Table of Contents Introduction …………………………………………………………. 1.0 Product Overview ……………………………………………………. 2.0 Controller Features ………………..…………………………………. 2.1 Application …………………………………………………………... 2.2 Installation and Operations ………………………………………..… 3.0 Location ……………………………………………………………… 3.1 System Design Basics …………………………………………..…… 3.2 Well Measurements …………………………………………………... 3.3 Figure 1: Solar Pump System Terms and Head Calculations Pump Installation ……………………………………………………... 3.
1.0 Introduction Thank you for selecting a SunPumps SCS series solar pump system. The SCS series pump and PCA series pump controller are the key components to high quality solar powered pumping systems. Their stand-alone, pollution free and low noise operation makes them an ideal solution for remote homes, wildlife and stock watering problems without violating the environment.
Table 1 Controller Model Min Max Voltage1 Voltage PCA-60BLS-M22 30 V 100 V PCA-120BLS-M22 90 V 200 V Min Power Max Power Set by 840 W LWC Set by 1500 W LWC Low Water Cutoff Min 50 W 50 W Low Nominal Water Voltage Cutoff Max 300 W 60 V 500 W 120 V 1 Min Voltage is the minimum voltage which the unit must see in order to start the pump. If this voltage is not obtained, the unit will not attempt to start the pump. Voltages lower than this will not hurt the unit.
3.0 Installation and Operation The following sections are outlined in a step-by-step format to guide you through the installation of a PCA series controller. Before installing any pump system, read all product manuals and review all system components to become familiar with the physical and electrical layout. Check all equipment for any product damage. Refer to applicable figure(s) as a guide during the installation. Controller door must be closed during normal operation.
3.2 System Design Basics (Read carefully before installation) 1. For optimum pump performance make sure that the wire is sized properly for the length of run between the pump and the solar modules. Wire sized too small will cause a decreased output from the pump. Keep the distance from the solar modules to the pump as short as possible. Refer to a DC wire loss chart for proper sizing. It is recommended to keep the voltage drop under 3%. 2.
Figure 1 Solar Pump System Terms & Head Calculations Vertical Lift Water Tank Sanitary Well Seal Pumping Level + Drop Pipe Vertical Lift + Friction Loss _____________ Feet _____________ Feet _____________ Feet (See Friction Loss Chart) Submersible Pump Cable = Total Dyn.
3.4 Pump Installation 1. The well should be clean and disinfected before the pump is installed. You should always clean and develop a new well before installing the pump. 2. Write the pump, motor and controller model number and serial number in the space provided on the last page in this Instruction Manual. This information will be needed when filling out the Warranty Card. And will aide in any troubleshooting which may be necessary. 3.
3.5 Wiring Prior to connecting any wires to the controller be sure you have a system wiring diagram to use as a reference. Generic system wiring diagrams are included in this manual for your convenience. (See Figures 2 and 3) Guessing at polarity and connection points is not worth the risk of potential product damage and/or personal injury. Ensure the wire sizes are of adequate diameter (gauge) to minimize voltage drop. Please refer to a DC voltage loss table or call your SunPumps dealer for assistance.
Figure 2 Controller Wiring Diagram (Power Connections)
1. Switch the controller to the OFF position. 2. Connect ground rod conductor to the controller chassis ground block (See Figure 2). 3. Connect solar module frame ground conductor and the pump ground conductor to controller chassis ground block (See Figure 2). 4. Connect pump motor leads to the lower terminal block. Red leg to “R”, yellow leg to “Y” and black leg to “B” (See Figure 2). 5. Connect the DC source supply negative (-), black conductor to the controller terminal labeled “PV-“.
Figure 3 Controller Wiring Diagram (Auxillary)
Figure 4 Dip Switch Settings Switch Switch Number Position 1 Description Function Default Setting OFF Remote Switch Logic Turns pump off when terminals connect. OFF 1 ON Remote Switch Logic Turns Pump on when terminals connect. OFF 2 OFF Low Water Cutoff Logic Turns pump off when terminals connect. OFF 2 ON Low Water Cutoff Logic Turns pump on when terminals connect.
3.6 Controller Settings The PCA series controllers have several settings (see figure 3). Most features include system configuration adjustments, some of which are user selectable by an eight position DIP-switch located on the face of the controller. Switch 1 is the Remote Switch Logic. With this switch off (down), terminals “RS+” and “GND” must be connected to turn the controller off. With this switch on (up), terminals “RS+” and “GND” must be connected to turn the controller on.
Remote Switch The Remote Switch interface can serve as an automatic system shutdown when used with a water storage tank mounted float switch, a pressure switch or it can also serve as a manual system shutdown with a remote system ON/OFF toggle switch. The remote logic circuit allows the use of standard “Pump-Up or Pump Down” float switches. Please refer to the following operation scenarios for configuration options.
2. Turn the “Speed Control” trim pot counter clockwise until the pump is pumping the desired minimum flow. This may be down to 0 gal/min but is not recommended for proper pump cooling. 3. Turn the “LP Adj.” trim pot clockwise until the pump shuts off. 4. Reset the “Speed Control” trim pot back to the desired position. Motor Speed Control The Output Power Limit Control circuit is used to control the speed of the pump motor and thus the flow rate of the pump.
3. If there are no blown fuses and no tripped breakers, check the open circuit voltage of your array. If the open circuit voltage is not correct trouble shoot the array to find the problem. If the open circuit voltage is correct, call Sun Pumps for further assistance. CONTROLLER TURNS ON BUT PUMP DOES NOT RUN 1. Make sure the On/Off switch is in the up position (On). The second LED is labeled “Run”. This indicates the pump is running. If it is on, go to the bore hole and listen for the sound of the motor.
PUMP IS RUNNING BUT THE OUTPUT IS LOW 1. Make sure you have full sun light at midday, that there are no clouds and no shadows on any part of the array. Then verify power going into the controller by measuring the voltage and current. Check this against the pump chart for your specific application. 2. If the power is correct for your pump model and array size then make sure the pump wires are connected to the proper terminals. If two wires are reversed the motor will be running in reverse.
4.1 BEFORE CALLING SUNPUMPS If at all possible when calling Sun Pumps for technical support there are a few things which will help to speed up the process and help us determine the cause of and solution to the system failure. The best way to get help is to call while you are physically at the location of your pump, have good sunlight, and have a multimeter and a screwdriver with you. Furthermore, please fill out the form below before calling.
5.0 Technical Specifications Model PCA-60BLS-M2 PCA-120BLS-M2 Max Input Voltage 100 200 Max Power 840 1500 Maximum ambient temperature is 120 F. Controller Dimensions and Weight Model PCA-60BLS-M2 PCA-120BLS-M2 Width Inches cm 6.3 16.1 6.3 16.1 Height Length Weight Inches cm Inches cm Pounds 4.2 10.7 7.7 19.5 4.2 4.2 10.7 7.7 19.5 4.2 kg 1.9 1.9 For future reference, please list your system data before installing the pump.
Warranty Statement SCS Series Pump Systems Limited Warranty – Twenty-Four Months SunPumps warrants to the original consumer that its products shall be free from defects in material and workmanship under normal applications and service conditions for a period of twelve (24) months after the original date of purchase, but not to exceed eighteen (30) months from the date of manufacture.
