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GRIDFREE The Back Gully Kit Installation Manual

Solar-powered water pump kit
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The Back Gully Kit
Solar-Powered Water Pump Kit
Installation Manual

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Summary of Contents for GRIDFREE The Back Gully Kit

  • Page 1 The Back Gully Kit Solar-Powered Water Pump Kit Installation Manual...
  • Page 2 WARNING - READ CAREFULLY • Please ensure you have read our resources online or spoken to a member of the team to make sure this is suitable for your application. • All fittings are 304 Stainless Steel. Please use in appropriate environments within appropriate Ph levels.

  • Page 3: Table Of Contents

    Contents The Back Gully Kit About This Manual Electrical Wiring Kit Contents Required Tools Required Components Wiring Overviews Tank to Tank Overview Dam to Tank Overview Pump Setup | Tank to Tank Installation Instructions | Tank to Tank Pump Setup | Dam to Tank...

  • Page 4: The Back Gully Kit

    The Back Gully Kit About This Manual This manual is an installation guide for two of the most common use cases for this kit: pumping from a tank to a tank, and pumping from a dam/pond to a tank. Please take care to follow the instructions relevant to your use case.

  • Page 5: Kit Contents

    Kit Contents 2x PERC MONO Solar Panels 1x Water Pump Charge Controller 1x Submersible Water Pump 1x Pair 6mm² Solar PV Cable 10m – with 20m Cable Pre-Crimped MC4 (Red + Black) 2x Z-Bracket Solar Panel Mount 1x PV DC Isolator Switch...

  • Page 6: Required Tools

    1x Tap 1x Pressure Switch 1x Pressure Gauge 2x T-Fitting 1x Check Valve 2x Male-Male Fitting 2x Thread Adapter Required Tools Screwdrivers Drill Large Spanner/Crescent Pipe Cutters Screws and Bolts Spanner Set Required Components + Design Piping: This kit requires that you provide and run your own piping. You will require a section between the pump and our fittings, and from these fittings up to your storage tank.
  • Page 7 Please ensure whatever materials you use are drinking water safe if this is the purpose of your installation. Have questions? Get in touch: (09) 218 5533 info@gridfree.store www.gridfree.store C4/27 Smales Road, East Tāmaki, Auckland, 2013 Mon-Fri, 9am-5pm (by appointment)

  • Page 8: Wiring Overviews

    Wiring Overviews High Water Tank Water Pipe Low Water Tank Power MPPT Well Tank Switch ON/OFF Enter IP66 FOGE PV ARRAY DC ISOLATOR ON I SISO SWITCH 2x Solar Panels Pump Power Cable Pressure Gauge PV DC Isolator Switch 6mm² Solar PV Cable Pair - 10m Pressure Switch Float Switch Cable Pump Charge Controller...
  • Page 9 Water Tank Water Pipe Power MPPT Well Tank Switch Enter ON/OFF Reservoir IP66 FOGE PV ARRAY DC ISOLATOR ON I SISO SWITCH 2x Solar Panels Pump Power Cable PV DC Isolator Switch Pressure Gauge 6mm² Solar PV Cable Pair - 10m Pressure Switch Pump Charge Controller Pressure Switch Cable...

  • Page 10: Pump Setup | Tank To Tank

    Pump Setup | Tank to Tank To Controller and Fittings Power Cable Suspension Cable Water Pipe Water Level Float Switch Check Valve Suspension Points Weight Pump Application #1: Tank to Tank Overview For the tank set up you will be mounting the pump directly in the tank.

  • Page 11: Installation Instructions | Tank To Tank

    Installation Instructions | Tank to Tank Tighten Tighten Apply thread tape Step 1) Install check valve on pump using thread tape to make a good seal. Thread tape should be wrapped in the opposite direction to the direction that you would turn the check valve to tighten it. This ensures the tape does not bunch up when tightened.
  • Page 12 Drill entry holes for the pipe and cables WARNING: Please take care to avoid doing anything that may void your water tank’s warranty or compromise your drinking water. Step 3) Make the entry holes for the pipe and the cables in an appropriate place at the top of your tank (if your tank is concrete you may need to do this differently.
  • Page 13 Entry Point Mark Step 5) Use your cable/rope to attach the pump to the water tank. Make sure the pump hangs off the bottom but close to it, to make sure you can use most of the water in the tank. Please note/measure the length from a reference point at the top of the tank to the intake of the pump so you can mark the intake level on the outside of the tank.
  • Page 14 Entry Point Mark Step 7) Install your float switch in the tank. The purpose of this is to prevent the pump from dry running. To ensure this works correctly you need to make sure the float switch is hanging with the end pointing at the ground before the pump inlet is exposed to air.
  • Page 15 Pump On: Pump Off:...
  • Page 16 Run the cables to the Charge Controller. (We recommend running cables through conduit.) Step 8) Run the power cable, float switch cable and pipe to the area where you are installing the charge controller and pressure switch. Note: It is recommended to run all cables through conduit to protect from environmental damage (such as UV) and pests.

  • Page 17: Pump Setup | Dam To Tank

    Pump Setup | Dam to Tank Application #2: Dam to Tank Overview (If you are installing the pump in a tank please go to page 10) Float Water Level Power Cable Water Pipe Check Valve Suspension Points Pump For the Dam-to-tank installation of the pump, you will be suspending the pump off the bottom using cable/rope and a float.

  • Page 18: Installation Instructions | Dam To Tank

    Installation Instructions | Dam to Tank Tighten Apply Tighten thread tape Step 1) Install check valve on pump using the provided thread tape to make a good seal. Thread tape should be wrapped in the opposite direction to the direction that you would turn the check valve to tighten it.
  • Page 19 Cable to Land Suspension Cables Step 3) Attach your pump to your float, making sure the pump will be suspended off the bottom but adequately submerged. It is also recommended to attach a cable/rope to the float or the pump that you can reach from shore.
  • Page 20 Step 4) Run the power cable and pipe to the area where you are installing the charge controller and pressure switch. Note: It is recommended to run all cables through conduit to protect from environmental damage (such as UV) and pests.

  • Page 21: Solar Panel Wiring

    Solar Panel Wiring Step 1) Wire the panels together by connecting the positive terminal of one panel to the negative terminal of another. This creates two solar array outputs: one positive (+), one negative (-). IP66 PV ARR AY DC ISOL ATOR ON I SISO SWI TCH...
  • Page 22 DO NOT connect the cable run to the solar panels until all solar wiring is complete. IP66 PV ARRAY DC ISOLATOR ON I SISO SWITCH Run the 6mm² Solar Cables from the solar panels to the DC isolator, and cut it to length. Make sure you have enough to go from the isolator switch to the controller.
  • Page 23 Scan the QR code to watch a demonstration video Step 2) Use wire strippers to strip the ends off the black and red 6mm² solar cables. Strip the cables to approximately 7mm in length. Gland nut (same for both wires) Metal Metal conductor A...
  • Page 24 Step 4) Starting with the red solar cable, place the silicon gland and gland nut onto the cable. Crimp “Metal Conductor A” onto the cable using the 6mm² crimping die. Pay extra attention to use the correct metal conductor, with the correct housing Step 5) Insert the crimped “Metal conductor A”...
  • Page 25 Step 6) Move onto the black solar cable. Place the silicon gland and gland nut on to the cable. Crimp “Metal conductor B” onto the cable using the 6mm² crimping die. Step 7) Insert the crimped “Metal conductor B” into the “Solar connector housing B”...
  • Page 26 Ensure the PV Array DC isolator is in the off position IP66 PV ARRAY DC ISOLATOR ON I IP66 SISO SWITCH PV ARRAY DC ISOL ATOR ON I SISO SWI TCH Step 8) Ensure the PV Array DC isolator is in the off position. Then, connect the PV cable run from the solar panels.
  • Page 27 WEL COM Step 10) Thread the other end of the cable through the cable gland and attach to the screw terminal so that it makes good contact. Power MPPT Well Tank Switch ON/OFF Enter IP66 PV ARRAY DC ISOLATOR ON I SISO SWITCH Step 11) The SISO switch should now be connected to the controller as above.

  • Page 28: Controller Wiring

    Controller Wiring Pump Charge Controller Power MPPT Well Tank Switch ON/OFF Enter IP66 PV ARRAY DC ISOLATOR ON I SISO SWITCH Pressure Switch Pressure Gauge FOGE Pump Power Cable Float Switch Cable In this section you will be wiring the panels, pump, and sensors into your controller.
  • Page 29 WEL COM WEL COM Step 1) Ensure all of your cables are run to the controller. These should include: the pump power cable (3 wires), the Pressure sensor (2 wires) and optionally the float switch (2 wires). Once all are routed to the controller and the controller is mounted, open the controller by undoing bolts on all four corners, using the allen key provided.
  • Page 30 Power MPPT Well Tank Switch ON/OFF Enter Step 2) Undo the middle gland shown above and thread the pump power cable through. WEL COM WEL COM Step 3) The pump power cable has 3 wires labelled W1, V1, and U1. Wire W1 into the W terminal, V1 to V and U1 to U.
  • Page 31 Power MPPT Well Tank Switch ON/OFF Enter Undo this gland nut to thread through the pressure switch cable. FOGE Step 4) Undo the cable gland on the right side as shown above, and thread the pressure switch cable through. WEL COM Step 5) There should be 2 wires within this cable.
  • Page 32 Power MPPT Well Tank Switch ON/OFF Enter Step 6) Float Switch Wiring (Required for pumping f rom tank) There should be 2 wires within this cable. Wire the brown wire into the TH terminal and the blue into the COM terminal. Once you have done this, tighten the gland back up over the cable, ensuring a tight seal is formed around the cable.

  • Page 33: Fittings Assembly

    Fittings Assembly In this section you will need to assemble the fittings that are supplied with the kit. FOGE Pressure Switch Pressure Gauge 3/4 to 1/8 3/4 to 1/8 Adaptor Adaptor Tee Fitting Male-Male Fitting When assembling, use thread tape of the threaded port on all fitting to ensure water tight sealing.
  • Page 34 FOGE To Pump To Header Tank Step 2) Attach your pipe fittings in the same way. Then attach the pipe from your pump to the sensor side of the fittings (left on diagram) and the pipe that runs to your header tank to the tap side (right on diagram).

  • Page 35: Pressure Switch Calibration

    Pressure Switch Calibration FOGE The pressure switch can be used to turn off the pump when the tank is full. This requires a float switch/ballcock float to shut off the line to the tank when the tank is full. When this happens the pressure in the line will increase to the pump’s maximum pressure.
  • Page 36 FOGE Step 1) Ensure PV isolator is off, and panels are in full sun before starting this process so you can calibrate the pressure switch. To do this, start by undoing the bolt on the top of the pressure switch. Step 2) Insert the long end of the 2mm Allen key provided into the hole where the bolt came out of and turn the allen key CLOCKWISE until it will not turn anymore.
  • Page 37 Power MPPT Well Tank Switch ON/OFF Enter Step 4) If the screen says “OFF” on the controller, press the on/off button. The pump should start shortly. Wait until the pump has been running for about 10 seconds and has reached full speed. Step 5) Then you can begin winding the allen key counter-clockwise.
  • Page 38 Step 7) Now turn the Allen key CLOCKWISE once in a full rotation. IP66 IP66 PV ARRAY PV ARRAY DC ISOLATOR DC ISOLATOR ON I ON I SISO SWITCH SISO SWITCH Step 8) Restart the controller by turning the DC Isolator Switch off then on again.
  • Page 39 Step 10) You should test the operation of the pressure switch and float switch before you leave the system to run. You can test the pressure switch by turning off your tap or ballcock on your pressure tank manually. You should see the Well light turn on the controller and the pump stop.

  • Page 40: Additional Info

    A good indication that you need a replacement screw is when the pump is outputting significantly less water than usual even in full sun. Contact Us Our website: gridfree.store Email us: info@gridfree.store Message us on Facebook: @GridFree.Store...
  • Page 41 Notes...
  • Page 42 Get in Touch. (09) 218 5533 info@gridfree.store www.gridfree.store C4/27 Smales Road, East Tāmaki, Auckland, 2013 Mon-Fri, 9am-5pm (by appointment)

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