TEXSTEAM® PUMPS

iCIP® Solar Solutions® Pump

Series 100, 200, 300, 400
INTELLIGENT CHEMICAL INJECTION PUMP

INSTALLATION & OPERATIONS PROCEDURES MANUAL

Class I Division 2

Revision 1.1.7.4
Table of Contents
Introduction ..........................................................................1 Configuration Firmware.......................................................12
Serialized Assemblies ...........................................................1 Firmware Installation Upgrade.............................................12
Installation Instructions .........................................................2 Motor Controller Enclosure .................................................12
Solar Panel Mounting ...........................................................2 Solar Converters .................................................................12
Solar Panel Alignment...........................................................2 Gel Cell Battery...................................................................13
Solar Panel Maintenance ......................................................4 Simplex/Duplex/Triplex Pump .............................................13
Solar Panel Wiring ................................................................4 Electric Motor .....................................................................13
Battery Enclosure .................................................................4 Pump Packing Tightness & Adjustment ..............................13
Pump & Motor Installation.....................................................5 Head Adjustment................................................................14
Motor Wiring Extension Harness ...........................................5 iCIP Pump Setup Examples ................................................15
Battery Wiring & Installation ..................................................5 Wiring Diagrams .................................................................16
Quick Set Pump Starting Parameters ...................................6 Servicing ............................................................................18
Manual Input Map of Pump Operations ................................8

Introduction THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS

I DIVISION 2, GROUPS C&D OR NON-HAZARDOUS
The benefits of solar powered chemical injection
LOCATIONS ONLY.
pumping systems offered by Dresser will provide years
of low maintenance, clean reliable service, zero noise Serialized Assemblies
pollution, without emissions to the surrounding envi- It is strongly advised that all assemblies remain a complete
ronment. Our goal is to pass along a quality product, or unbroken serialized set for proper functionality. These as-
both a renewable resource and affordable investment semblies have been adequately sized based on the following
to our customers. variables: Daily Solutions Volume, Head Size, Well Pressures,
To insure quality of product, functionality, operating Regional Solar Hours, Temperature, Number of Days without
procedures, warranty and service pertaining to equipment Sun Light, and Quantities of Batteries and Solar Panels.
provided by Dresser to our customers, consult a qualified
manufacturing representative.

iCIP Solar Pump | 1

 Solar Panel Mounting
Solar Panel Mounting
Mounting hardware to attach the solar panels to the pole
Solar Panel has been pre-assembled to aid in field installation. Prior to
placement of the 3-outlet 2.0 inch diameter Pipe Tee, loosen
the Azimuth (direction the solar panels face) adjustment Set
Screw. Reference Figure 3. Position the bottom inlet on
top of the pole, making sure it is firmly centered and seated
down. Make sure that there aren’t any shadows that could
contact any portion of the solar panel.
Enclosure: NEMA
3RMotor Controller, Tilt Locking Set-Screws
iCIP® controller, Solar
Converter, and Gel
Chemical Injection Pump Cell Battery
and DC Motor

Figure 1 – iCIP® (Intelligent Chemical Injection Pump) Pump

General Configuration

Installation Instructions
The iCIP® (Intelligent Chemical Injection Pump) pump assem-
bly comes with connections which are provided to protect
against accidental electrical shock. There are connectors
inline provided for both the battery(s) and the solar panel(s). Azimuth Locking Set-Screw
The connectors should not be connected while the iCIP®
pump is being assembled or during any maintenance period.
Solar Panel Alignment
Solar Converter (+ White)
During “sun hours” the solar panels are used to recharge
Solar Panel (+ White)
the battery voltage used during the night or non sun hours.
The solar mounting assembly should be adjusted to achieve
Maximum Effective Irradiance or Maximum Peak Power
(maximum sun hours). Configuring the azimuth (direction the
Solar Panel (- Black) Solar Converter (- Black) solar panels face) and horizontal (tilt) placement of the Solar
Panels is critical and should be adjusted or aligned at midday
Figure 2– Solar Panel and Battery Connections to achieve maximum “sun hours”.
To adjust both the direction the Solar Panels face and the tilt
A 2.0 inch diameter schedule 40 galvanized coated 6 foot positions on the Solar Panel Mounting, there are (3)
mounting pole has been provided for attaching both the 5/8 in.- Set Screws on the 3-outlet 2.0 in. diameter Pipe Tee
Solar Panels and Battery Enclosure. The pole can be firmly component of the mounting assembly, which will require a
attached to a leg of a solutions tank rack. An alternative 5/16 Allen Wrench. Reference Figures 3 and 4.
method for securing the mounting pole would be to drive a STEP 1: Direction: Adjust the Solar Panel Array Azimuth
T-post into the ground, slip the pole over the T-post and add (direction the solar panels face) by facing the assembly
a generous amount of Quick-Set concrete to the top opening towards true South, not magnetic south. True South (Solar
of the pipe. Noon) is defined as the position halfway between Sunrise
U-bolts have been included to secure the battery enclosure and Sunset. Determine the halfway point between sunrise
to the mounting pole. The distance from the ground to the and sunset for a given day, and face the solar panels in that
underside of the enclosure should be approximately 36 direction.

inches. This will allow the operator to sit comfortably on a STEP 2: Tilt: Dresser recommends the tilt angle be set for
stool while making input changes to the Motor Controller winter or the winter solstice (December 21). Use one of the
or to isolate the solar panel and battery power supplies for following methods to set the tilt of the solar panels.
routine maintenance. Avoid over tightening of the U-bolt nuts Method 1: Reference Figure 6 to obtain the desired Tilt
to prevent damage to the battery enclosure. angle with respect to the latitude of the end customer’s well
For Safety purposes, the battery and solar panels location on the right side of the graph. Follow the curve
should not be connected until all other assembly across the graph to the left side to “Photovoltaic Module
steps have been completed. Angle (Deg.)” with reference to the horizontal plane.
Use a cheap protractor, and a foot long piece of string
with a small weight attached to the end to set the tilt of
the solar panels.

2 | Dresser
Method 2: First, determine the latitude of the install location. After adjusting the Azimuth and Tilt angle, tighten down the
Then subtract the Sun Declination Angle (-23.5°) from the set screws that secure the 3-outlet Pipe Tee fitting to the
latitude. This method for finding this angle can be seen in the 2.0 in. mounting pole.
following example provided. Reference Figure 4.
Tilt Angle = Latitude Angle – (Declination Angle).
Example: Site: Houston TX, Latitude = 29°8’
Latitude (29.8°) – Declination Angle (-23.5°) = 53.3°

Pipe Tee
Figure 4 Figure 5

Solar Panel Angles for Various Latitudes

100
70°
90 65°
60°
80 55°
50°
70 45°
40°
Photovoltaic Module Angle (Deg.)

60 35°
30°
50 25°
20°
40 15°
10°
30 5°
0°
20
Your Latitude (Deg.)

10

-10

-20

-30
12/21 1/20 2/19 3/21 4/20 5/20 6/19 7/19 8/18 9/17 10/17 11/16 12/16
Day of the Year
Figure 6 – Solar Panel Tilt vs. Well Latitude Location

iCIP Solar Pump | 3

Solar Panel Maintenance Route the solar
panel cable through
Very little maintenance is necessary other than the periodic enclosure opening
cleaning of the Solar Panel screen. This will optimize the
charging capabilities, by enhancing the light transmission.
Use a mild soap solution, warm water and a clean soft towel
to remove dust, bird dropping, etc. Use of any greasy
substances or sharp tools might scratch the protective
covering.
Motor Connection
Handle the solar panels with care. The cells can easily be
damaged do the fragile nature of the multicrystalline silicon
cell structure. Irreparable damage can be caused by any
Figure 7
impacting, twisting, or bending action of the panel assemblies.
Do not drill or weld the frame if possible.
Motor Controller Enclosure
NEMA 4X Rated
Solar Panel Wiring
Solar Converter
Panels Provided with Unit: Using a piece of cardboard,
keep the Solar Panels covered while making any electrical
connection to the Solar Panel Junction box. Follow the
instructions and wiring diagram (eference Figure 16) for proper
polarity connectivity. Always use insulated tools to avoid high
voltage and current produced by the solar panels. Install
the cable glands as needed into the side of the Solar Panel Sub Panel
Junction box. Position a screw driver on the diameter of the
circular plastic plug to remove the knockout. Install the cable
gland, avoiding over tightening. Slide power cable through the
cable gland and hook up white wire to positive contact and
Gel Cell
the black wire to negative contact. Where multiple panels are
Battery
used, unless only one solar panel cable is protruding from the
battery enclosure, all Solar Panels are to be wired to a unique
solar panel cable assembly. In some instances, two panels
will be wired in parallel (connecting Positive to Positive and
Negative to Negative). Close the junction box and secure the
lid using the captive screws provided. Figure 8 – Enclosure: Battery, Motor Controller, and Solar
A simple plug/socket assembly has been provided to isolate Converter
or to disconnect the power from the Solar Panels to the
electrical charging system for safety and general maintenance.
Do not plug in until all other connections have been
completed. After all connections have been made,
remove the cardboard cover. Battery Enclosure
Panels Provided by Customer: Using a piece of cardboard, The Battery Enclosure is constructed from a marine grade all
keep the Solar Panels covered while making any electrical aluminum exterior shell, neoprene door seal, security latch,
connection to the Solar Panel Junction box. Follow the instruc- and front ventilation. The enclosures are available in
tions and wiring diagram (reference Figures 21-24) for proper 1-5 battery types that are rated and meet NEMA 3R-rating.
polarity connectivity. Always use insulated tools to avoid high For 1, 2, 3 Battery Enclosures use the two U-bolts provided,
voltage and current produced by the solar panels. Route the to mount the empty Battery Enclosure firmly to the secured
solar panel wiring through the enclosure opening (Figure 7). 6 foot pole, approximately three feet from the ground to the
Install and tighten the cable gland connector into the side of underside of the enclosure. Over tightening of the U-bolts
the enclosure. Each solar panel wiring assembly should be should be avoided. The 4 battery enclosure is a top hinge type
routed through a unique opening. chest which will lay on the ground. The Motor Controller, Solar
Converter and Terminal Strip come pre-assembled on the Sub
In some instances, two panels will be wired in parallel Panel from Dresser. This Sub Panel is located on the upper
(connecting Positive to Positive and Negative to Negative). back wall of the Battery Enclosure. It has been secured and is
A simple plug/socket assembly has been provided to isolate or offset from the back mounting surface of the enclosure using
to disconnect the power from the Solar Panels to the electrical four #10-32UNC Studs.
charging system for safety and general maintenance.
Do not plug in until all other connections have been
completed. After all connections have been made,
remove the cardboard cover.
For Safety purposes, the battery and solar panels
should not be connected until all other assembly
steps have been completed.

4 | Dresser
Motor and Pump Install Supply Power to iCIP® Pump
Connect the DC motor cable end (circular connector) to the
Connect color coded cable(s) from battery to same cable with
mating connector (panel mount) on the battery enclosure.
color coded connector within enclosure that terminates to
Reference Figure 7. A standard 6 foot motor wire harness
terminal block.
comes pre-assembled using a 14+ P CID2 all weather
connecting receptacle. This connection can easily be Connect color coded cable(s) from solar panel to same color
connected and disconnected for ease of installation or coded connector within enclosure that terminates to terminal
relocation. Reference Figure 9. block.
The system should now be operational. The LED display on
the controller should be illuminated.
Quick Set Pump Starting Parameters
1. Toggle down through the menu tree (Reference Figure
14) using the joystick control (Reference Figure 13). Go
to “SETUP/UNITS” and pick the units of measure US
(Quarts/Day) or SI (Liters/Day). Press down on the joystick,
“DONE” should be displayed.
2. Next go to “SETUP/HEAD SIZE” or Pump Head Size.
This will automatically set the pump displacement with
Figure 9 regards to the cam and plunger diameter. Select on of
the following head sizes: 3/16, 1/4, or 3/8 depending on
Motor Wiring Extension Harness the size delivered.
An additional 14 foot Wiring Harness Extension for 24 Volt Press down on the joystick, “DONE” should be displayed
motor is available only through Dresser manufacturing facilities. Select the head size based on the volume requirements
P/N SP2100 Extension Cable will be provided with (2) 14 + P based on Table 1 for 45 RPM motors and Table 2 for 65
CID2 all weather connecting receptacles. PRM motors.

Battery Wiring Install 3. Lastly go to “SETUP/DAILY VOLUME” and hold down

the joystick either up or down to increase or decrease
Once the enclosure has been mounted onto the pole or the daily volume. Press down on the joystick, “DONE”
placed on the ground, the battery(s) can then be inserted should be displayed. Daily volume is dependant on the
into the battery enclosure. Reference Figures 10-12 and units of measure selected above in Step 1 and head size.
schematics for wiring and installation steps.
4. Toggle up to “OPERATION”, move the joystick to the
On multiple battery installations, a ground wire has been right and select “RUN”, press down on joystick,
provided to be connected from battery negative to battery “DOWN” should be displayed, and the iCIP pump should
negative. The black wire should be connected from a negative now be operating and pumping.
battery post to the negative connection on the terminal block
on the enclosure backplate.

Pos +

Neg –

Figure 10 – Single Battery

Neg –

Pos +

Pos +

Figure 11 – Double Battery

Figure 12 – Triple Battery Positive Cable End

iCIP Solar Pump | 5

For 45 RPM Motor Select the Head size based on the volume required on Table 1
Head Size # of Heads RPM Range Volume Range Units of Pressure Range (psi)
Measure
Low High Low High Standard High Pressure
Single 5 45 1.75 (1.66) 26.31 (24.87) Quarts (Liters)/Day 0 – 5000 5000 – 7000
3/16” Duplex 5 45 1.75 (1.66) 52.62 (49.79) Quarts (Liters)/Day 0 – 5000 5000 – 7000
Triplex 5 45 1.75 (1.66) 73.93 (74.69) Quarts (Liters)/Day 0 – 5000 5000 – 7000
Single 5 45 3.07 (2.91) 46.07 (43.61) Quarts (Liters)/Day 0 – 5000 0 – 5000
1/4” Duplex 5 45 3.07 (2.91) 92.14 (87.19) Quarts (Liters)/Day 0 – 5000 0 – 5000
Triplex 5 45 3.07 (2.91) 138.21 (130.79) Quarts (Liters)/Day 0 – 5000 0 – 5000
Single 5 45 11.52 (10.90) 103.68 (98.12) Quarts (Liters)/Day 0 – 1500 1500 – 3000
3/8” Duplex 5 45 1.52 (10.90) 207.36 (196.23) Quarts (Liters)/Day 0 – 1500 0 – 1500
Triplex 5 45 1.52 (10.90) 311.04 (295.35) Quarts (Liters)/Day 0 – 1500 0 – 1500
Single 5 45 20.48 (19.38) 184.29 (174.43) Quarts (Liters)/Day 0 – 1000 0 – 1000
1/2” Duplex 5 45 20.48 (19.38) 368.58 (348.80) Quarts (Liters)/Day 0 – 1000 0 – 1000
Triplex 5 45 20.48 (19.38) 552.87 (523.10) Quarts (Liters)/Day 0 – 500 0 – 500
Table 1 – Head Size vs. Volume Range

For 65 RPM Motor Select the Head size based on the volume requirements on Table 2
Head Size # of Heads RPM Range Volume Range Units of Pressure Range (psi)
Measure
Low High Low High Standard High Pressure
Single 5 65 2.9 (2.8) 38.0 (35.9) Quarts (Liters)/Day 0 – 5000 5000 – 7000
3/16” Duplex 5 65 2.9 (2.8) 76.0 (71.9) Quarts (Liters)/Day 0 – 5000 5000 – 7000
Triplex 5 65 2.9 (2.8) 114.0 (107.8) Quarts (Liters)/Day 0 – 5000 5000 – 7000
Single 5 65 5.1 (4.8) 66.6 (63.0) Quarts (Liters)/Day 0 – 5000 0 – 5000
1/4” Duplex 5 65 5.1 (4.8) 133.2 (126.0) Quarts (Liters)/Day 0 – 5000 0 – 5000
Triplex 5 65 5.1 (4.8) 199.8 (189.0) Quarts (Liters)/Day 0 – 5000 0 – 5000
Single 5 65 11.5 (10.9) 149.8 (141.7) Quarts (Liters)/Day 0 – 1500 1500 – 3000
3/8” Duplex 5 65 11.5 (10.9) 299.6 (283.5) Quarts (Liters)/Day 0 – 1500 0 – 1500
Triplex 5 65 11.5 (10.9) 449.4 (425.2) Quarts (Liters)/Day 0 – 1500 0 – 1500
Single 5 65 20.5 (19.4) 266.2 (252.2) Quarts (Liters)/Day 0 – 1000 0 – 1000
1/2” Duplex 5 65 20.5 (19.4) 532.4 (503.8) Quarts (Liters)/Day 0 – 1000 0 – 1000
Triplex 5 65 20.5 (19.4) 798.6 (755.7) Quarts (Liters)/Day 0 – 500 0 – 500

Table 2 – Head Size vs. Volume Range

6 | Dresser
Motor Controller and Solar Solution Series Options
The Motor Controller has been designed to provide four ■ The “Solar Solutions Series 300” or “Communications”
different configuration packages, series 100, 200, 300, and Module will incorporate the following
400. Reference Figure 14. • All of the features of the “Solar Solutions Series 100”
■ The Basic “Solar Solutions Series 100” will incorporate • The ability to remotely access or communicate live
the following pump data from the controller/system via a Modbus
• Programmable controller w/ 4-digit LED display over a non-Isolated RS485 half duplex (bi-directional)
• Manual input capabilities utilizing 5 position joystick serial communication port and displayed on a screen
or monitor live conditions of on-site pump data.
• Continuous duty motor
RS-232 Communication Baud Rates or BPS (bits per
• RS232 communication interface. Configurations Second) Transmission Speeds available: 1200, 9600,
files can be downloaded with the aid of a laptop PC. and 19200
These configurations files are easily saved and
■ The fourth or “Series 400” will integrate both the “Solar
stored in an Excel or XLS format.
Solutions Series 200” and “Solar Solutions Series 300”.
• Viewable diagnostic parameters
Note that in the scheduling time parameters the time
• Field proven Texsteam pump “ON” is in seconds, but the time “OFF” is in minutes.
• MPPT solar panel charge controller with charge
management Options
• Gel cell batteries ■ Analog and digital inputs and outputs. The I/O are
• Low battery management available in two configurations
• Programmable volumes from 1.75 Qt/day to 184 • 2 I/O option – two analog or digital inputs or outputs
on a simplex unit with the 45 RPM motor and • 12 I/O - The following I/O are available
2.92 Qt/day to 266 with the 65 RPM motor
■ Five analog inputs
• Pressure from 0 – 7000 psi available
■ One analog output
• Alarm configuration
■ Three digital inputs
• Schedule configuration
■ Three digital outputs
• CSA/UL certification option
■ High pressure option – The high pressure enables the
■ The “Solar Solutions Series 200” or “Data Logging” Module pump to achieve higher than standard pressure ranges.
will incorporate the following
■ Power supply option – Power supplies are available to run
• All of the features of the “Solar Solutions Series 100” the iCIP pump from either a 120VAC or 24DC
• Ability to logg /store / save data electrical supply
• Easy time frequency between logged data ■ Adjustable plunger – Adjustable stroke length pumps are
• Capture data at a maximum of available on the second and third head of duplex or triplex
1440 minutes (20,000 record capacity) of on-site pump systems
data, such as power consumptions, battery charge ■ Lockout / Tagout switch – A keyed switch located on the
condition, solar panel output wattage, pumping total outside of the enclosure to disable the motor during
volume, ambient temperature, well pressure, tank level, scheduled maintenance.
alarm or security protocol. This data can be accessed
■ Motor disconnect switch – A switch located on the
and retrieved using an on-site laptop via the RS232 bus
outside of the enclosure used to disable the motor
with the UserTerminal iCIP pump software or via
during schedules maintenance.
RS485 interface.
■ Pressure transducer – Pressure transducers are available
for a wide range of pressures desired.
■ Ultrasonic tank level – An ultrasonic transducer available of
a wide range of tank sizes.

PC Data Logging I/O, and

Communication
Module Connection

LED Display

RS 232/485 PC Interface
Joystick Selector Connection

Termination

iCIP Solar Pump | 7

Menu Trees
FAULT Displays current faults

STOP Stop the pump motor

OPERATION
Start the pump motor
RUN

RUN SCHEDULE Run a schedule

SETUP DAILY VOLUME n,nn Volume required - head size dependent

UNITS US Quarts

SI Liters

MAIN HEAD SIZE 3/16 First head size

START UP STOP Select option, 1/4

will initiate once
RUN power supplied 3/8
to controller
RUN SCHEDULE 1/2

CLOCK MINUTE 0-59 Set the minutes

HOUR 0-23 Set the hour

DAY 1-31 Set the day

MONTH 1-12 Set the month

2000-2078 Set the year

YEAR
Select 1 if single head unit or mulitple head unit and
NO. OF MAIN HEADS 1 wish to display head volumes independently. Primary head: 1
Select 2 dual head unit and adding up the
2 volumes of both heads. Primay heads: 2
Select 3 of triple head unit and adding up the
3 volumes if all three heads. Primary heads:3
2ND HEAD SIZE NONE
3RD HEAD SIZE NONE
3/16
3/16 Select appropriate head size
1/4
Select “None” if no head present
1/4
3/8
3/8
1/2
1/2
PERFORMANCE BATTERY VOLTS DC Voltage

CHARGE AMPS Charge from solar panel(s)

MOTOR AMPS Amps to motor

RPM Speed of pump

ACTUAL VOLUME Volume of primary head(s)

REQUESTED VOLUME Requested volume of primary head(s)

SCHEDULE Schedule settings

ALARMS Alarm settings

TEMPERATURE Temperature of controller

RUN TIME Time pump running

TOTAL DELIVERED Volume delivered of primary head(s)

CHARGE AMP HR Total charge amp hrs

MOTOR AMP HR Total motor load amp hrs

ANALOGS Analog settings

2ND REQUESTED VOLUME Volume requested of 2nd head

3RD REQUESTED VOLUME Volume requested of 3rd head

2ND TOTAL DELIVERED 2nd head volume delivered - Qts/Ltr

3RD TOTAL DELIVERED 3rd head volume delivered - Qts/Ltr

8 | Dresser
 iCIP Controller Menu Tree - Advanced

OPERATION

SCHEDULES SCHEDULES 1-10 SOURCE DISABLED Schedule is disabled

To enter advanced menu; from SCHEDULE Daily volume is used to regulate RPM
setup, press the joystick in and
hold in for 10-15 seconds until
“Schedules” is displayed MODBUS Modbus setpoint is used

AIN 1 - 5 The scaled value of analog in 1-5 is used

DAILY VOLUME n,nn Schedule based volume, min/max based on pump size

START MINUTES 0-59 Schedule will start on this minute

START HOURS 0-23 Schedule will start on this hour

STOP MINUTES 0-59 Schedule will stop on this minute

STOP HOURS 0-23 Schedule will stop on this hour

ON TIME 0-600 Pump will run for this time in seconds

OFF TIME 0-600 Pump will stop for this time in minutes

ALARMS ALARM 1-10 SOURCE DISABLED Alarm is disabled

AIN 1 - 5 Use Analog 1-5 as alarm

DIN 1 - 3 Use Digital 1-3 as alarm

PUMP VOLUME Use Pump Volume as alarm

PUMP RPM Use Pump RPM as alarm

BATTERY VOLTAGE Use Battery Voltage as alarm

CHARGE CURRENT Use Charging Current as alarm

MOTOR CURRENT Use Motor Current as alarm

TEMPERATURE Use Controller Enclosure Temperature as alarm

SET POINT n,nn Source: AIN & Temperature; -327.68 to 327.67

Source: DIN; O or 1
Source: RPM; 0 to 6553.5
All others; 0 to 655.35
COMPARISON Source greater than Setpoint
GREATER
ACTION CHANGE VOLUME Modify volume by
modifier percentage GREATER OR EQUAL Source greater than or equal to Setpoint
FORCE VOLUME Force volume to
modifier value EQUAL Source equal to Setpoint

FORCE SCHEDULE Force a specific

schedule LESS OR EQUAL Source less than or equal to Setpoint

FORCE A OUT Force analog out

to modifier value LESS Source less than Setpoint

FORCE D OUT 1 Force on Digital Out 1

Force on Digital Out 2

FORCE D OUT 2

FORCE D OUT 3 Force on Digital Out 3

RUN FAN Force on Digital Out 3 (Remains active with or w/o option)

MODIFIER n,nn Change volume; 0 to 999.9%

Force Volume range limited by pump size
Force schedule; 1 to 10
PUMPS STROKE VOLUME n,nn Pump plunger volume Force Analog Out; 0 to 1000.00
Force Digital Out sets value to 0
Fan control sets value to 0
n,nn Minimum pump RPM
MIN SPEED

MAX SPEED n,nn Maximum pump RPM

LOW BATTERY STOP PUMP 11.00 Move the joystick up and down
to change the value.
Press in to save the setting.
RESTORE PUMP 12.00 “Done” indicates the value saved

iCIP Solar Pump | 9

 iCIP Controller Menu Tree - Analog & Digital Inputs & Outputs Setup

OPERATION To enter advanced menu; from setup, press the joystick in and
hold in for 10-15 seconds until “Schedules” is displayed
SCHEDULES

ALARMS
The Input Output module must be plugged in the iCIP controller
before any Input/Output parameters can be reached.
PUMPS

ANALOG INPUTS ANALOG IN 1 OFFSET n,nn Schedule the desired zero or offset value

ANALOG IN 2 SPAN n,nn Select the desired full scale value

Determine the smoothing or averaging
ANALOG IN 3 AVERAGING 0 - 12 of the input signal. A larger number
slows the input response time
ANALOG IN 4

ANALOG IN 5

ANALOG OUTPUT ANALOG OUT OFFSET 0 - 65535 Schedule the desired zero or offset value

SPAN 0 - 65535 Select the desired full scale value

SOURCE AIN 1 Use Analog Input 1 as the source

AIN 2 Use Analog Input 2 as the source

AIN 3 Use Analog Input 3 as the source

AIN 4 Use Analog Input 4 as the source

AIN 5 Use Analog Input 5 as the source

PUMP SPEED Use Pump Speed as the source

BATTERY VOLTS Use Battery Volts as the source

CHARGE AMPS Use Charging Amps as the source

MOTOR AMPS Use Motor Amps as the source

TEMPERATURE Use the Controller Enclosure Temperature as the source

MODBUS Use Modbus register 40003 as the source

ZERO Force the output to Zero

FULL SCALE Force the output to Full Scale

MIN OUT nnnnn Set the minimum allowed output value

MAX OUT nnnnn Set the maximum allowed output value

DIGITAL INPUTS DIGITAL IN 1 POLARITY HIGH IS ON The input will be off when de-energized

DIGITAL IN 2 HIGH IS OFF The input will be on when de-energized

DIGITAL IN 3 ON DELAY 0 - 600.0 Input turn “On” delay in seconds

OFF DELAY 0 - 600.0 Input turn “Off” delay in seconds

DIGITAL OUTPUTS DIGTAL OUT 1 POLARITY HIGH IS ON The output will be de-energized when off

DIGITAL OUT 2 HIGH IS OFF The output will be energized when off

DIGITAL OUT 3 ON DELAY 0 - 600.0 Output turn “On” delay in seconds

OFF DELAY 0-600.0 Output turn “Off” delay in seconds

10 | Dresser
 iCIP Controller Menu Tree - Logging Setup

OPERATION

SETUP

LOGGING INTERVAL 0 - 1440 Set the time between logging data from 0 - 1440 seconds

START - STOP START LOGGER Start the logger

STOP LOGGER Stop the logger

** The iCIP controller clock should be set before starting the logger**

The logging module (series 200 or 400) must be plugged in to the iCIP controller
before any logging parameters can be reached

iCIP Controller Menu Tree - Modbus RTU Communication Setup

OPERATION

SETUP

COMMUNICATION COM ADDRESS 1 - 255 Set the Modbus address

COM SPEED 1200 Set port speed to 1200 baud

9600 Set port speed to 9600 baud

19200 Set port speed to 19200 baud

2400 Set port speed to 2400 baud

4800 Set port speed to 4800 baud

The Modbus module (series 300 or 400) must be plugged in to the iCIP controller
before any Modbus parameters can be reached

iCIP Solar Pump | 11

Figure 15 – Solar Pump User Terminal Software

Firmware Installation Motor Controller Enclosure

An install/uninstall Firmware Upgrade Options module is A covered NEMA rated enclosure housing has been provided
required and will be provided with reference to product Solar to protect personnel from accidental exposure to electrical
Solutions Series installation Identification or serial number. This components and also provide a degree of protection to the
module will be available in the event of a firmware upgrade to electronics from the environment. Avoid static discharge
the iCIP controller. into the circuitry when servicing or connecting electrical
connections.
Upgrade Firmware on iCIP Controller
1. Insert Firmware Upgrade Options module into Options Solar Converters
connector on front of iCIP controller. These charge controllers use the latest in technology to further
a. The display should read Upgrade PGM. boost the performance current produced by the solar panels
with the aid of micro processor solar power management
2. Move the joystick to the right. tool. The result is a highly efficient solar power converter.
a. The display should read WAIT. When solar energy is being produced using solar panels,
b. The display will next display the version of the a microprocessor measures and determines the optimum
firmware saved in the module. operating charging point to charge the battery. A low voltage
disconnect is included in the design to protect the battery from
3. Move the joystick to the right. excessive discharge. Two LED’s provide a visual indication
a. The display should read ARE YOU SURE. as to the status of the controller. A temperature sensor is also
4. To upgrade the firmware press the center of the joystick. provided to monitor battery temperature; this sensor provides
feedback to the solar converter and will adjust battery charge
5. The display should read 1 then 2 and finally DONE. conditions accordingly as the temperature changes.
6. Remove the Firmware Upgrade Option Module to
complete the upgrade.

12 | Dresser
Gel Cell Battery
Plunger Packing Kit O-Ring Seal
All batteries conform to BCI specifications. Batteries are
maintenance free. Sealed construction eliminates: periodic
watering, corrosive spills and fumes. Electrolyte will not stratify, Packing Nut
no equalization charging required. Allows for faster recharging
intervals. Battery operating temperatures range from -76°F
(-60°C) to 140°F (60°C). All batteries in multi-battery configura-
tions are to be wired in parallel (connecting Positive to Positive
and Negative to Negative). All batteries cables are equipped
with a current limiting device to protect against an over current
condition. Priming Valve

Simplex/Duplex/Triplex Pump
All pump heads have a standard 316 stainless steel body and O-Ring Seal
Plunger
incorporate the Texsteam proven plunger and packing design
technology. Pump outputs are a basic setup input feature.
The daily volume input requirement and the head size are all
that is needed, simply “Set It and Forget It”. Daily volumes Locking Nut
can be entered in either SI (System International) Liters/Day
or US customary units in Quarts/Day. Output volumes remain Figure 18 – Chemical Injection Pump Head
constant as pressure requirements change. Min/Max daily
volumes based on continuous duty range from 1.75 to 552
Elimination of Pump Drag and Friction
quarts/day (1.66 to 522 Liters). Output pressures ranges up to
maximum of 7000 PSI. Packing Tightness
65 RPM ranges 2.9 to 798 quarts/day (2.8 to 755 liters) Particular attention should be given to Packing Nut tightness.
Over tightening of Packing Nut can result in excessive loses of
Electric Motor electrical power, which effects battery life, and pre-mature seal
packing degrading. The method for tightening all Texsteam
DC electric motors have gone through rigorous testing prior pumps is the same. NEVER ADJUST PACKING WITH THE
to distribution to market. The motors are designed for: high PUMP RUNNING. Loosen the Packing Nut until you can
efficiency, low power consumption, long life, continuous duty feel that it is free, then retighten until you feel a snug fit, then
cycle and maintenance free. one more little tightening, the size of one (only) notch in the
Packing Nut. If this does not work, stop the pump and tighten
Texsteam Field only one more notch.
Head Available in Proven Pump
3/16”, 1/4”, 3/8”,
and 1/2”

Motor Cover

DC Motor
Mounting Base

Figure 17 – Pump and Electric DC Motor Assembly

iCIP Solar Pump | 13

Head Adjustment
Between 3 and 4 screw threads should be present once the
locking nut to secure the head to the pump base has been
tightened. Reference Figure 19.

3 to 4 threads should be visible

Figure 19

An adjustment should be performed to minimize friction

between the coupling and pump housing. Reference
Figure 20.

Adjust gap between coupling and bearing

face to 1/16” or greater

Figure 20

14 | Dresser
ICIP Pump Setup Examples
Temperature Controlled Injection - Use of an alarm to control the start and stop of chemical injection based on
the ambient temperature.
• Example based on a previously installed temperature probe and connected to Analog Input 1
• From the alarm menu select the following: (Reference menu trees)
◆ Analog Input 1:
■ Source: Select “AIN 1”
■ Comparison: Select “>=”
■ Setpoint: Enter desired temperature that pump will turn on and off
■ Action: Select “Change volume”
■ Modifier: Enter 0

Temperature Probe Setup - Setup of an analog temperature probe used to monitor ambient temperature.
Typical application: Monitoring of ambient temperature to trigger an event, ie. change volume or initiate a schedule.
• Example based on an installed Dresser temperature probe to Analog Input 1
• From the Analog Input menu select the following: (Reference menu trees)
◆ Analog Input 1:
■ Offset: Enter
❖ 757 for Fahrenheit scale
❖ 800 for Centigrade scale
■ Span: Enter
❖ 2725 for Fahrenheit scale
❖ 1420 for Centrigrade scale
■ Averaging: Enter 0

Low Volume Injection - Setup of a schedule to inject chemical at specific times of day or small volumes.
Typical application: Injection of volumes less than 1.75 quarts per day.
Example based on a required volume of one quart per day chemical injection utilizing a 3/16” head.
Consult your Dresser representative for other volumes requirements.
• From the Schedule Input menu select the following: (Reference menu trees)
◆ Schedule 1:
■ Source: Select: “Schedule”
■ Daily Volume: Input: 2.92
■ Start Minutes: Input: 1
■ Start Hours: Input: 0
■ Stop Minutes: Input: 1
■ Start Hours: Input: 0
■ Time On: Input: 60
■ Time Off: Input: 2
• Select “Run Schedules” from the Operation menu

Logging Performance Data - Setup to log performance data at predetermined intervals.

Typical application: Series 200 unit. Log and review iCIP pump parameters and analyze trends.
Example based on a 20 minute time between logged data.
• iCIP pump must be equipped with a logging module.
• From the Logging Input menu select the following: (Reference menu trees)
◆ Interval: Input 1200
◆ Start - Stop: Select: “Start Logger”

iCIP Solar Pump | 15

Wiring Diagrams
Wiring diagrams provided with units when shipped. Consult
Dresser if an additional or specific wiring diagram is needed.

16 | Dresser
Servicing

WARNING Emergency field repairs by authorized service technicians are

strongly advisable. Repairs made by un-authorized
EXPLOSION HAZARD -
technicians will void any warranty. To assure safety of
SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR CLASS 1, DIVISION 2. equipment and personnel, only Dresser recommended
replacement parts shall be installed. And above all,
disconnect power from the iCIP® pump before servicing.
ADVERTISSEMENT
Damage to wiring and operating equipment may be
- RISQUE D’EXPLOSION -
LA SUBSTITUTION DE COMPOSANTS PUET avoided with careful reviewing the operating and installation
RENDRE CE MATERIEL INACCEPTABLE POUR LES procedures document by qualified personnel. At all times,
EMPLACEMENTS DE CLASSE 1, DIVISION 2. operating safety of electrical equipment is imperative to avoid
injury to personnel.

WARNING IMPORTANT
- EXPLOSION HAZARD - Read this instruction document with special attention
DO NOT REPLACE ANY COMPONENT to warnings, cautions and safety concerns. FAILURE
UNLESS POWER HAS BEEN SWITCHED TO ADHERE TO THESE INSTRUCTIONS COULD
OFF OR THE AREA RESULT IN SAFETY HAZARDS WHICH MAY
IS KNOWN TO BE NON-HAZARDOUS. RESULT INJURY TO PERSONNEL, MOTOR/
CONTROLLER DAMAGE OR OTHER ELECTRICAL
ADVERTISSEMENT EQUIPMENT. Doubts or reservations with regards to
- RISQUE D’EXPLOSION - installations or maintenance with reference to connecting
COUPER LE COURANT OU S’ASSURER QUE your “Solar Powered” Chemical Injection Pump system
L’EMPLACEMENT EST DESIGNE NON DANGERUEX should refer to the detailed sections supplied in this
AVANT DE REPLACER LE COMPOSANTS. manual. For additional instruction, classification or
assistance, contact an authorized Service Center.

WARNING
- EXPLOSION HAZARD - WARNING
DO NOT DISCONNECT EQUIPMENT UNLESS
Avoid personnel injury involving equipment that is in
POWER HAS BEEN SWITCHED OFF OR THE AREA
motion. Always remove or disconnect power prior
IS KNOWN TO BE NON-HAZARDOUS.
to service to the motor, motor controller, batteries,
charge controller, solar panels.
ADVERTISSEMENT
- RISQUE D’EXPLOSION -
AVANT DE DECONNECTER L’EQUIPEMENT, COUPER
LE COURANT OU S’ASSURER QUE L’EMPLACEMENT
EST DESIGNE NON DANGEREUX.

iCIP Solar Pump | 17

 About Dresser, Inc.
Dresser, Inc. is a leader in providing highly engineered
infrastructure products for the global energy industry. The
company has leading positions in a broad portfolio of prod-
ucts, including valves, actuators, meters, switches, regula-
tors, piping products, natural gas-fueled engines, retail fuel
dispensers and associated retail point-of-sale systems, and
air and gas handling equipment. Leading brand names within
the Dresser portfolio include Dresser Wayne® retail fueling
systems, Waukesha® natural gas-fired engines, Masoneilan®
control valves, Consolidated® pressure relief valves, and
Roots® blowers. It has manufacturing and customer service
facilities located strategically worldwide and a sales presence
in more than 100 countries.

Dresser, Inc.
16240 Port Northwest Drive
Houston, Texas 77041-2645 USA
Ph: 832.590.2306 Fax: 713.849.2879
Toll Free Phone: 800.945.9898 Email: [email protected]
www.dresser.com/texsteampumps

©2010 Dresser, Inc. www.dresser.com

Texsteam and Dresser are registered trademarks of Dresser, Inc. Solar Solutions IOM, Class 1 Div 2
6.10