Page 1
Page 2
Table of Contents
Introduction ………………………………………………………………………... 1.0
Precautions
Product Overview …………………………………………………………………. 2.0
Table 1: Model Differences
Controller Features ………………..………………………………………………. 2.1
Application ………………………………………………………………………... 2.2
Installation and Operation ..………………………………………………………… 3.0
Warning
Location …………………………………………………………………………… 3.1
Installation Basics ...…………………………………………………………….…... 3.2
Wiring ……………………………………………………………………………… 3.3
Figure 1: Controller Wiring Diagram
Figure 2: Voltage Regulation
Figure 3: Dip Switch Settings
Controller Settings ………………………………………………………………… 3.4
Auxiliary Control Circuits ………………………………………………..…...……… 3.5
Over-Current Shut-Down Circuit
Sensor Low Water Cutoff
Remote Switch
Low Power Shut-Down Circuit/Sensorless Low Water Shut-Down Circuit
Input Voltage Threshold Adjustment
Output Power Limit Circuit
Figure 4: Display Screens
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 (928) 348-9652 Fax (928) 348-9653
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Controller Model
Min Start
Voltage1
Max Input
Voltage2
Low Battery
Voltage
3
Max
Power
Nominal
Voltage
Dead Battery
Shut Down
4
PCC-48BLS-M2
49 V
63.9 V
47 V
2000 W
48 V
44V
1.0 Introduction
Thank you for selecting a SunPumps battery powered pump system. Sun Pumps battery pumps and PCC series
Sensorless Brushless DC - pump controller are the key components to high quality battery 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 pumps are multi-stage centrifugal or piston, three phase brushless sensorless DC powered, pumps
constructed of high quality parts. 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 battery bank and a three phase brushless sensorless 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. Three
phase brushless DC motors cannot be run from a battery bank without a controller.
Although these PCC series pump controllers 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 PCC-series controller. Product damage and/or personal
injury may result.
Do not exceed the voltage rating of the controller.
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 Sensorless Brushless DC
motors. 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.
Currently SunPumps has only produced one version of this controller. The default set points and electrical
characteristics are detailed in the table below.
Table 1
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 but may harm batteries. This voltage can be
adjusted. See Input Voltage Threshold Adjustments. 2At 64 volts the controller will turn off in overvoltage. 3Low Battery Voltage
is the voltage threshold which will cause the controller to turn the pump off after 45 seconds. This voltage can be adjusted. See
Input Voltage Threshold Adjustments.
4
Dead Battery Shutdown is similar to note 2 but will shut down the pump immediately. This voltage can be adjusted. See Input
Voltage Threshold Adjustments.
Page 4
2.1 Controller Features
1. Current boosting for matching the load requirements of the pump.
2. Adjustable voltage regulation of the battery bank.
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. Battery Ready 4. RS Stop, 5. Low Battery, 6. Over-
Current, 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-48BLS-M2 controllers are designed for is the interface between a battery bank and a
SunPumps three phase Brushless Sensorless DC motor.
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 a PCC series controller. 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 on a system capable of producing over 50 amps can result in non-warrantied
product damage. Please check polarity before connecting power to the controller. All 48 volt
systems should have a fuse/breaker rating of no more than 50 amps.
This controller is for SunPumps three phase Sensorless Brushless DC Motors only. DO NOT
use this controller on Brush-Type motors, Sensor Type Brushless DC motors or on any AC
motor. Damage to the controller will result.
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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 physical battery bank size, wire runs, wire size, conduit runs, trenching, controller accessibility,
tank location, pump head etc. 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. The controller is not designed for use in direct sunlight and should be mounted in a shaded
location. The controller must be mounted in a vertical position for proper cooling and to keep the electronics dry.
This general physical layout is conducive to clean installation both aesthetically and electrically.
3.2 Installation 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 battery bank. Wire sized too small will cause a decreased output from the pump. Keep
the distance from the batteries 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. 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.
3. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-heating of
the controller.
4. 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.
5. The controller should be grounded to the pump motor housing, the frame of any conductive battery box
and to an 8-foot ground rod. Use only a copper lug to attach the ground wire. The Ant thing which is
cemented in the ground will not provide an adequate ground. SunPumps recommends that you always
use a DC surge/lightning arrestor on the battery side of the controller. (Midnight Solar MN-SPD surge
arrestor is recommended)
6. Do not ground the battery positive or negative electrical wires.
3.3 Wiring
Prior to connecting any wires to the controller, be sure you have a system wiring diagram to use as a reference (see figure
2). 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. Wire gauge being too small will cause excessive voltage losses to the motor
and will reduce the flow rate of the pump. Also be certain that you have the right type of wire for your usage. Any wires
which will be in water must be rated for such an application. SunPumps recommends using stranded wire for all DC
applications.
All other system equipment should be installed before proceeding to wire the controller. Double check polarity and wire
termination tightness before powering up the system.
CAUTION: Batteries are capable of large amounts of current. Install a fused disconnect or circuit breaker
between the batteries and the controller of the pump. Maximum fuse/breaker rating is 50 amps. If using
photovoltaic panels to charge the batteries, remember that they produce DC electricity when exposed to sunlight.
Install a disconnect switch between the solar modules and the charge controller.
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Figure 1 Controller Wiring Diagram
Page 7
1. After mounting the controller, switch the controller to the OFF position.
2. Verify all dip switches are off at this time.
3. Connect ground rod conductor to the controller chassis ground block.
4. Connect battery box frame ground conductor to controller chassis ground block.
5. Connect the green pump ground conductor to controller chassis ground block.
6. Connect pump motor leads to the corresponding “Pump Motor” terminals on the controller. Red to “Red”, yellow
to “Yellow” and black to “Black”.
7. Verify that the disconnect switch is in the off position. Connect the DC source supply negative (-), the black
conductor, to the controller terminal labeled “-” on the “Battery Input”. (NOTE: The power should be connected to
the controller through a fused disconnect or appropriately sized breaker and it should be in the OFF position before
connecting power to the controller).
8. Connect the DC source supply positive (+), the red conductor, to on the controller terminal labeled “+” on the
“Battery Input”. (NOTE: The power should be connected to the controller through a fused disconnect or
appropriately sized breaker and it should be in the OFF position before connecting power to the controller).
9. Refer to the next section for “Remote Switch” and “Low Water Cutoff” connections as well as “Adjustment
Procedures” for configuration, if applicable.
10. For new installations, be certain to allow the batteries to fully charge before powering the controller.
11. At this point, all system components are installed and wired, double check conductor polarities, wire termination
tightness and controller configuration. With a DC volt meter check the battery bank voltage at the input of the
disconnect switch. Pay particular attention to the polarity of the voltage. Verify it is correct. Most battery systems
will cause non warrantied damage to the controller if connected in reverse polarity. Record the actual and
theoretical voltages for future reference. You may do this on the Before Calling Sun Pumps Worksheet near the end
of this manual. Check the voltages for proper range for your specific system.
12. After you have verified the voltage and polarity, switch the disconnect switch on. If the polarity is correct the
controller will go through its normal boot up cycle. When it is finished, the first LED light will be on.
13. Turn the “On/Off “switch to the ON position. It may take up to 15 seconds for the pump to show signs of
running. However, the “Run” light on the controller will light immediately if the motor is preparing to run.
The system should be operational. If the system does not start and turns on any error lights or gives you an error
message, proceed to the troubleshooting guide.
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Figure 2 Battery Voltage Regulation
State
Voltage
Behavior
Over Charge
> 64 V
Controller will not attempt to start pump when more than 64 volts is
seen on the input terminals. Less than 64 V on the input will reset this
fault. If the pump is running when the input goes to 64 V, the pump
will immediately be shut down.
Nominal Operating
Range
49 V – 64 V
Controller will start and run the pump according to the position of the
on/off switch, remote switch, and low water cutoff inputs. It takes 30
seconds in this range or cycling the on/off switch while the input is in
this range to allow the controller to attempt to start the pump.
Pump Start
Threshold
49 V
Minimum voltage for the controller to start the pump. Input voltages
less than this for 45 seconds or more will cause the controller to protect
the batteries from excessive discharging.
Pump Run
Hysteresis
47 V – 49 V
If the pump is running and the voltage drops into this range, the pump
will continue to run. If the controller shuts down the pump for any
reason, the voltage will have to attain 49 V for 30 seconds to start the
pump again.
Pump Run
Threshold
47 V
Minimum voltage for the pump to run. Voltages lower than this for 45
seconds will turn the pump off. Pump will not start until 30 seconds of
input voltage above 49 V has been achieved or the on/off switch is
cycled while the voltage is above the Pump Start Threshold.
Dead Battery
44 V
Pump will immediately shut down and will stay off until 30 seconds of
49 V or more is attained on the input to the controller or the on/off
switch is cycled while 49 V – 64 V is applied to the input terminals.
*Note: At any time cycling the on/off switch will reset all faults, timers and status and bypassing the timer,
establish the current state immediately.
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Switch
Switch
Description
Function
Default
Setting
Number
Position
1
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.
OFF
3
ON
Input Voltage Thresholds
Adjust 1
Reduces the input voltage
requirements See Table 2
OFF
4
ON
Input Voltage Thresholds
Adjust 2
Reduces the input voltage
requirements See Table 2
OFF
5,6 Not used at this time
Should be in the off position for
proper operation
OFF
7
ON
Display Freeze
Holds display on current screen
OFF
8
ON
Battery Protection Override
Disables the battery bank
protection.
OFF
Figure 3 Dip Switch Settings
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3.4 Controller Settings
The PCC series controllers have several settings (see figure 4). 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
disconnected to turn the pump on. With this switch on (up), terminals “RS+” and “GND” must be connected to turn
the pump on.
Switch 2 is the Low Water Cutoff Logic. With this switch off (down), terminals “RS+” and “GND” must be
disconnected to turn the pump on. With this switch on (up), terminals “RS+” and “GND” must be connected to turn
the pump on.
Switches 3 and 4 are Input Voltage Threshold Adjustments. See Table 2 in Input Voltage Threshold Adjustment for
more information.
Switch 7 is used to control the user interface. When switch 7 is down, the LCD will display various screens
conveying pump and controller operating parameters. The display will cycle through each screen at a predetermined
rate. For troubleshooting and some setup features certain screens are desired. By turning the switch number 7 on,
the display will stop cycling and the current screen will stay on the display.
Switches 5 and 6 are not used at this time and should remain down.
Switch 8 is used as a battery protection DISABLE. It is used to bypass the battery protection features shown in
Figure 3 in cases when water must be pumped. Over voltage protection by the controller still functions. In other
words if the input voltage is greater than 64 V, the controller will still not attempt to run the pump. Do not operate
your pump with switch 8 in the on position for extended periods of time. Only use it when it is absolutely
necessary as it can cause the controller to ruin batteries which are connected to it by discharging them too
far. Sun Pumps, Inc. warranty does not cover damages to batteries.
3.5 Auxiliary Control Circuits
The auxiliary control circuits are configured and controlled with the “Dip Switches”, “Speed Control” and the “RS”,
“LW” and “GND” terminals. (See Figure 4)
These circuits offer expanded capability and are described here. The remote switch control is for float switches
(storage tank level), pressure switches or a remote system “ON/OFF” toggle switch. The motor speed control is for
adjusting the flow rate of the pump. There are also the low water cutoff and over current protection circuits. See
each corresponding detailed description below.
NOTE: Use only “Shielded Wire” to run from the remote switch to the controller and the ground wire must
be grounded to the controller side only. Induced voltages from lightning storms or two-way radio transmissions
could damage the controller.
Over-Current Shut Down Circuit
The over-current shut down circuit will turn the controller off any time the current exceeds the current limit of the
controller. When it turns the controller off it will remain off for 3 minutes and then turn on again. When it turns off
an error light will light and the display will say Over-Current under the Sun Pumps Inc. on the first screen. After the
3 minutes, when it turns on again, if it is still pulling excessive current it will continue to shut down for 3 minutes
and try to restart.
Page 11
Sensor Low Water Cutoff Circuit
Minimum Start
Voltage
Low Battery
Voltage
Dead Battery
Shutdown
Both Dip Switches OFF
49 Volts
47 Volts
44 Volts
Dip Switch 3 ON
48 Volts
46 Volts
43 Volts
Dip Switch 4 ON
48 Volts
45 Volts
42 Volts
The sensor type low water cutoff circuit is designed as a safety feature to protect your pump from running dry or
your tank from over flowing. This feature is designed for use in the submersible SCS systems with the ground wire
installed. For use with the SCB or SCP systems contact SunPumps for assistance. The “LW” terminal of the
controller should be attached to a low water sensor electrode which is mounted in your tank or well. The system can
be used to detect low water or to detect high water depending on the position of switch 2 on the dip switch. When
dip switch 2 is in the off 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 one minute timeout is included in this feature.
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.
With switch number 1 in the OFF position, the controller is configured to accommodate a Normally Open (N.O.)
float switch or remote toggle switch. In this configuration the controller will operate as follows:
PUMP ON
float switch open = water tank low = pump ON
PUMP OFF
float switch closed = water tank high = pump OFF
With switch number 1 in the ON position, the controller is configured to accommodate a Normally Closed (N.C.)
float switch, pressure switch or remote toggle switch. In this configuration the controller will operate as follows:
PUMP ON
float switch closed = water tank low = pump ON
PUMP OFF
float switch open = water tank high = pump OFF
The remote switch feature does not have a time out since many of these units are used for pressure systems. The
pump should immediately begin running when the remote switch is turned to “On”.
Input Voltage Threshold Adjustments
The Input Voltage Threshold Adjustment is available to help accommodate for differences in battery banks, systems
with other power draws (such as inverters or other pumps), or systems which are not able to be located near the
battery bank. The Input Voltage Threshold Adjustment will modify the Minimum Start Voltage, the Minimum Run
Voltage and the Dead Battery Shutdown Voltage. See Table 2 below.
Table 2
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Low-Power Shut-Down/Sensorless Low Water Cut-Off Circuit (LPLW)
The Low-Power Shut-Down/ Low Water Cut-Off Circuit (LPLW) turns the pump off any time the controller output
power drops below a functional level. This may be caused by lack of power from the solar panels or from running
out of water. This protects the pump in stall conditions and saves wear on the system when no or very little water is
being pumped. This feature must be adjusted for your specific application.
This feature is always monitoring the output of the motor. If you are not interested in using this feature turn the “LP
Adj” trim pot fully counter-clockwise. This will give the pump the minimum low power set point possible.
Output Power Limit Circuit (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. It is primarily used for low producing wells where the pump output is matched to the production rate of the
well. However it can also be used any time specific flow rates are required.
Output Power Limit Adjustment
The purpose of this procedure is to adjust the output power of the controller and thus reduce the water flow of the
pump. If tests have shown the pump will out produce the well capacity, then the controller “Speed Control” feature
can be used to match the flow rate of the pump to the production of the well.
1. With the system installed and controller properly configured, allow the pump to run at full power at mid-day
until the pump starts surging.
2. Slowly turn the “Speed Control” trim pot located on the face of the controller counter clockwise until the pump
stops surging. This is the point where the pump flow rate equals the well production. This process will probably
take a few attempts to “balance” the system for optimum water production. If maximum water is not a critical
issue you may want to reduce the pumps flow rate an additional 5% to 10% to insure the pump will not run dry.
(NOTE: The trim pot has a 15- turn range. It may take multiple complete turns in a counter-clockwise direction
before you will notice any change in water output or output power on the display).
Page 13
Figure 4 Display Screens
NOTE: If the system is powered up with switch 7 on, the display will only show the
SUNPUMPS INC. screen. Turn off switch 7 to unfreeze the display.
Page 14
4.0 Troubleshooting
Sun Pumps, Inc. is dedicated to its customers and will gladly help you trouble shoot any problems with your system.
However, especially during the busy summer pumping season, we may not be able to help you right away. Using
this trouble shooting guide as your first resource when your system is not working properly can save you valuable
time in getting your system fully functional. If at any time however, you are not comfortable 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. If it is not on, verify that the controller is
properly wired, including polarity, and that the input terminals have at least 35 volts. Less than 35 volts at the
input terminals and the unit may show no signs of operation. If you do have at least 35 volts in the right
polarity, contact Sun Pumps for further assistance.
2. If the expected voltage is not present, disconnect the battery bank from the controller using the disconnect, and
check any fuses and breakers in the system. Replace blown fuses and reset tripped breakers.
3. If there are no blown fuses and no tripped breakers, check the voltage of your battery bank. If the battery bank
voltage is not correct troubleshoot it to find the problem. Double check all of the terminal connections for
integrity. If the battery bank 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)
2. The third LED is labeled “Battery Ready”. This light must be on for the controller to start the pump. If this
light is off, it is generally caused by insufficient input voltage or if the sufficient voltage timer has not recorded
enough time at the sufficient voltage to run. If the Low Voltage LED is lit, the 30 seconds of sufficient voltage,
49 V, has not been achieved. If both the Low Voltage and Over Current LED are lit it indicates a Dead Battery
Condition. Then a 30 second timer of sufficient voltage, 49 V, must timeout as well. Cycle the on/off switch.
This will bypass the timers and reset the dead battery condition. If 49 volts or more are present, the Battery
Ready light should light and the pump will start. If the Battery Ready light does not turn on, check the input
power. This may be done on the display screen, input voltage is labeled “DC BUS”. If it is below 49 volts you
must charge your batteries or use the Input Voltage Threshold Adjustment procedure under Controller Settings
in this manual. If the voltage is above 49 V and the “Battery Ready” light does not turn on or the pump does
not run, check the other lights for errors. If the voltage is higher than 64 V, your batteries are over charged and
the controller will not attempt to start the pump. Discharge your batteries until the bank reads less than 64 V. If
you cannot find any problems contact Sun Pumps for further assistance.
3. The second LED is labeled “Run”. This indicates the pump is running. If it is on, check the power reading on
the LCD screen of the controller. If it is greater than 50 watts, go to the pump and check for the sound of the
motor. Check for breaks in the pipe. If you cannot find a problem call Sun Pumps for further assistance.
4. Check the fourth LED, labeled “RS Stop”; this is the remote switch shutdown indicator. If it is on, the remote
circuit or low water cutoff circuit is preventing the controller from running the pump. Check the display to see
if the controller has shut down for a Remote Switch error or Low Water error. Set the #1 and #2 dip switches to
off and disconnect the remote switch and low water cutoff depending on the error displayed on the screen.
Cycle the on/off switch. If the pump starts, troubleshoot the remote switch or low water cutoff accordingly. If
the pump does not start and the LED is still lit, call Sun Pumps for further assistance.
5. 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. Check the pump for a short to ground using an ohm meter and call Sun Pumps for
further assistance.
6. If the seventh LED, labeled “Fault Condition”, is on, this indicates a motor or ground fault fuse error. Check the
controller display for the type of fault. Check motor wiring and connections. If the screen displays “GF FUSE
OPEN” the ground fault fuse has been blown. Check your system for ground loops and replace the fuse with a
500 VDC 1A rated fuse. If this does not solve the issue, contact Sun Pumps for further assistance.
Page 15
7. Check for proper dip switch settings on your controller. Switches 5 and 6 must be in the off position for proper
operation. Also dip switch 8 should be in the off position except when water is absolutely necessary. Damage
to batteries may result in use of switch 8. Damage to battery systems is not covered under the pump or
controller warranty.
PUMP IS RUNNING BUT THE OUTPUT IS LOW
1. Make sure you have a full battery bank and that you have sufficient voltage. Then verify power coming out of
the controller. Look at the LCD screen and read the voltage, current and power. Check this against the pump
chart for your specific application.
2. If the power is correct for your pump model and battery bank 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. It may still pump but not
at the full rated output.
3. If the wires are correct, check a DC voltage loss chart for the current shown on the LCD screen of the
controller. Improperly sized wire can reduce the performance of the pump.
4. If the wires are correctly sized, verify that your system does not have any leaks where water can be lost. If you
cannot determine the problem, contact Sun Pumps for further assistance.
PUMP DRAWS EXCESSIVE CURRENT (More than the rating of the pump, but less than the rating of the
controller)
1. Check wiring diagram for proper connection.
2. Check for skinned wires or faulty connections. Check all connections for tightness.
3. Check for locked motor armature. Watch the motor shaft or fan blade on the motor as the controller attempts to
start the pump. You should see a couple of “twitches” as the controller prepares to run the pump. If the motor
still does not run. Contact the Sun Pumps for further assistance.
Page 16
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. This information will provide us with most of the
preliminary information we need to help you. If you cannot physically be at the site, filling out the worksheet is a
must.
Pump Model Number: ____________________
Pump Serial Number: ____________________
Motor Serial Number: ____________________
Controller Model Number: ____________________
Software Version ____________________
Date Purchased: ____________________
Solar Module Specifications:
Model Number ____________________
Rated Watts ____________________
Voc ____________________
Vmp ____________________
Isc ____________________
Imp ____________________
Solar Modules Connected in Series _______________ X Voc _______ = _________ Array Voc
Solar Modules Connected in Series _______________ X Vmp _______ = _________ Array Vmp
Series Strings Connected in Parallel_______________ X Isc _________= _________ Array Isc
Series Strings Connected in Parallel_______________ X Imp _________= _________ Array Imp
Batteries Connected in Series _______________ X _______ V = _________ V
Series Batteries Connected in Parallel_______________ X _________ I = _________ I
Battery Specifications:
Model Number ____________________
Rated Amp-Hours ____________________
V ____________________
I ____________________
Charge Controller Model:
Rated Amps ____________________
Rated Voltage ____________________
Well Specifications:
Well Depth ____________________
Well Diameter ____________________
Static Water Level ____________________
Pumping Level ____________________
Pump Setting ____________________
Please record the following before calling:
Battery Bank Voltage:
Charge controller input voltage:
Charge controller output voltage:
Highest power consumed:
Error messages:
Illuminated LEDs:
Dip switches setting
Page 17
Warranty Statement
PCC 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 twenty-four (24) months after the original date of
purchase, but not to exceed thirty (30) months from the date of manufacture.
At its option, SunPumps will repair or replace any SunPumps product, which has failed due to a defect in material or
workmanship during this warranty period. A PCC series controller must be installed in conjunction with the pump to
validate the warranty. This limited warranty shall not apply if the SunPumps product has been damaged by unreasonable
use, accident, negligence, mishandling, misapplication, alteration, modification, abrasion (sand damage to pump), shipping,
service or modification by anyone (other than by SunPumps), or failure which are caused by products not manufactured by
SunPumps, or should the products serial number being altered, or by damage that is attributable to an act of God, or by any
other causes unrelated to defective materials or workmanship. Any disassembly whatsoever of the product voids all
warranty.
The original purchaser MUST complete and send in the warranty registration card, with the pump serial number and the
controller serial number for warranty validation. No warranty performance will be rendered without a valid warranty
card on file at the SunPumps factory.
There are no express warranties except as listed above. SunPumps shall have no responsibility for damage to property,
persons, animals, or other loss or injury resulting from the use of a SunPumps product. The purchaser’s exclusive remedy
shall be only as stated herein. This warranty is in lieu of all other warranties expressed or implied.
Except for the warranty that the products are made in accordance with the specifications therefore supplied or agreed to by
customer, SunPumps makes no warranty expressed or implied, and any implied warranty of merchantability or fitness for a
particular purpose which exceeds the forging warranty is hereby disclaimed by SunPumps and excluded from any
agreement made by acceptance of any order pursuant to this quotation.
UNDER NO CIRCUMSTANCES WILL SUNPUMPS BE LIABLE FOR ANY CONSEQUENTIAL OR
INCIDENTAL DAMAGES, LOSS OR EXPENSE ARISING IN CONNECTION WITH THE USE OF OR THE
INABILITY TO USE ITS GOODS FOR ANY PURPOSE WHATSOEVER. ALL PRODUCTS ARE SOLD AS IS
WITH ALL FAULTS. SUNPUMPS MAXIMUM LIABILITY SHALL NOT IN ANY CASE EXCEED THE
PURCHASE PRICE FOR THE GOODS CLAIMED TO BE DEFECTIVE OR UNSUITABLE.
SunPumps is not responsible for labor, transportation, and related costs incurred by the customer to make allegedly
defective equipment available to the factory for inspection re-installation, lost profits or costs caused by interruption of
service. SunPumps is not responsible for loss or damage to products, owned by customer and located on SunPumps
premises, caused by fire or other casualties beyond SunPumps control.
This equipment is not to be used for anything other than its intended purpose as stated in this manual.
For future reference, please list your system data before installing the pump.
Installation Date______________________ Static Water Level_______________________
Pump Model_________________________ Pumping Level_________________________
Pump Serial No.______________________ Additional Vertical Lift___________________
Controller Model_____________________ Pump Depth___________________________
Controller Serial No.___________________ Total Dynamic Head____________________
Warranty Card No.____________________ Well Depth___________________________
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