Sun Pumps PCC-BT-M2 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

Installation Basics …...……………………………………………………………... 3.2

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

Figure 1: Controller Wiring Diagram
Figure 2: Dip Switch Settings

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

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

Current Regulation
Remote Switch
Low Power Shut-Down Circuit
Output Voltage Adjustment (Motor Speed Control)
Figure 3: 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

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

Phone [phone] Fax [phone]

1.0 Introduction

Thank you for selecting a SunPumps PCC-BT series solar pump system. The PCC-BT series pump
controller is a key component 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.

The PCC-BT series controllers are microprocessor based solid state DC power converters designed as the
interface between a solar module array and a brush type 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 and accessories.

Although these PCC-BT 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-BT 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-BT series controllers were designed for brush type 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 longer dependable, trouble free service. The controller is
designed for an open circuit voltage up to 300 volts DC with a recommended nominal voltage from 30 to
no greater than 220 volts DC. The nominal voltage of the system should be sized according to the desired
pump voltage and power. The controller has various settings for the maximum current and will be
discussed later in this manual.

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.

(Maximum Power Point Tracking or MPPT)

3. Current regulation at 5, 7.5, 10, or 14 amps. (Configurable via dip switches)

4. Settable output voltage regulation 195 to 0 volts (Factory default is set to 195 volts).

5. Adjustable output motor voltage control for precision output flow and motor protection.

6. Reverse polarity protection (20 amperes maximum) on the input terminals.

7. Transient protection and surge suppression (additional lightning arrestor is also recommended).

8. Digital display indicating status including 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. 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. Two remote switch interfaces – float switch or remote shutdown –Normally Open or Normally

Closed, user selectable logic.

14. Zero, three, seven and ten minute turn on delay for Remote Switch 1.

15. Low Power Shut Down circuit

2.2 Application

The only application the PCC-BT series controllers are designed for is the interface between a solar module
array and a compatible brush type DC motor. Check with SunPumps, Inc. for motor compatibility.

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-BT series controller. The procedure for installing the SCB, SCP or pump jack is not
in the scope of this manual. 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 on a panel system capable of producing over 20 amps will result in
non-warrantied product damage. Please check polarity before connecting power to the
controller.

This controller is for brush type DC motors only. Do NOT use this controller for other
types of motors. Compatible motors must be used. Proper voltage and current rating
of the motor is essential. Be certain to set the current and voltage of the controller to
protect your motor. Proper sizing of the solar panel array will maximize the efficiency
and production of the system.

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–BT 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 pump installation. 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 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. Due to the aggressive action of DC power, it is essential that any wire splice be made correctly.

This splice must be watertight if it is to be submerged. Improper sealing of the splice will cause
poor pump performance and may cause damage to the system. Wire splicing must be done in
accordance to local, state and national electrical codes. A submersible 3 wire splice kit is
recommended for watertight connections.

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

heating of or damage to 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. A convenient place to mount the

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

5. The controller should be grounded to the pump motor housing, the frame of the solar modules

and to an 8-foot ground rod. 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)

6. Do not ground the array 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 1). 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.

All other system equipment should be installed before proceeding with wiring the controller. Double check
polarity and wire termination tightness before powering up the system.

CAUTION: Photovoltaic panels produce DC electricity when exposed to sunlight. Install a disconnect
switch between the solar modules and the controller.