Sun Pumps SIJ 2.2-1300P-135 BL User Manual
Table of Contents
Introduction ………………………………………………………………………... 1.0
Precautions
Product Overview …………………………………………………………………. 2.0
Table 1: Differences in Controller Models
Controller Features ………………..………………………………………………. 2.1
Application ………………………………………………………………………... 2.2
Installation and Operation .………………………………………………………… 3.0
Warning
Location …………………………………………………………………………… 3.1
System Design Basics ……………………………………………………………... 3.2
Pump Installation ………………………………………….……………………….. 3.3
Inlet Condition Check-List
Wiring ……………………………….……………………………………………… 3.4
Figure 1: PCA Controller and Motor Wiring Connections
Figure 2: PCA Controller Wiring Diagram (Auxiliary)
Figure 3: PCA Dip Switch Settings
Figure 4: PCC Controller Wiring Diagram
Figure 5: PCC Dip Switch Settings
Controller Settings ………………………………………………………………… 3.5
Auxiliary Control Circuits ………………………………………………..…...……… 3.6
Over-Current Shut-Down Circuit
Sensor Low Water Cutoff
Remote Switch
Low Power Shut-Down Circuit/Sensorless Low Water Shut-Down Circuit
Output Power Limit Circuit
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 Pump
Table 2: Friction Loss Table
Table 3: Preventive Maintenance Chart
Warranty Statement ………………………………………………………………… 6.0
Phone (928) 348-9652 Fax (928) 348-9653
Controller Model
Min
Voltage1
Max
Voltage
Min Power
Max
Power
Low Water
Cutoff Min
Low Water
Cutoff Max
Nominal
Voltage
PCA-60BLS-M2
30 V
100 V
Set by LWC
840 W
50 W
300 W
60 V
PCA-120BLS-M2
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
1.0 Introduction
Thank you for selecting a SunPumps SIJ series solar plunger pump system. The SIJ series pump and PC 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 high pressure and high head pumping applications
such as pumping up high hills or injection water or chemicals into a high pressure system. The operating pressure can be as
high as 2000 PSI, depending on the pump model.
SunPumps SIJ series systems are solar powered, triplex plunger pumps, utilizing a sensorless brushless DC motor. The
brushless DC motors are constructed of high quality, anodized, die-cast aluminum and the controller is mounted in a powder
coated, die cast, NEMA 3R enclosure. These pumps are designed specifically for water delivery in remote locations.
The PCA-BLS series controllers are microprocessor based solid state DC power converters designed as the interface between a
solar module array and a three phase 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 SIJ series pump systems are easy to install, please read this manual to become familiar with the pump
and 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 at
something is not worth the potential of product damage and/or severe personal injury.
Shut down all power when working on the system.
Do not feed live wires into the PCA-BLS-M2. Personal injury or other damage may result.
Do not exceed the voltage rating of the controller.
Do not start or run the pump dry.
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.
Verify wiring connections between the controller and the motor before starting the pump.
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 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. 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. Sensorless “Low Water” circuit
16. Low Power Shut Down circuit
2.2 Application
The only application the PCA & PCC-BLS 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 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
SIJ series pump and PCA & PCC series controller. The procedure for installing the SIJ triplex plunger pump is the same as
any standard AC plunger 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-warranted
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 AC, Brush-Type or Sensor Type Brushless DC motors. Damage to the controller and/or motor
will result.
Caution
All High Pressure Systems require a primary pressure regulating device (i.e. regulator, unloader) and a secondary pressure
relief device (i.e. pop-off valve, relief valve). Failure to install such relief devices could result in personal injury or damage
to pump or property. SunPumps does not assume any liability or responsibility for the operation of a customer’s high
pressure system. Read all CAUTIONS and WARNINGS before commencing service or operation of any high pressure
system. The CAUTIONS and WARNINGS are included in each service manual and with each Accessory Data sheet.
3.1 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! Always follow State and Local Building Codes.
The PCA or 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 (Read carefully before installation)
1. The pump discharge piping should be sized for efficient pump operation. We suggest using the Friction
Loss Tables (Table 2) to calculate the Total Dynamic Head using different pipe sizes. Use no less than a
1/2” suction pipe and increase the pipe size if the run is over 3 feet.
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. The SIJ series triplex plunger pumps have poor suction lift capabilities and require a flooded suction or
positive head on the suction. Positive head can be up to 75 PSI.
4. Always fill the suction pipe and the pump with water before you turn the pump on. If the pump is
operated dry, damage to the pump will occur and dry running is not covered under warranty.
5. If pumping from a tank or any source that could run low on water, install a low water float switch to
protect the pump from running dry.
6. If a pressure switch is used in the system, choose one with a Low Pressure Cut-Off. If the pump runs
dry the pressure will drop and the low pressure switch will turn the pump off.
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 with a AWG #8 wire. 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.
3.3 Pump Installation
1. 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 if necessary.
2. Inspect all components for shipping damage and insure that you have all the components that are required for
a complete installation.
3. Locate the pump on a flat surface close to the water source but do not mount in direct sunlight. The motor
requires free circulation of air so always install in a well-ventilated and dry area. The motor should be kept dry
and out of the rain and weather.
4. Keep the suction line as short and as direct as possible. This reduces the friction losses through the pipe and
fittings. The suction line should have continuous slope from the lowest point in the line to the inlet of the
pump. Make sure there are no loops or high spots in the suction line that could trap air. To avoid air pockets,
slope the horizontal pipe continuously upward from the water source to the pump by at least 1” for every 30”
of horizontal run.
5. Make sure the suction joints are tight. The suction line should be the ½” or larger. Increase the pipe size to ¾”
if the pipe run is over 3 feet.
6. The SIJ series pump includes an unloader valve on the discharge side of the pump. Make sure it is adjusted to
relieve at a pressure that is under the pressure rating of the pipeline.
7. Always fill the suction pipe and the pump with water before you start the pump. Always use a pipe thread
sealant.
Inlet Condition Check-List
Review Before Start-Up
Inadequate inlet conditions can cause serious malfunctions in the best designed pump. Surprisingly, the simplest of
things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS
CHECK-LIST BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can be
no ONE best way to set-up a system. All factors must be carefully considered.
INLET SUPPLY should be adequate to accommodate the maximum flow being delivered by the pump.
1. Open inlet shut-off valve and turn on water supply to avoid cavitating pump. DO NOT RUN PUMP DRY.
2. Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. RPM changes may be required.
3. Avoid closed loop systems without a Thermo Valve high temperature protection.
4. Avoid low vapor pressure and high viscosity liquids.
5. Higher temperature liquids tend to vaporize and require positive heads.
6. When using an inlet supply reservoir, size it to provide adequate liquid to accommodate the maximum output of the pump, generally a
minimum of 6-10 times the GPM (however, a combination of system factors can change this requirement); provide adequate baffling in
the tank to eliminate air bubbles and turbulence; install diffusers on all return lines to the tank.
INLET LINE SIZE should be adequate to avoid starving the pump.
7. Line size must be a minimum of one size larger than the pump inlet fitting. Avoid thick walled fittings, tees, 90 degree elbows or valves in
the inlet line of the pump to reduce the risk of flow restriction and cavitation.
8. The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION systems to avoid collapsing.
9. The simpler the inlet plumbing the less the potential for problems. Keep the length to a minimum, the number of elbows and joints to a
minimum (ideally no elbows) and the inlet accessories to a minimum.
10. Use pipe sealant to assure air-tight, positive sealing pipe joints.
INLET PRESSURE should fall within the specifications of the pump.
11. Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure. With adequate inlet plumbing, most pumps will perform
with flooded suction. Maximum inlet pressure is 75 PSI (5.25 BAR).
12. After prolonged storage, pump should be purged of air to facilitate priming. Disconnect any discharge port and allow liquid to pass
through pump.
INLET ACCESSORIES are designed to protect against over pressurization, control inlet flow, contamination and provide ease of servicing.
13. A shut-off valve is recommended to facilitate maintenance.
14. A stand pipe can be used in some applications to help maintain a positive head in the inlet line.
15. Inspect and clean inlet filters on a regular schedule.
16. A pressure gauge is recommended to monitor the inlet pressure and should be mounted AS CLOSE TO THE PUMP INLET as possible.
Short term, intermittent cavitation will not register on a standard gauge.
17. All accessories should be sized to avoid restricting the inlet flow.
18. All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction.
BY-PASS TO INLET Care should be exercised when deciding the method of by-pass from control valves.
19. The SIJ Series pumps come standard with a Regulating Unloader to handle by-pass liquid directed to the inlet line of the pump. If other
than standard valve is used, exercise caution to use proper flexible hose and adequate diameter.
20. A low-pressure flexible cloth braid (not metal braid) hose should be used from the by-pass connection to the inlet of the pump.
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