Sun Pumps SCP 48-18-48Y BC User Manual
Manufactured & Serviced By:
Made in America
SunPumps, Inc.
325 E. Main St.
Safford, AZ 85546
(928) 348-9652
OPERATION AND
INSTALLATION
MANUAL
HV Model
SCP SERIES
Brushless DC
SOLAR ELECTRIC
POOL PUMPS
1 HP to 3 HP
4009458
Conforms to UL Stds 1081 & 1563
Table of Contents
Introduction ………………………………………………………………………... 1.0
Precautions
Safety Instructions
Product Overview …………………………………………………………………. 2.0
Table 1: Differences in Controller Models
Controller Features ………………..………………………………………………. 2.1
Controller Applications ……………..……………………………………………... 2.2
Installation and Operations ……………………………………………………….. 3.0
Warnings
System Location …………………………………………………………………… 3.1
System Design Basics ……………………………………………………………... 3.2
Solar Pump System Terms and Layout
Pump Installation ………………………………………………………………….. 3.3
Pump Basket Strainer ……………………………………………………………… 3.4
Figure 1:
Wiring ……………………………………………………………………………… 3.5
Figure 2: PCA Control Panel Wiring Diagram
Figure 3: PCC Control Panel Wiring Diagram
Figure 4: 48 Volt Control Panel Wiring Diagram
Figure 5: PCA Dip Switch Settings
Figure 6: PCC Dip Switch Settings
Controller Settings ………………………………………………………………… 3.6
Auxiliary Control Circuits ………………………………………………..…...……… 3.7
Remote Switch
Output Power Limit Circuit
Low Power Shut-Down Circuit
Low Water Shut-Down Circuit
Over-Current Shut-Down Circuit
Figure 7: PCC Series 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 (928) 348-9652 Fax (928) 348-9653
1.0 Introduction
Thank you for selecting a SunPumps SCP series solar pool pump system. The SCP series pump and PCA or 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 swimming
pool filtration, spas, hot tubs water falls, pond water circulation and flood irrigation.
SunPumps SCP series pumps are single-stage centrifugal type with sensorless brushless DC motors designed
specifically for pool water filtration but can be used for water falls or low head irrigation systems as long as it is
part of a permanent installation. Do not use with storable pools.
The PC series brushless DC 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 PC series pump controllers are easy to install, please read this manual to become familiar
with the controller features, functions, connection points and various configurations. Save this manual and
other relevant product information in a safe place for future reference.
PRECAUTIONS
Safety First – Always understand what you are doing when working with any form of electricity.
Guessing at something is not worth the potential of product damage and/or severe personal injury.
Improper installation may create an electrical hazard which could result in damage to property,
injury or death. Read and follow all instructions.
Shut down all power when working on the system. Do not attempt to feed live wires into the PC-
series controller or product damage and/or personal injury may result.
Do not exceed the voltage rating of the motor and controller.
Do not splash water on the controller especially when the cover is open.
Mount the controller in a shaded, well vented area and in a vertical position out of reach of any
pool or spa users.
Installation of this system should be done by a licensed Electrical or Pool Contractor in accordance
with the National Electrical Code and all applicable local codes and ordinances. Improper
installation will create an electrical hazard which could result in death or serious injury to
servicemen, pool users or others due to electrical shock.
For a replacement manual contact SunPumps directly. For replacement stickers we recommend
contacting a local spa dealer, but can be ordered from SunPumps. Contact SunPumps for further
details.
IMPORTANT SAFETY INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following:
1) READ AND FOLLOW ALL INSTRUCTIONS
2) WARNING – To reduce the risk of injury, do not permit children to use this product unless they are
closely supervised at all times.
3) A wire connector is provided on this unit to connect a minimum 8 AWG (8.4 mm²) solid copper ground
conductor between this unit and any metal equipment, metal enclosures of electrical equipment, metal
water pipe, or conduit within 5 feet (1.5 m) of the unit.
4) WARNING – Risk of Accidental Drowning. Extreme caution must be exercised to prevent unauthorized
access by children. To avoid accidents, ensure that children cannot use a spa or hot tub unless they are
closely supervised at all times.
5) DANGER – To reduce the risk of drowning from hair and body entrapment, install a suction fitting(s)
with a marked flow rate that equals or exceeds the flow rate marked on the equipment assembly.
6) DANGER – To reduce the risk of injury, do not remove the suction fittings. Never operate a spa or hot
tub if the suction fittings are broken or missing. Never replace a suction fitting with one rated less than the
flow rate marked on the equipment assembly.
7) DANGER – Risk of Electric Shock. Do not permit any electric appliance, such as a light, telephone,
radio, or television, within 5 feet (1.5 m) of a spa or hot tub.
8) WARNING – Risk of Electric Shock. Install at least 5 feet (1.5 m) from inside wall of hot tub or spa using
nonmetallic plumbing. This equipment must be attached to a ground fault circuit interrupter.
9) WARNING – To reduce the risk of injury:
a) The water in a spa should never exceed 40°C (104°F). Water temperatures between 38°C (100°F) and 40°C
are considered safe for a healthy adult. Lower water temperatures are recommended for young children and
when spa use exceeds 10 minutes.
b) Since excessive water temperatures have a high potential for causing fetal damage during the early months
of pregnancy, pregnant or possibly pregnant women should limit spa water temperatures to 38°C (100°F).
c) Before entering a spa or hot tub, the user should measure the water temperature since the tolerance of water
temperature-regulating devices varies.
d) The use of alcohol, drugs, or medication before or during spa or hot tub use may lead to unconsciousness
with the possibility of drowning.
e) Obese persons and persons with a history of heart disease, low or high blood pressure, circulatory system
problems, or diabetes should consult a physician before using a spa.
f) Persons using medication should consult a physician before using a spa or hot tub since some medication may
induce drowsiness while other medication may affect heart rate, blood pressure, and circulation.
10) CAUTION – This pump is for use with permanently-installed pools and may also be used with hot tubs
and spas if so marked. Do not use with storable pools. A permanently-installed pool is constructed in or on
the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is
constructed so that it is capable of being readily disassembled for storage and reassembled to its original
integrity.
11) Do not install within an outer enclosure or beneath the skirt of a hot tub or spa.
12) You can purchase more spa warning signs from your local spa supplier or directly from SunPumps,
Inc..
13) SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
Controller Model
Min
Voltage1
Max
Voltage
Min Power
Max
Power
Low Water
Cutoff Min
Low Water
Cutoff Max
Nominal
Voltage
PCA-60BLS-M22
30 V
100 V
Set by LWC
840 W
50 W
300 W
60 V
PCA-120BLS-M22
90 V
200 V
Set by LWC
1440 W
50 W
500 W
120 V
PCC-120BLS-M2
2
90 V
200 V
Set by LWC
1500 W
100 W
585 W
120 V
PCC-180BLS-M2
2
120 V
300 V
Set by LWC
2250 W
100 W
1023 W
180 V
PCC-240BLS-M22
220 V
380 V
Set by LWC
3000 W
100 W
1023 W
240 V
2.0 Product Overview
The SunPumps PCA-BLS-M2 and PCC-BLS-M2 series controllers were designed specifically for SunPumps
Sensorless Brushless DC motors. When properly installed and configured, the features incorporated into this
stand-alone system will control and protect your pump system permitting many years of dependable, trouble free
service. SunPumps has produced multiple versions of this controller. The PCA controller is for lower power
applications and lacks an LCD screen. Functionally the notable differences are certain set points and electrical
characteristics which 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.
2
All controller models have the same basic operating features, functionality and setup. A display screen and the voltage and
power tolerances are the only differences of concern to the end user. This manual will only differentiate when necessary for
clarity.
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. (PCC Series Only)
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. 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 Sensorless “Low Water” circuit
16. Low Power Shut Down circuit
2.2 Controller Application
The only application the PC series controllers are designed for is the interface between a solar module array and
SunPumps Sensorless Brushless DC motors. Do not use this controller on a brush type or AC motor.
No other applications or DC power sources are recommended or warranted 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 SCP series pump and PC series controller. The procedure for installing the SCP series pool
pump is the same as a standard AC pool pump. Any licensed pump contractor will be familiar with the proper
installation procedures. Installation and operation should be in accordance with national and local electrical codes,
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 20 amps will result in nonwarranted product damage. Please check polarity before connecting power to the controller.
These controllers are for SunPumps 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.
3.1 System Location
As the majority of system installations vary greatly, only general comments can be made as to 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!
For locating the pump, damp, non-ventilated locations should be avoided. Motors and controllers require free
circulation of air to aid in cooling.
The PCA and PCC-series controllers can either be mounted indoors or outdoors. Locate all system equipment as
close as possible to each other. The controller must be mounted in a vertical position for proper cooling and to
keep the electronics dry. The controller should be located close to the pump if possible. This general physical
layout is conducive to clean installation both aesthetically and electrically.
3.2 System Design Basics (Read carefully before installation)
1. The pump discharge piping should be sized for efficient pump operation. Pipe size being too small will create
greater friction losses which require more power to operate and thus a higher solar module cost.
2. Make sure the pool filter is size correctly for the flow rate of the pump. A filter sized too small will create higher
friction losses and will increase the power requirements and thus the cost of the system.
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 as specified by the National Electric Code. 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%. Refer to the wire sizing
guide on the SunPumps web site under Engineering. Always use liquid-tight flexible metallic conduit and liquidtight fittings between the controller and the pump motor.
4. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-heating of the
controller.
5. 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. The controller should be mounted as close to the pump as possible.
6. The controller should be grounded to the pump motor housing, the frame of the solar modules and to an 8-foot
ground rod. Use only a copper lug to attach the ground rod. Always use a DC surge/lightning arrestor on the panel
side of the controller. (Midnight Solar MN-SPD surge arrestor is recommended)
7. Do not ground the PV array positive or negative electrical wires.
3.3 Pump Installation
Your pump system has some warning labels included. These should
be viewable to those near the system. Replacement warnings are
available for purchase though your local pool/spa dealer or
SunPumps, Inc.
The pump has two weep holes located on the underside of the pump
end. This is designed to allow water to drain in the instance that the
shaft seal fails and the pump end leaks. If you notice water draining
from these holes, the seal may need to be replaced to prevent motor
damage.
1. The pump should be located next to the pool filter in a sheltered location. It is highly recommend that you
install unions on both the suction and the discharge ports for easy pump removal for future service. Never
over tighten pipe connections. Use only pipe sealant formulated specifically for plastic.
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. Inspect all components for shipping damage and insure that you have all the components that are required for
a complete installation.
4. Select a well-ventilated, shaded location in which to vertically mount the controller. Mount the controller far
enough from the pool where it can not get wet.
3.4 Pump Basket Strainer
This pump has a basket strainer, sometimes called a “Hair and Lint Pot” located in the front section of the pump
volute. Inside this chamber is a basket which must be kept clean of leaves and debris at all times. View the basket
through the “See-Through Lid” to inspect for various accumulations of trash. Regardless of the length of time between
filter cleaning, it is most important to visually inspect the basket at least once a week. A dirty basket will reduce the
efficiency of the filter and also put an abnormal stress on the pump motor which could result in failure.
Warning: Do not open the strainer pot if the pump fails to prime or if the pump has been operating without water in
the strainer pot. Pumps operated in these circumstances may experience a buildup of vapor pressure and may contain
scalding hot water. Opening the pump may cause serious personal injury. In order to avoid the possibility of personal
injury, make sure the suction and discharge valves are open and strainer pot temperature is cool to the touch, then with
extreme caution, you can open the strainer lid. Do not open the strainer pot lid while the pump in in operation.
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