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 1000 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 Water Tank Vertical Lift Sanitary Well Seal Pumping Level _____________ Feet Vertical Lift _____________ Feet Friction Loss _____________ Feet + Drop Pipe + Submersible Pump Cable Draw Down (See Friction Loss Chart) = 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 Switch Switch Number Position 1 Dip Switch Settings 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.
position, the low water cutoff circuit expects not to touch water. If water comes into contact with it, and completes the circuit to ground, the pump will shut off until the water is removed and the delay timer times out. A three minute timeout is default for this feature but is modifiable by switches 3 and 4 to 10 or 30 minutes respectively. This timeout applies to remote switch and low water cutoff.
LPLW Adjustment The Low Water Cut-Off Circuit and the Low Power Shut-Down circuit are adjusted using the same trim pot labeled “LP Adj.” on the controller. The default is the arrow pointing straight up. This is sufficient for most systems but adjustment will maximize the life and output of your system. Follow the steps below to adjust this feature. 1. Turn the “LP Adj.” trim pot fully counter clockwise. 2.
performing any of these tasks, or do not fully understand the system, it is better to call than to guess. Before calling please go through the section below labeled “Before Calling Sun Pumps” and complete the steps there. CONTROLLER DOES NOT TURN ON 1. Check the LED’s on the face of the controller. The top LED, labeled “Power In”, should be on. This indicates power is connected to the controller and the polarity is correct.
4. If the sixth LED, labeled “Over Current” is on, the controller has exceeded its current limit and shut down. Turning the controller off then on again will reset this fault. If the controller continues to need high current, it will turn itself off again. Verify the nominal voltage of your array. If the calculated Vmp for your array is higher than 200 V, the controller may go into over current. Remove one series panel from each string and try again.
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 1000 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 PCA Series Pump Controllers 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.
