Sun Pumps BLM-SB-103S-120Y User Manual

Table of Contents

Introduction ………………………………………………………………………... 1.0

Precautions

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

Pump Installation ………………………………………………………………….. 3.4

Wiring ……………………………………………………………………………… 3.5

Controller Settings ………………………………………………………………… 3.6

Auxiliary Control Circuits ………………………………………………..…...……… 3.7

Troubleshooting …………………………………………………………...……….. 4.0

Before Calling SunPumps …………………………………………………………... 5.0

Warranty Statement ………………………………………………………………… 6.0

Table 1: Differences in Models

Warning

Figure 1: Solar Pump System Terms and Layout

Figure 2: Control Panel
Figure 3: Dip Switch Settings

Over-Current Shut-Down Circuit
Sensor Low Water Cutoff
Remote Switch
Low Water Shut-Down Circuit
Low Power Shut-Down Circuit
Output Power Limit Circuit
Figure 4: Display Screens

Controller does not turn on

Controller turns on but pump does not run

Pump is running but the output is low
Pump draws excessive current
Before Calling Sun Pumps

Phone [phone] Fax [phone]

2

2

1.0 Introduction

Thank you for selecting a SunPumps SCS series solar pump system. The SCS series pump and PCC series
Sensorless Brushless DC - 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, irrigation projects, and wildlife and stock watering without violating the environment.

SunPumps SCS series pumps are multi-stage centrifugal, DC powered, submersibles constructed of high
quality stainless steel. These pumps were designed specifically for water delivery in remote locations.

The PCC-BLS series controllers are microprocessor based solid state DC power converters designed as the
interface between a solar module array and a sensorless brushless DC pump motor. The purpose of the
controller is to operate the high efficiency, high reliability DC motor and maximize the total daily water
output while providing protection for the pump as well as providing an interface with other related
pumping system equipment.

Although these SCS series pump systems are easy to install, please read this manual to become
familiar with the controller features, functions, connection points and various configurations. For
future reference, keep this manual and other relevant product information in a safe place.

PRECAUTIONS

• Safety First – Always understand what you are doing when working with any form of
electricity. Guessing may cause product damage and/or severe personal injury.

• Shut down all power when working on the system.

• Do not attempt to feed live wires into the PC-series controller. Product damage and/or

personal injury may result.

• Do not exceed the voltage rating of the controller.

• Do not set the controller to exceed the power rating of the motor. See 3.6 Controller Settings.

• Do not splash water on the controller when the cover is open.

• Mount the controller in a shaded, well vented, vertical position.

• Installation of this system should be done by a licensed Pump Contractor.

2.0 Product Overview

The SunPumps PCC-BLS-M2 series controllers were designed specifically for SunPumps SCS-series,
Sensorless Brushless DC submersible pumps. When properly installed and configured, the unique features
incorporated into this stand-alone system will automatically control and protect your pump system
permitting many years of dependable, trouble free service. SunPumps has produced multiple versions of
this controller. The differences between the two are certain set points and electrical characteristics which
are detailed in the table below.

Table 1

Controller Model Min

Voltage1
PCC-120BLS-M2
PCC-180BLS-M2
PCC-240BLS-M22 220 V 380 V Set by LWC 3000 W 100 W 1023 W 240 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.

2

Both controller models have the same operating features, functionality and setup. Voltage and power tolerances are

the only differences of concern to the end user. This manual will only differentiate when necessary for clarity.

90 V 200 V Set by LWC 1500 W 100 W 585 W 120 V

120 V 300 V Set by LWC 2250 W 100 W 1023 W 180 V

Max

Voltage

Min Power Max

Power

Low Water
Cutoff Min

Low Water

Cutoff Max

Nominal

Voltage

2.1 Controller Features

1.

Current boosting for matching the load requirements of the pump.

2.

Voltage regulation of the solar electric array at its maximum power point. (MPPT)

3.

Over-current protection via integrated electronic circuit breaker.

4.

Reverse polarity protection (10 amperes maximum) on the input terminals.

5.

Voltage and current limiting to pump motor.

6.

Transient protection and surge suppression.

7.

Adjustable output motor power control for precision output flow.

8.

Digital display indicating status, power, voltage, current and more.

9.

System ON/OFF switch.

10.

LED indicators; 1. Power In, 2. Motor Run, 3. MPPT, 4. RS Stop, 5. Low Power, 6. Over­Current, 7. Fault Condition.

11.

Weather resistant powder coated, die cast aluminum enclosure with a hinged door.

12.

Rising clamp screw terminal blocks – no fork terminals required.

13.

Pre-adjusted pump configuration and power source selection.

14.

Remote switch interface – float switch or remote shutdown –Normally Open or Normally
Closed, user selectable.

15.

Sensor and sensor less “Low Water Cutoff” circuit

16.

Low Power Shut Down circuit

2.2 Application

The only application the PCC series controllers are designed for is the interface between a solar module
array and SunPumps Sensorless Brushless DC motors.

No other applications or DC power sources are recommended or warrantied unless written
approval is provided by the SunPumps factory.

3.0 Installation and Operation

The following sections are outlined in a step-by-step format to guide you through the installation and
configuration of an SCS series pump and PCC series controller. The procedure for installing the SCS
submersible pump is the same as a standard AC submersible pump. Any licensed pump contractor will be
familiar with the proper installation procedures. The installation and operation should be in accordance
with local regulations, accepted codes of good practice and common sense. This pump should be installed
by a licensed professional pump installer.

Before installing any pump system read all product manuals then 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.

Warning

Reverse polarity on a panel system capable of producing over 10 amps will result in
non-warrantied product damage. Please check polarity before connecting power to the
controller.

This controller is for SunPumps Sensorless Brushless DC Motors only. Do not use this
controller on Brush-Type motors or Sensor Type Brushless DC motors. Damage to the
controller will result.

3.1 Location

As the majority of system installations vary greatly, only general comments can be made about the
installation location. Prior to installing the system, it is suggested to make a system layout plan. During
the system layout, take into consideration any potential shading of the solar electric modules, wire runs,

wire size, conduit runs, trenching, controller accessibility, tank location, pump head etc. Shading even a
small portion of the array can reduce the output of the entire array and thus reduce or completely stop the
output of the pump. There is no substitute for a good plan!

The PCC-series controller can either be mounted indoors or outdoors. Locate all system equipment as
close as possible to each other. For top of pole mount racks, the controller is usually mounted on the north
side (shaded side) of the mounting pole. The controller must be mounted in a vertical position for proper
cooling and to keep the electronics dry. The pole should be located close to the well (bore hole). This
general physical layout is conducive to clean installation both aesthetically and electrically.

3.2 System Design Basics

1. The pump discharge piping should be sized for efficient pump operation. We suggest using the

Friction Loss Tables to calculate the Total Dynamic Head using different pipe sizes. As a rule of
thumb use 1” for up to 8 GPM, 1 ¼” for up to 25 GPM, 1 ½” for up to 40 GPM and 2” for up to
70 GPM.

2. 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%.

3. Due to the aggressive action of DC power, it is essential that any under-water splice be made
correctly. This splice must be watertight. Improper sealing of the splice will cause poor pump
performance and may cause damage to the system. A submersible 4 wire splice kit is
recommended for this watertight connection.

4. Never rest the pump on the bottom of the well (bore hole). This can cause the pump to fill with
mud and damage the impellers. It is recommended that the pump be set at least 10 feet off of the
bottom of the bore hole. If this is not possible the pump may be placed a minimum of 5 feet above
the bottom of the well. If possible, install the pump above the well casing perforations. This will
allow any sand intrusion to settle below the pump.

5. Never install a pump in a well that has had an oil-lubricated line shaft turbine in it without
cleaning it first. Any drip oil remaining in the water may damage the pump shaft bearing
sleeves.

6. On deep wells, a check valve should be installed in the drop pipe every 200 feet.

7. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-

heating of the controller.

8. Never lay the controller on the ground or mount the controller in a horizontal position. The
controller should be mounted in a vertical position only. A convenient place to mount the

controller is on the north side (shaded side) of the solar module array.

9. The controller should be grounded to the pump motor housing, the frame of the solar modules
and to an 8-foot ground rod. If the well casing is steel it may be used as the ground rod. Drill
and tap a hole in the casing or weld a bolt to the casing for the ground lug. Use only a copper
lug to attach the ground wire. The cemented support structure pole will not provide an adequate
ground. Do not ground the positive or negative electrical wires. Always use a DC
surge/lightning arrestor on the panel side of the controller. (Midnight Solar MN-SPD surge
arrestor is recommended)

10. Do not ground the array positive or negative electrical wires.

(Read carefully before installation)

3.3 Well Measurements

Before installing the pump measure the depth of the well (bore hole) and static water level. The static
water level is the distance from the top of the well casing to the water level in the well (bore hole). This
information is necessary in determining the pump setting (See Figure 1).

Figure 1 Solar Pump System Terms & Head Calculations

Water Tank

Sanitary Well Seal

Pumping Level _____________

Drop Pipe

+

Vertical Lift _____________

+

Friction Loss _____________

Submersible Pump Cable

(See Friction Loss Chart)

Total Dyn. Head _____________

=

Vertical
Lift

Feet

Feet

Feet

Feet

Draw
Down

Determining Total Dynamic Head

Static Water Level

Total Dynamic Head = PL + VL + FL

Pump Level

Pump Setting

SCS Submersible Pump

Pumping Level

Pumping level is the vertical distance in feet from the discharge pipe at the well head to the water level
in the well while pumping at the specified flow rate.

Vertical Lift

Vertical lift is the vertical distance in feet from the discharge pipe at the well head to the discharge pipe
at the top of the water tank.

Friction Loss

Friction loss is the resistance to flow through a pipeline measured in PSI drop and converted to head
feet. The amount of loss depends on the diameter of the pipeline, the length of the pipeline, the flow rate,
the number and type of fittings and the coefficient of friction of the pipeline material. Refer to friction
loss tables for your specific application. (There is a Friction Loss Program on the SunPumps web site in
the engineering section at www.sunpumps.com.)