, Mk I/e and Mk II controllers

If the connections are incorrectly made, or if the two pairs of panels are different from one another or exposed to the sun in a different way, the system MAY NOT WORK at all or may not work properly.
If the controllers are not new, it is good practice to check the positions of the internal switches BEFORE proceeding with the installation.

REMINDER

The Sunprimer will start the motor about three minutes (Mk I/d and Mk I/e) or two minutes (Mk II) after the circuit has been completed.

TWO PANEL 2 x 12V = 24V APPLICATIONS

With Mk I/d controller

WHERE YOU ARE USING TWO PANELS with a MK I/d controller:

Open the controller box move the black switch to "Two panels" mode.
FIRST Connect the two panels in series.
THEN connect the POSITIVE of the panels to the BROWN of the Sunprimer, and the NEGATIVE of the panels to the YELLOW-GREEN of the Sunprimer.
Carefully INSULATE separately from each other the BLACK and the BLUE wires of the Sunprimer, which are not used.
Note that the Mk I/d Sunprimer for 4 PV panels when used with 2 panels acts as a starter booster only. The Mk I/e Sunprimer has been specially developed for use with 24V two panel and 24V battery systems.

With Mk I/e controller

WHERE YOU ARE USING TWO PANELS with a Mk I/e controller:
Switches inside the Mk I/e controller have been put correctly in position at the factory, with the black mode switch situated under the supplementary circuit in "Four panels" mode, and the switch on the upper circuit near the float switch wire in "ON" position.
Wire as for the Mk I/d unit.
If the Mk I/e controller is not new, check switch positions before proceeding.

With the Mk II controller

WHERE YOU ARE USING TWO PANELS with a Mk II controller:
DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII
Connect the pump to the controller as for 48V installations.
Then first connect together the brown and blue wires of the largest cable coming out of the controller, then connect the two panels in series so as to obtain 24V nominal, then connect the positive of the pair of panels to the combined brown and blue controller wires.
Then connect negative of the panels to the yellow/green controller wire.
Carefully insulate the black controller wire, which is not used.
The small float switch cable coming out of the controller is wired as for 48V isntallations.
General single- or two-pole on-off switches may if considered necessary be fitted on the positive wires (or on the positive and negative wires) of the panels. NEVER, NEVER insert any switch or other control device between the Sunprimer and the pump.

2 X 24V PANEL APPLICATIONS

Please consult the manufacturer

24V BATTERY APPLICATIONS

With the Mk I/e controller

Switches inside the Mk I/e controller are already correctly in position, with the black panel mode switch under the supplementary circuit card in "Four panels" mode, and the switch on the upper circuit near the float switch wire in "ON" position.
Wire as for the Mk I/d unit, but INSERT A GOOD QUALITY 3 AMP FUSE (this is not supplied with the pump) on the positive (brown) wire between the battery set and the controller.
If the Mk I/e controller is not new, check switch positions before proceeding.

With the Mk II controller

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII
A general single- or two-pole switch must be fitted to the positive (or to the positive and the negative) of the battery set.
INSERT A GOOD QUALITY 3-4 AMP FUSE (this is not supplied with the pump) on the positive (combined brown and blue) wire between the battery set and the controller. A standard motor vehcle fuse is appropriate.
Connect the pump to the controller as for 48V installations.
Then first connect together the brown and blue wires of the largest cable coming out of the controller, then connect the two panels in series so as to obtain 24V nominal, then connect the positive of the pair of the battery set to the combined brown and blue controller wires.
Then connect negative of the battery set to the yellow/green controller wire.
Carefully insulate the black controller wire, which is not used.
The small float switch cable coming out of the controller is wired as for 48V isntallations.
The product warranty does not cover damage caused by failure to install an on-off switch or a fuse or by the failure of such switch and fuse to work properly. For extra safety it is recommended that two identical fuses be mounted in series.
To ensure optimum battery duration a good quality automatic system for the control of battery charging and discharging cycles including LVD (Low Voltage Disconnect) should be installed, in particular to avoid excessive or long duration battery discharge conditions. The pump should work only when the battery set is appropriately charged and should be switched off when the set is discharged. The Mk II controller incorporates a device which switches the pump off should the input voltage go down to about 22V. This device should be considered a second line of defence and does not substitute correct manual or automatic management of battery use.

36V BATTERY APPLICATIONS

The Solar Spring pump may be connected WITHOUT CONTROLLER to 36V nominal battery sets in cases where special current surge for start up is not required.

Do not use pumps with 3mm or 2.6mm cams for battery applications without controller. This is because:

a) 3mm pumps need 56V on start up.

b) Commercial fuses are inaccurate and may take some time to react

A GOOD QUALITY 3-4 AMP SAFETY FUSE (this is not supplied with the pump) MUST BE FITTED on the positive (combined brown and blue) wire between the battery set and the controller. A standard motor vehcle fuse is appropriate.
The product warranty does not cover damage caused by failure to install an on-off switch or a fuse or by the failure of such switch and fuse to work properly. For extra safety it is recommended that two identical fuses be mounted in series.
Electric connection on start up MUST ALWAYS BE INSTANTANEOUS. If the connection is gradual and progressive, the pump may not start, and in this case high short circuit current conditions would occur with the pump stopped, and this would burn out the fuse.
ALWAYS test with general switch and safety fuse fitted.
Refer to comments under 24V battery systems concnering measures supporting optimum battery duration.

48V BATTERY APPLICATIONS

Do not use pumps with 3mm or 2.6mm cams for battery applications.

This is because:

a) 3mm pumps need 56V on start up.

b) Commercial fuses are inaccurate and may take some time to react

48V battery installations are potentially dangerous in that excessive surge current can be generated unless appropriate steps are taken to avoid risk of demagnetisation of the motor and rapid wear and tear of the motor brushes.
In addition to the general switch and the fuse mentioned for 36V battery installations, 48V battery systems must also have both in actual installations and during eventual tests an electrical resistance OF AT LEAST 0.68 Ohm to act as a limiter. This can be installed by inserting between THE BATTERY AND THE PUMP a 0.68 Ohm 25W resistor. The resistance of the electrical cable itself is sufficient for this purpose provided AT LEAST 50 meters of 2.5mm2 cable or AT LEAST 80 meters of 4.0mm2 cable or AT LEAST 120 meters of 6mm2 cable is installed.
Installation of systems with battery sets over 48V nominal voltage is PROHIBITED.

THREE PANEL APPLICATIONS

Although the system will work more effciently with 4 panels, the Mk I/d Sunprimer can also be used with 3 panels.
The panels have to be connected in series as for two panels. The black panel mode switch situated underneath the supplementary circuit of the Mk I/d Sunprimer is on "two panel" mode.

The configuration uses the full power of all three panels, but (just as is the case for use with 2 panels) it does not use the series/parallel switching mechanism. The system used with a Mk I/d controller will therefore operate for fewer hours per day, and the system will operate slightly less efficiently than it would with 4 panels. The Mk I/d system's initial starting power is the same as it would be if there were just two panels, but the normal working power is that of three panels.

Conditions of use lie between those for two panels and for four panels. In typical conditions you would use 3mm cam with 4 panels (with the Hyboost) and 2.2mm cam with 2 panels (without the Hyboost). So, you would use in this case a pump with a 2.6mm cam without the Hyboost unit with panels > 70Wp. If the panels were smaller it would be better to use a smaller cam. If you try to use a 3mm cam with Hyboost with 3 panels, you will not harm the pump, but the system is going to start later in the morning, finish earlier in the evening, and it may stop completely when clouds go over. It will therefore pump more water when insolation is good but less water over the whole day. It would therefore globally speaking operate less efficiently.

USE OF HIGH VOLTAGE MODULES IN VERY COLD AREAS

If certain types of high-voltage modules now being introduced to the market are used with the Sunprimer in very cold areas, there is a risk that AT CELL TEMPERATURES below -5 degrees C. it be advisable to install a voltage limiter between the panels and the Sunprimer unit.

INSTALLATION INDEX

FOR MORE INFORMATION ON THE SOLAR SPRING PUMP PLEASE GO TO: SOLAR SPRING COVER PAGE

RETURN TO:

PRODUCTS OFFERED

If you cannot find the information you require on these pages, please contact Terry Manning by e-mail on : pumps@flowman.nl or telephone or fax him at 0031-227-604128.

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