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White International DAB iCON Series Instruction Manual

Solar powered borehole pumps
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DAB iCON
Solar Powered Borehole Pumps
Instruction Manual
2018
™
Borehole Manual 2018 | 1
Disclaimer: Every effort has been made to publish the correct details in this brochure.
No responsibility will be taken for errors, omissions or changes in product specifications.

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Summary of Contents for White International DAB iCON Series

  • Page 1 DAB iCON Solar Powered Borehole Pumps Instruction Manual 2018 ™ Borehole Manual 2018 | 1 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 2: Table Of Contents

    CONTENTS Introduction……………………………………………………………………... Construction Features of the DAB S4 Pump…………………………………... Construction Features of the iCON Solar Motor………………………………. iSolar Controller…………………………………………………………………. Operation and Features……………………………………………………. isolar Controller Installation………………………………………………… 7 Controller Operating Instruction…………………………………………… 8 Technical Specification ……………………………………………………. Installation Options ……………………………………….……………… 9 - 10 Electrical Connections …………………………………………………… 11 - 12 Cable Selection ……………………………………………………………...

  • Page 3: Introduction

    INTRODUCTION ICON solar motor powers the new DAB system for the supply of clean water based on the most widely available renewable energy, the sun. By means of the electric power supplied by a series of photovoltaic panels and taking advantage of the combination of a DAB S4 series 4”...

  • Page 4: Construction Features Of The Dab S4 Pump

    CONSTRUCTION FEATURES OF THE DAB S4 PUMP Multistage centrifugal type with radial or semi-axial impellers. Pump and motor directly coupled with rigid coupling. Technopolymer impellers with stainless steel wearing parts, fitted on floating clearance rings made of synthetic low abrasion material, and technopolymer diffusers that impart significant wear resistance to the pump.

  • Page 5: Construction Features Of The Icon Solar Motor

    CONSTRUCTION FEATURES OF THE ICON SOLAR MOTOR Innovative design allows the motor to be powered by both AC and DC power sources. The motor is available in two models, one with a maximum power output (P2) of 1100 W and the other with a maximum power output (P2) of 2400 W and are suitable for selected DAB pumps only.

  • Page 6: Isolar Controller

    iSOLAR CONTROLLER Operation and features The iSOLAR controller is capable of the following functions: Display input power Display of mode of AC Display of mode of DC Display of tank full Display of tank empty AUTO MODE Ability to select the incoming power source. In AC MODE, the incoming power source can be from Mains power supply or a generator.

  • Page 7: Isolar Controller Installation

    iSOLAR CONTROLLER INSTALLATION WARNING • The power supply from any DC or AC supply can cause serious harm or death from electrocution. • Apply appropriate safety procedures when working on or with any system component. • Only suitably qualified personal should be involved in the electrical connection / disconnection and handling of the equipment.

  • Page 8: Controller Operating Instruction

    iSOLAR CONTROLLER Controller Operating Instruction Before operating any components in the system preform a visual inspection of the installation for damage cause by weather events, stock, pests or human interference. Solar panels should be clean and not in shade. All wiring terminated, no bare wires exposed. Check pump is completely immersed when in a surface water source.

  • Page 9: Installation Options

    SETTING FLOW METER FUNCTION • Without flow meter connected set switch 1 to ”off” condition. • With flow meter connected set switch 1 to “on” condition. TIMER ADJUSTMENTS Flow meter restart timer adjustment Generator off delay timer adjustment INSTALLATION OPTIONS Electric Float Switch (One Or Two) Level Control...

  • Page 10: Installation Options

    INSTALLATION OPTIONS Mechanical Float Switch iSOLAR Controller Pressure Switch 10 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 11: Electrical Connections

    iSOLAR CONTROLLER Electrical Connections With One Float Switch. FLOW – L1 L2 (GND) (GND) (GND) SIGNAL SIGNAL GENERATOR PUMP (Optional) SINGLE PHASE 90-280V AC FLOAT SWITCH (Optional) SOLAR PANEL FLOW METER 55/90-380VMPP DC (Optional) TWL = TARGET TANK WATER LEVEL WWL = WELL WATER LEVEL USE 3 WIRE FLOAT SWITCHES WIRED FOR TANK FILL (OPEN ON RISE - BLACK AND BLUE WIRES) With Two Float Switches...

  • Page 12: Electrical Connections

    iSOLAR CONTROLLER Electrical Connections Pressure Switch FLOW FLOW L1 L2 – L1 L2 (GND) (GND) (GND) (GND) (GND) (GND) SIGNAL SIGNAL SIGNAL SIGNAL STANDARD STANDARD GENERATOR GENERATOR PRESSURE PRESSURE (Optional) SWITCH ~AC~ SWITCH SINGLE PHASE PUMP PUMP SINGLE PHASE SOLAR PANEL 90-280V AC 90-240V AC 90-360V DC...

  • Page 13: Cable Selection

    CABLE SELECTION 0.37 0.44 0.75 Metric Cable (0.5) (0.75) (1.0) (1.5) (2.0) (3.0) (HP) Stranding Area mm Metres Metres Metres Metres Metres Metres 7/0.67 7/0.85 7/1.04 7/1.35 7/1.70 1117 Select the appropriate sized cable to use from the Energy source to the iCON 4” Motor. Ensure when measuring to include depth of bore when fitting motor down a bore or well.

  • Page 14: Dimensions

    iSOLAR CONTROLLER Dimensions Dimensions: 267mm (H) x 180mm (W) x 86mm (D) iSOLAR MOTOR Dimensions: 670mm (H) x 99mm (Dia) Weight 12 kg 14 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 15: Installation

    iSOLAR 4” MOTOR GENERAL INSTALATION NOTES Water Source and Pump Installations Options The water source must be “clean water”, free from contaminates such as, dirt, dust, loose rocks, decaying organic matter and other foreign bodies that could block the intake screen or fowl the impeller stack.

  • Page 16: Solar Panels

    SOLAR PANELS For DC operation, power supplied by solar panels is required. DC voltage input range 55 – 380VMPP (440VOC) DC for BIA-M110SOL. DC voltage input range 90 – 380VMPP (440VOC) DC for BIA-M240SOL. Below is a selection table based on 200W solar panels. The panels would be wired in series or in combination of 2 strings of panels in series, connected in parallel.
  • Page 17 Solar Panel Recommendation All Electrical Data @ STC Pump Model Nominal Panel Brand Wattage Size Strings VOC (V) VMPP (V) ISC (A) IMPP (A) Power Power LOW FLOW Phono Solar 60 cell 42.77 85.54 32.19 64.38 9.82 9.82 9.32 9.32 DAB-S4A18SOL Phono Solar 60 cell...

  • Page 18: Installation

    This becomes the angle the panels are orientated from the horizontal to face the sun directly. eg: White International Pty Ltd Office, 60 Ashford Ave, Milpera NSW -33.934217 Latitude / 150.98830 Longitude Panel Orientation: 34 Degrees from horizontal facing NORTH SOLAR AVAILABILITY As a general rule-of-thumb panels will receive 3.5hr or more of solar irradiation during winter...

  • Page 19: Wiring

    Wiring for 2 to maximum 8 x 200W* Solar panels. SOLAR PANELS WIRING Wiring for 2 to maximum 8 x 200W* Solar panels. Wiring for 10 to maximum 16 x 200W* Solar panels. Wiring for 10 to maximum 16 x 200W* Solar panels. Wiring for maximum 10 x 300W* Solar panels.

  • Page 20: Performance Curves

    PERFORMANCE CURVES DAB-S4A18SOL 805147 12.5 100M DAB-S4A18SOL SOLAR POWER WATTS Example: DAB-S418SOL pump will deliver 12.5 l/min at 40 m head with 280 W energy from solar panels. Estimated daily delivery in winter with 4 solar hours per day = 12.5 l/min x 60 minutes x 4 hours = 3000 litres/day.

  • Page 21: Dab-S4A36Sol

    PERFORMANCE CURVES DAB-S4A36SOL 805150 Borehole Manual 2018 | 21 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 22: Dab-S4B12Sol

    PERFORMANCE CURVES DAB-S4B12SOL 805148 DAB-S4B12SOL SOLAR POWER WATTS 22 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 23: Dab-S4B24Sol

    PERFORMANCE CURVES DAB-S4B24SOL 805151 110M 130M DAB-S4B24SOL 1000 1200 1400 1600 SOLAR POWER WATTS Borehole Manual 2018 | 23 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 24: Dab-S4B32Sol

    PERFORMANCE CURVES DAB-S4B32SOL 805364 24 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 25: Dab-S4B48Sol

    PERFORMANCE CURVES DAB-S4B48SOL 805155 Borehole Manual 2018 | 25 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 26: Dab-S4C9Sol

    PERFORMANCE CURVES DAB-S4C9SOL 805149 DAB-S4C9SOL SOLAR POWER WATTS 26 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 27: Dab-S4C19Sol

    PERFORMANCE CURVES DAB-S4C19SOL 805152 DAB-S4C19SOL 1000 1200 1400 1600 SOLAR POWER WATTS Borehole Manual 2018 | 27 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 28: Dab-S4C25Sol

    PERFORMANCE CURVES DAB-S4C25SOL 805365 100M 120M DAB-S4C25SOL 1000 1200 1400 1600 1800 2000 SOLAR POWER WATTS 28 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 29: Dab-S4C39Sol

    PERFORMANCE CURVES DAB-S4C39SOL 805156 Borehole Manual 2018 | 29 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 30: Dab-S4D13Sol

    PERFORMANCE CURVES DAB-S4D13SOL 805153 DAB-S4D13SOL 1000 1200 1400 1600 SOLAR POWER WATTS 30 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 31: Dab-S4D17Sol

    PERFORMANCE CURVES DAB-S4D17SOL 805366 DAB-S4D17SOL 1000 1500 2000 2500 SOLAR POWER WATTS Borehole Manual 2018 | 31 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 32: Dab-S4D25Sol

    PERFORMANCE CURVES DAB-S4D25SOL 805146 110M 130M DAB-S4D25SOL 1000 1500 2000 2500 3000 3500 SOLAR POWER WATTS 32 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 33: Dab-S4E8Sol

    PERFORMANCE CURVES DAB-S4E8SOL 805154 DAB-S4E8SOL 1000 1200 1400 1600 SOLAR POWER WATTS Borehole Manual 2018 | 33 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 34: Dab-S4E12Sol

    PERFORMANCE CURVES DAB-S4E12SOL 805367 DAB-S4E12SOL 1000 1500 2000 2500 SOLAR POWER WATTS 34 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.

  • Page 35: Dab-S4E17Sol

    PERFORMANCE CURVES DAB-S4E17SOL 805145 DAB-S4E17SOL 1000 1500 2000 2500 3000 3500 SOLAR POWER WATTS Borehole Manual 2018 | 35 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 36 PERFORMANCE CURVES DAB-S4F7SOL 805144 DAB-S4F7SOL 1000 1500 2000 2500 3000 SOLAR POWER WATTS 36 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 37 Borehole Manual 2018 | 37 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 38 38 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 39 Borehole Manual 2018 | 39 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 40 40 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 41 Borehole Manual 2018 | 41 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 42 42 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 43 Borehole Manual 2018 | 43 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 44 44 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 45 Borehole Manual 2018 | 45 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 46 Solar Panel Recommendation All Electrical Data @ STC Pump Model Nominal Panel Brand Wattage Size Strings VOC (V) VMPP (V) ISC (A) IMPP (A) Power Power LOW FLOW Perlight 72 cell 45.48 90.96 37.89 75.78 5.66 5.66 5.28 5.28 LOW FLOW Perlight 72 cell 45.48...

  • Page 47: Dab 4" Submersible Pumps

    INSTALLATION AND OPERATION MANUAL FOR DAB 4” SUBMERSIBLE PUMPS WITH ICON SOLAR 2.2 KW MOTOR S4A – S4B – S4C – S4D – S4E - S4F Borehole Manual 2018 | 47 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 48 The following Warranty conditions shall apply to DAB ICON SOLAR submersible pump installation. White International shall not be held responsible for damage caused by improper installation, use of cable and control boxes or level controls which are not approved by White International, negligent or careless handling, lightning, improper voltage supply, corrosion due to impure water, wear caused by sand, gravel or other abrasives in the water being pumped.

  • Page 49: Typical Submersible Installation

    gauge which is the same diameter and length as the pump to be used into the bore. If the gauge does not bind, it is safe to install the pump. Never support the weight of the pump by the drop (power) cable or by the safety rope. Refer instructions in section PUMP DROP PIPE.

  • Page 50: Depth Of Intallation

    DEPTH OF INSTALLATION Make sure that the unit is at least one metre above any gravel layer and one metre below the minimum drawdown level. If during the initial operation, the pump lowers the well water level until suction is discontinued, then lower the pump where feasible, or install a protection device, or reduce the flow rate of the pump to prevent over-pumping.
  • Page 51 PN RATING MAX PUMP MAX KPA AT MAX PSI AT MAX DEPTH MAX DEPTH HEAD (M) BY TOP OF BORE TOP OF BORE (FT) CURVE 1103 1172 1241 1379 1517 Polythene drop pipe can be selected by reference to the pump curve and its suitability can be checked on site by checking the maximum pressure read at the top of the bore reference to the maximum depth allowed.

  • Page 52: Wiring

    The use of old drop cable or white flat is not recommended. Use water-proof cable only, i.e, Aquaflex AQM rated for immersion to 100 m (500m immersion rated also available) obtainable from White International. The table indicates the correct size electrical drop cable and maximum lengths to be used.
  • Page 53 Make sure that the water proof heat shrink is heated sufficiently to cause resin to flow to create a water tight seal. If possible, it is good to practice run the pump briefly in a container of water (water must be over the suction inlet) to check on operation before installation in the bore.
  • Page 54 NEVER OPEN THE GATE VALVE ABRUPTLY as this may raise sand and deposits. The pump should be run for a period of 30 minutes to check that it does not pump the bore dry. This would be obvious by large fluctuations on the pressure gauge and the ammeter as the pump flow surges.

  • Page 55: Pressure System Installation

    PRESSURE SYSTEM INSTALLATION When a submersible pump is to be used as a pressure system, the following items are required. A pressure tank of at least 30 litres draw off. A pressure switch, which is available from White International in a kit complete with pressure gauge and 3 way tee piece which allows plumbing to the pressure tank.
  • Page 56 THE TROUBLE IS? WHAT TO LOOK FOR Pump doesn’t start Faulty pressure switch Control box in sun or near heat source Wrong control box being used Defective control box Hydraulic overload Water logged pressure tank Low voltage supply to motor (low solar irradiation) ISOLAR controller switching between energy sources No water delivered Low solar irradiation...
  • Page 57 SERVICING AND MAINTENANCE INSTRUCTIONS S4 SERIES DISMANTLING REMOVAL OF THE VALVE BODY (117): Unscrew the four screws (52), which hold the strainer and cable guard. Remove the strainer (42) and cable guard (39). Loosen and remove the nuts and washers that attach the pump to the motor and separate the pump and motor. Using an oil filter wrench grip the liner (69) and secure the wrench in a vice.
  • Page 58 S4A-S4B-S4C-S4D-S4E-S4F 2 YEAR PUMP WARRANTY 58 | Borehole Manual 2018 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 59 Notes Borehole Manual 2018 | 59 Disclaimer: Every effort has been made to publish the correct details in this brochure. No responsibility will be taken for errors, omissions or changes in product specifications.
  • Page 60 Subject to the conditions of the warranty, White International will repair any defective products free of charge at the premises of our authorised service agents throughout Australia and New Zealand if a defect in the product appears during the warranty period.

This manual is also suitable for:

IsolarIcon series

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