Sun Pumps SJT10-120BL User Manual

Table of Contents

Introduction ………………………………………………………………………... 1.0

Precautions

Product Overview …………………………………………………………………. 2.0
Table 1: Differences in Models

Controller Features ………………..………………………………………………. 2.1

Application ………………………………………………………………………... 2.2

Installation and Operation .………………………………………………………… 3.0

Warning

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

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

Shallow Well Pump Installation ………………………….……………………….. 3.3

Figure 1: Typical Shallow Well Suction Pipe Installation

Figure 2: Typical Shallow Well Pump Installation

Adjusting Pressure on Jet …..………………………….………………………….. 3.4
Typical Pressure System Installation …………………….……………………….. 3.3

Figure 3: Typical Pressure System Installation

Wiring ……………………………………………………………………………… 3.4

Figure 4: Controller and Motor Wiring Connections
Figure 5: Controller Wiring Diagram (Auxiliary)
Figure 6: 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 Pumps

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

Phone [phone] Fax [phone]

Controller Model

Min

Voltage1

Max

Voltage

Min Power

Max

Power

Low Water
Cutoff Min

Low Water

Cutoff Max

Nominal

Voltage

PCA-60BLS-M2

2

30 V

100V

Set by LWC

840 W

50 W

300 W

60 V

PCA-120BLS-M2

2

90 V

200 V

Set by LWC

1000 W

50 W

500 W

120 V

1.0 Introduction

Thank you for selecting a SunPumps SJT series solar jet pump system. The SJT series pump and PCA 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 remote homes, irrigation projects, and wildlife and stock watering without violating the
environment.

SunPumps SJT series systems are solar powered, shallow well jet pumps, utilizing a sensorless brushless DC motor. The brushless DC
motors constructed of high quality, anodized, die-cast aluminum and the controller is mounted in a powder coated, die cast, NEMA 3R
enclosure. These pumps were 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 SJT 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 series controllers were designed specifically for SunPumps sensorless brushless three phase DC 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. SunPumps has produced two versions of this
controller. The notable differences between the two 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

Both controller models have the same 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. System ON/OFF switch.

9. LED indicators; 1. Power In, 2. Motor Run, 3. MPPT, 4. RS Stop, 5. Low Power, 6. Over-Current, 7. Fault Condition.

10. Weather resistant powder coated, die cast aluminum enclosure with a hinged door.

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

12. Remote switch interface – float switch or remote shutdown –Normally Open or Normally Closed, user selectable.

13. Sensor and sensorless “Low Water” circuit

14. Low Power Shut Down circuit

2.2 Application

The only application the PCA-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 SJT series
pump and PCA series controller. The procedure for installing the SJT shallow well jet pump is the same as any standard AC jet 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.

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-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 to

calculate the Total Dynamic Head using different pipe sizes. Use no less than a 1 ¼” suction pipe and increase the pipe size if
the run is over 50 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 SJT series shallow well jet pumps have a maximum suction lift capability of 25 feet at sea level. For every 1000 feet

above sea level the suction lift will be decreased by 1 foot.

4. Always use a foot valve on the suction pipe with a negative suction lift. Keep the suction pipe in a straight sloping line

without any loops where air could be trapped. Keep the suction pipe as short as possible. To avoid air pockets, slope the
horizontal pipes continuously upward from the water source by at least 1 inch for every 30 inches of horizontal pipe.

5. 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 impellers will occur and dry running is not covered under warranty.

6. 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.

7. 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.

8. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-heating of the controller.

9. 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.

10. 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. Always use a DC surge/lightning arrestor on the
panel side of the controller. (Midnight Solar MN-SPD surge arrestor is recommended)

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

3.3 Shallow Well 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.

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 same size or larger than the suction port, 1 ¼”. Increase the pipe

size if the pipe run is over 50 feet.

6. Install a foot valve at the end of the drop pipe, if the well is 2” or larger. Lower the drop pipe with the foot valve into the well. Keep

the foot valve off the bottom of the well at least 5 feet if possible. This will lower the chance of debris being pulled into the suction
screen or the pump. Barbed type connectors should always be double clamped. For poly pipe, compression fittings are
recommended.

7. Connect the suction pipe to the suction end of the pump as shown in Figure 1.

8. Install a 1” priming tee to the discharge port of the pump as shown with the pipe plug at the top. The pipe plug can be removed to fill

the suction pipe and the pump housing with water before start-up. After priming the pump, reinstall the pipe plug and tighten.
Always use a pipe thread sealant.

9. For an open discharge system, install a control valve on the discharge line as shown in Figure 2. The valve is used to regulate the

internal pressure of the pump for proper jet performance. Connect the pipeline from the valve to the place of use.

Figure 1 Typical Shallow Well Suction Pipe Installation

Figure 2 Typical Shallow Well Pump Installation

3.4 Adjusting The Pressure On The Jet Pump (For Open Discharge)

If the system is used with an open discharge, pumping into a non-pressurized tank, there must be internal pressure in the pump housing for the
jet to operate properly. This is provided by adjusting the control valve on the discharge pipe as shown in Figure 2. (Not included with the
pump.)

The required minimum pressure varies with pump speed, elevation and suction lift so there is no easy way of predetermining the minimum
internal operating pressure. With solar power and changing sunlight conditions there will be varying motor speeds so the best time to make
the adjustment is at mid-day in with clear skies with full sunlight.

The easiest way to adjust the control valve is by sound. If the internal pump pressure for your specific pumping application is too low the
pump will cavitate and cavitation makes an audible sound. Cavitation occurs when the local static pressure is below the vapor pressure. To
stop the pump from cavitating, the internal pump pressure must be increased above the vapor point. To do this the control valve on the
discharge pipe is slowly adjusted toward the closed position until you hear the cavitation stop. You can watch the pressure gauge to see what
this minimum internal pressure is for your application.

3.5 Typical Pressure System Installation

1. Follow the same installation procedures in Section 3.3 for the “Shallow Well Pump Installation” with the exception of the location of

the pressure gauge and the control or gate valve.

2. Install a check valve control center, a pressure gauge and a pressure switch between pump and the pressure tank. Make sure both the

pressure gauge and the pressure switch are on the tank side of the check valve in the 1/4” NPT tapped holes.

3. Install a gate valve on the discharge pipe as shown in Figure 3.

4. When choosing a pressure switch make sure the “minimum pressure” required by the jet is at or above the cut-in pressure on the

pressure switch. Usually a 30-50 pressure switch is a safe choice if you do not know what it is. Keep in mind the cut-in pressure can
be adjusted up or down to fit your specific application.

Figure 3 Pressure Tank Installation

3.6 Wiring

Prior to connecting any wires to the controller, be sure you have a system wiring diagram to use as a reference (see figure 3). 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. Cover the panels with a blanket or with a non­opaque material before wiring. Install a disconnect switch between the solar modules and the controller.

Follow the proper color code between the controller and the motor terminals. If the motor turns in the reverse direction the impeller
and diffuser will be damaged and this is not covered under warranty.

1. After mounting the controller, turn the on/off switch to the OFF position.

2. If you are using a remote switch, like a float switch, set dip switch 1 to the correct position for the type of switch being used. (“Normally

Open” or “Normally Closed”.) If you are not using a remote switch leave switch 1 off.

3. Verify all remaining dip switches are off at this time.

4. Connect ground rod conductor to the controller chassis ground block.

5. Connect solar module frame ground conductor to controller chassis ground block.

6. Connect the green pump ground conductor to controller chassis ground block.

7. Connect pump motor leads to the corresponding “Pump Motor” terminals on the controller. Red to “Red”, yellow to “Yellow” and black

to “Black”. (CAUTION) If the wire connections are not correct the motor will turn in a reverse direction and the impeller will
unscrew from the shaft and damage the impeller and the diffuser. This will not be covered under warranty.

8. Verify the disconnect switch is in the off position. Connect the DC source supply negative (-), the black conductor, to one of the

controller terminals labeled “Negative” on the “Solar Array Input”. (NOTE: The power should be connected to a disconnect switch and it
should be in the OFF position before connecting power to the controller).

9. Connect the DC source supply positive (+), the red conductor, to one of the controller terminals labeled “Positive” on the “Solar Array

Input”. (NOTE: The power should be connected to a disconnect switch and it should be in the OFF position before connecting power to
the controller).

10. Refer to the next section for “Remote Switch” connections and “Adjustment Procedures” for configuration, if applicable. Sensor type

low water cutoff is supported by the controller but not for booster pumps at this time. If you would like to use one contact SunPumps for
assistance.

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 array open circuit voltage (Voc) on the array side of the disconnect switch and the module
polarity. Record the Voc for future reference. You may do this on the Before Calling Sun Pumps Worksheet near the end of this
manual. Check this voltage reading against the “Voc” range for your specific system in the chart below. (Figure 3)

12. After you have verified the voltage and polarity, switch the disconnect switch on - if the polarity is correct the first LED light will be on.

13. Turn the “On/Off “switch to the ON position. 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.

Figure 4 Controller Wiring Diagrams

Motor Electrical Junction Box

Figure 5 Controller Wiring Diagram
(Auxiliary)

Switch

Switch

Description

Function

Default Setting

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 Low Water Logic

OFF

3 Low Water 10 Minute Time Delay

OFF

4 Low Water 10 Minute Time Delay

OFF

5 Not used at this time

Should be in the off position for

proper operation

OFF

6 Not used at this time

Should be in the off position for

proper operation

OFF

7

Not used at this time

Should be in the off position for

proper operation

OFF

8 Not used at this time

Should be in the off position for

proper operation

OFF

Figure 6 Dip Switch Settings

3.7 Controller Settings

The PCA series controllers have several settings (see figure 3). 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 connected to turn the controller
off. With this switch on (up), terminals “RS+” and “GND” must be connected to turn the controller on.

Switch 2 is the Low Water Cutoff Logic. With this switch off (down), terminals “RS+” and “GND” must be connected to turn the

controller off. With this switch on (up), terminals “RS+” and “GND” must be connected to turn the controller on. If you want to use this
feature with the booster pump system, contact SunPumps for further assistance.

Switches 3 and 4 are delay timer adjustments. The delay timer is used for the remote switch and the low water cutoff. This timer by
default is set for a 3 minutes. Switch 3 will increase the timer to 10 minutes; Switch 4 will increase it to 30 minutes. See Remote
Switch and Low Water Cutoff for more information.

Switches 5, 6, 7 and 8 are not used at this time and should remain down.

3.8 Auxiliary Control Circuits

The auxiliary control circuits are configured and controlled with the “Dip Switches”, “LP Adj.”, “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 th e flow rate of the pump.
There is also the low water cutoff, low power shut down 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. 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.

Sensor Low Water Cutoff Circuit

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
three minute timeout is default for this feature but is modifiable by switches 3 and 4 to 10 or 30 minutes respectively. This timeout
applies to remote switch and low water cutoff.

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

switch closed = water tank low = pump ON

PUMP OFF

switch open = water tank high = pump OFF

A three minute timeout is default for this feature but is modifiable by switches 3 and 4 to 10 or 30 minutes respectively. This timeout
applies to remote switch and low water cutoff.

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 Adjust” trim pot
fully counter-clockwise. This will give the pump the minimum low power set point possible.

LPLW Adjustment

The Low Water Cut-Off Circuit and the Low Power Shut-Down circuit are adjusted using the same trim pot labeled “LP Adj.” on the
controller. The default is the arrow pointing straight up. This is sufficient for most systems but adjustment will maximize the life and
output of your system. Follow the steps below to adjust this feature.

1. Turn the “LP Adj.” trim pot fully counter clockwise.

2. Turn the “Speed Control” trim pot counter clockwise until the pump is pumping the desired minimum flow. This may be down

to 0 gal/min but is not recommended for proper pump cooling.

3. Turn the “LP Adj.” trim pot clockwise until the pump shuts off.

4. Reset the “Speed Control” trim pot back to the desired position.

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 clock wise 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 a15- turn range. It usually takes many complete turns in a counter-clockwise direction before you will
notice any change in water output or output power on the display).

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 30 volts. Less than 30 volts at the input terminals and the unit may show no signs of operation. If you
do have at least 30 volts in the right polarity, contact Sun Pumps for further assistance.

2. If the expected voltage is not present, disconnect the panels from the controller using the disconnect switch, 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 open circuit voltage of your array. If the open circuit voltage is not

correct trouble shoot the array to find the problem. If the open circuit 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 second LED is labeled “Run”. This indicates the pump is running. If it is on, go to the bore hole and listen for the sound of the

motor. Check for breaks in the pipe. If you cannot find a problem call Sun Pumps for further assistance.

3. 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. Set the #1 and #2 dip switches to off and disconnect the remote
switch and low water cutoff. Turn the switch off then back on. If the light goes out and the pump starts, troubleshoot the remote
switch and low water cutoff individually. If the pump does not start and the LED is still lit, call Sun Pumps for further assistance.

4. Check the fifth LED, labeled “Low Power”; this is the low power shutdown indicator. If it is on, the controller detected a low

power or low water condition. The low power shut down is a common occurrence on days which have clouds which block the sun
momentarily. First check the input voltage to the controller. Verify that this exceeds the minimum voltage in Table 1. If it does not
meet or exceed the minimum voltage, you do not have enough power to start your pump. Note: To accurately trouble shoot this
feature there should be absolutely no clouds blocking the sun at any time during the following tests. If you have enough input
voltage, turn the controller off then on again to reset this fault. If the low power or low water condition still exists then the
controller will start but shut down again. Turn the blue pot labeled “LP Adj” all the way counter-clockwise. Cycle the pump off
then on. If the pump does not shut down, the low water cutoff was causing the error. If you want to use this feature, readjust the low
water cutoff as seen earlier in this manual. If the does not run properly, skip to step 7. Check to verify the pump is not running out
of water. If your pump is not running out of water, 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. Verify the nominal
voltage of your array. If the calculated Vmp for your array is higher than 200 V, the controller may go into over current. Remove
one series panel from each string and try again. Check the pump for a short to ground using an ohm meter and call Sun Pumps for
further assistance.

6. Check motor wiring and connections. Also check the ground fault fuse, it may have been blown.

7. 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.

8. Check for proper dip switch settings on your controller. Switches 5, 6, 7, and 8 must be in the off position for proper operation.

9. Check for proper controller input voltage. If the pump is not running, the input voltage should be the array open circuit voltage,

(Voc). Verify that this voltage is below the maximum input voltage allowed for your controller (model dependent see Table 1).
Check the Voc on the label on the back of the solar modules and multiply this figure times the number of modules that are
connected in series. This number should be + - 10% of the measured reading. If it is not then confirm all electrical terminations are
tight and secure. Use a DC volt meter to check each solar module for proper open circuit voltage (Voc). One bad module will drop
the voltage on the complete series string.

PUMP IS RUNNING BUT THE OUTPUT IS LOW

1. Make sure you have full sun light at midday, that there are no clouds and no shadows on any part of the array. Then verify power

going into the controller by measuring the voltage and current. Check this against the pump chart for your specific application.

2. If the power is correct for your pump model and array 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 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.

4. Make sure the water in the well is not drawing down past the suction capability lift of the pump.

5. Check the suction screen on the foot valve to see if it is plugged.

6. Make sure the hole in jet nozzle is not plugged. (Part No. 41459)

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 underwater splice.

3. Check for locked motor armature. With the pump out of the well, remove the pump end from the motor (if this is not feasible skip

this step and contact Sun Pumps). Allow the controller to attempt to start the motor. If the motor still does not run, contact Sun
Pumps for further assistance.

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

Warranty Statement

SJT Series Brushless DC Jet Pumps
PCA 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 (24) months after the original date of purchase, but not to exceed eighteen (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, no other brand controller is authorized for use with this pump. A PCA 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______________________
Pump Model_________________________
Pump Serial No.______________________
Controller Model_____________________
Controller Serial No.__________________
Warranty Card No.___________________