Sun Pumps PCA-30M1D 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

Warning

Location …………………………………………………………………………… 3.1

System Design Basics ……………………………………………………………... 3.2

Figure 1: Solar Pump System Terms and Head Calculations

Well Measurements ……………………………………………………………… 3.3

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

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

Figure 2: Control Panel
Figure 3: Dip Switch Settings

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

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

Remote Switch
Low Water Shut-Down Circuit
Power Limit (Speed Control)

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

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

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

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

Phone [phone] Fax [phone]

1.0 Introduction

Thank you for selecting a SunPumps SDS series solar pump system. The SDS series pump and PCA-30­M1D series pump controller are the key components to high quality solar powered pumping systems. Their
stand-alone, pollution free operation makes them an ideal solution for remote homes, irrigation projects,
and wildlife and stock watering without violating the environment.

SunPumps SDS series pumps are diaphragm type, DC powered, submersibles constructed of high quality
stainless steel for the SDS-D and SDS-Q series pumps and Ryton and stainless steel for the SDS-T series
pumps. These pumps were designed specifically for water delivery in remote locations.

The PCA series controllers are microprocessor based solid state DC power converters designed as the
interface between a solar module array and the SDS series 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 SDS 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.
 Do not splash water on the controller when the cover is open.
 Mount the controller in a shaded, well vented, vertical position.

2.0 Product Overview

The SunPumps PCA-30-M1D series controllers were designed specifically for SunPumps SDS-series, 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.

When used as a solar electric panel direct system the PCA series controllers will provide pump protection
from over-voltage and over-current conditions as well as current boosting in low sunlight conditions.

2.1 Controller Features

1. Current boosting for matching the load requirements of the pump.

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

3. Over-current protection via integrated electronic circuit breaker.

4. Voltage and current limiting to pump motor..

5. Adjustable output motor power control for precision output flow.

6. System ON/OFF switch.

7. LED indicators; 1. Power In, 2. Motor Run, 3. Remote Switch, 4. Over-Current, 5. Low Water

Cut-Off

8. Weather resistant enclosure with a hinged door.

9. Rising clamp screw terminal blocks – no fork terminals required.

10. Pre-adjusted pump configuration and power source selection.

11. Remote switch interface – float switch or remote shutdown –Normally Open or Normally

Closed, user selectable.

2.2 Application

The only application the PCA 30M1D series controllers are designed for is the interface between a solar
module array and SunPumps SDS series DC pumps.

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 SDS series pump and PCA series controller. The procedure for installing the SDS
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.

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 will result in non-warrantied product damage. Please check polarity
before connecting power to the controller.

This controller is for SunPumps SDS Series DC Pumps only. Do not use this controller
on Sensorless Brushless DC 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 PCA-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 (Read carefully before installation)

1. Use no larger than ½” drop pipe for SDS-D and SDS-T series pumps and ¾” drop pipe for SDS-

Q series pumps. Because of the low flow rates of the SDS series pumps, the water velocity is
not fast enough to carry any sand and sediment to the surface. These small particles may settle
inside the pump as well as the drop pipe causing pump damage.

2. If there is a known sand problem, a sand shroud or a screen is required. The minimum casing

diameter for an SDS-D and T series pump with a sand shroud is 5” (12.7 cm) and for and SDS­Q series pump it is 6” (15 cm). Sand damage to an SDS series pump is not covered under
warranty. It is therefore highly recommended that sand shrouds be installed on all SDS series
pumps in an unproven well.

3. 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%.

4. 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 3 wire splice kit is
recommended for this water tight connection.

5. Never install the pump over 50 feet (15 meters) under the static water level. Excessive water

pressure on the pump housing may cause seal damage and allow water to enter the motor
housing.

6. Never rest the pump on the bottom of the well. This can cause the pump to fill with mud and

damage the diaphragm. 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 (bore hole). If possible, install the pump above the well casing perforations. This will
allow any sand intrusion to settle below the pump.

7. 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 diaphragm and
seals.

8. Never chlorinate a well while the pump is installed. Heavy concentrations of chlorine will

damage the diaphragm and seals.

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

heating of the controller.

10. 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.

11. 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.

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

3.3 Well Measurements

Before installing the pump measure the depth of the well 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. This information is necessary in
determining the pump setting (See Figure 1).

Figure 1 Solar Pump System Terms & Head Calculations

Determining Total Dynamic Head

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.)