Installation & Service Installation & Service Manual 2010
Contents
1. 2010 Installation amp Service Manual B Models for battery power or AC applications only Please record your MODEL B Serial Your shipment may arrive with the motor and pump in two 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 Belt Drive Install the motor pulley on the motor shaft Oil the shaft first to make future removal easier Mount the pulley with the setscrew end facing away from the motor Place one setscrew in the slot on the shaft but do not tighten the screws yet Bolt the motor to the mounting blocks loosely Hold a straight edge against the motor face to check that it is parallel to the large pulley Adjust belt tension for about 1 2 inch deflection and tighten the motor mounting bolts Turn the pump by hand and then tighten the setscrews on the motor pulley 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 remove it to replace piston seals leathers occasionally If your water is very dirty you will need more frequent maintenance s2. Tall Screw Adjust this one to set both cutin amp cut out ure Set it for the cut in that Second Short Screw you desire This one adjusts Counterclockwise will cut out pressure only lower fhe setting 115VAC Models Wire exactly as above White is neutral and black is hot 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 wired in series will extinguish the arc spark that forms when the contacts break This greatly increases switch reliability Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual Pressure Tank If you are using this pump in a pressurizing system you need a pressure tank available from any pump supplier or from your dealer Use a MINIMUM 40 GALLON sized tank Important Adjust the pre charge air properly You must do this with water exhausted from the tank so that your water pressure is zero Then set the air pressure to 2 or 3 PSI below your cut in pressure If you readjust your pressure switch settings remember to adjust the pre charge again Surge Tank A piston pump produces a pulsating flow A surge tank is a tank with a cushion of air inside a small pressure tank that take
3. VEL Keep oil filled ONLY to the bottom of the inspection window Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com a 2010 Installation amp Service Manual 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 1 2 HP models Remove the 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 sh
4. ank 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 valve or foot valve at the base of the intake line so that it holds prime Startup Procedure 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 Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual 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 st
5. d to prime the pump by pouring water into the port marked prime on the pump The idea is to completely fill the intake pipe so that the pump does not have to pump 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 Foot Valve If your pump s intake is to be higher than the water source it must have a check valve or a foot valve at the intake These items are available from your local pump supplier See priming 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 intake 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 It is not necessary to filter the water to a totally clear state Your pump can tolerate a moderate amount of sediment Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual 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 continuou
6. he 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 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 piston rod to move through its full stroke 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 60 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 We use this advantage on our solar direct pumping systems It is curious to note 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 Regarding 115VAC Models Only Your motor is a DC motor AC power is con
7. let 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 1 TIGHTEN THE PACKING NUT around the piston rod when water leaks too much Tighten it lightly while the pump is running Do not over tighten it or more power will be consumed It will always leak slightly 2 CHECK BELT TENSION Belt should deflect no more than about 1 2 12 mm A repeating groaning noise indicates a slipping belt Tighten it immediately 3 PUMP LEATHERS are the seals that form the heart of the pump When they are worn the pump will turn faster 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 LE
8. liminate pulsation and noise If pulsation persists install a ST 3000 Surge Tank available from your Dankoff Solar Pumps dealer or any expansion tank of around 1 Gal size See text BR Use 1 or larger pipe in accordance with plumbing standards E not shown Pipe or hose from Pressure Relief Valve to safe drainage Store spare parts and Instruction Manual in a clearly marked box nearby Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual Expect some water to drip from the rod packing Traces of oil may also leak from the 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
9. o leave plenty of work space The pump and the belt guard must be screwed or bolted down to a base of wood concrete or steel Your mounting structure must support the weight of the pump and the attached piping 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 it loose Level the mounting base to insure proper oil distribution Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual solar Force Piston Pump System Layout with clearances Top View Servicing cup Suge Tank leathers mounts here requinng 15 Observe minimum clearances for inspection and maintenance as show Bolt the pump directly to a strong firm surface NOT on on rubber pads Expect traces of water and oil leakage at the rod packing Piping Mintake Use 1 1 4 pipe OR LARGER consult a pipe sizing chart to determine a size for very low pressure drop Treat this much like a drain line Avoid humps to eliminate air pockets See text regarding suction limitations Ej and Outlet to Pressure Tank For a 3040 model pump install a 1 1 4 X 1 reducer fitting at the pump outlet then use 1 1 4 pipe and check valve Keep it as short and straight as possible Try to use 45 elbows instead of 90 elbows Low friction piping will help to e
10. ould last about 10 years or more After a few years you can measure your wear and predict the life expectancy 1 4 HP models Remove the two plastic screws on the rear of the motor Be gentle Pick out the metal piece and withdraw the brushes New brushes measure 3 4 long Replace them before they wear to 1 4 They should last about 5 years or more 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 Procedure 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 sandpaper We ha
11. retch 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 A new belt will stretch after the first few hours of use Re tighten as necessary 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 should 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 out
12. 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 It is most important to minimize resistance to flow on the intake side Place the pump as near as possible to the 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 cavitations 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 nee
13. s leakage at the rod packing Use a spring loaded check valve with a rubber seat 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 for advice Also see Surge Tank option 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 DC Models 1 2 HP models Red Positive Black Negative 1 4 HP models White Negative Black Positive Direction of Rotation Clockwise If motor turns in the wrong direction reverse the wiring 115VAC Models To reduce shock hazard connect the green wire to a grounding conductor in accordance with electrical codes 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 or fuse is the electrical safety valve that prevents such damage Failure to install a proper fuse or circuit breaker will void your warranty A circuit breaker is better than a fuse Most AC breakers cannot be used for DC circui
14. s water in and out and completely smoothes the pulsating flow This greatly increases the efficiency of your system Your existing pressure tank will provide this function IF it is located very close to the pump with no more than one or two elbows between the pump and the tank AND IF it is no larger than 45 gallons Otherwise add a surge tank In any case if your pipes shake or if you observe pressure pulsations in your system add a surge tank The surge tank contains an air bladder much like a balloon inside with a tire type air fitting on top 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 surge tank using a tire gauge 3 Note the CUT IN pressure as determined by your pressure switch typically about 30 PSI Is there much vertical lift from the pump outlet up to your pressure tank If so add the lift pressure Note the vertical lift feet from the pump to the tank This number divided by 2 31 PSI Add this to your cut in pressure for the next step 4 Adjust the air pressure by letting some air out or pumping more in to approximately ONE HALF of the cut in 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 T
15. ts 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 type 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 Place the fuse or breaker close to the power source rather than at the motor so that it protects the entire wire run from faults as well as the motor Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual Pressure Switch If you are using this pump in a pressurizing system you need a pressure switch available from any pump or electric supply or from your dealer You may use the type used for AC pumps 1 2 HP models require the large heavy duty size The pressure switch determines at what pressures your pump will turn on cut in and off cut out You may adjust your switch to your liking or leave it set at the factory settings The lower the pressure the less energy will be required Ground Ground DC Power source First
16. ve a customer who pumps water that 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 Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com 2010 Installation amp Service Manual 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 slip joint tyoe 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 t
17. verted to DC by a rectifier in the junction box on the motor If you have a long power line leading to your pump it may be susceptible to high voltage surges induced by lightning Surges can destroy the rectifier Observe proper grounding and install a lightning arrestor at each end of your power line You may obtain such devices from a pump supplier A failed rectifier will usually causing a short circuit blowing your fuse or breaker If you obtain one from an electronic supplier be sure it is rated at a high voltage We use 1000 PIV 15 Amps or larger Please Keep This Manual in a Safe Place You will want to refer to this for years to come Innovative Solar Solutions Inc 1730 Camino Carlos Rey Unit 101 Santa Fe NM 87505 Main 866 856 9819 Fax 704 973 0666 www innovativesolar com
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