RPS PRO Series User manual

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Designed for
both pros and
beginners!
INSTALLATION MANUAL
PRO SERIES
Watch the full
Pro Series install
video
Watch the full
Pro Series install
video

Dear Customers,
In an effort to shape the way our company does business, our mission statement
includes a series of pledges to you, our customers.
We pledge to give you the power! Controlling your own ability to pump water out of
the ground, whether in the field or at home, allows you to be more resilient. Freeing
your water source from the grid is a major step towards self-sufficiency. You just bring
the DIY spirit! Our engineers will be on the other end to offer specialized knowledge
and answer questions, so you can install our solar pumps confidently and gain total
control over your water supply.
We pledge to be a company our grandfathers would have trusted. The
all-too-common practice of outsourcing customer support after the sale is one we
wholeheartedly oppose. We are an American, family-run company and our USA
engineers, who will support you before and after the sale, are the best in the industry.
We gain most of our business from word-of-mouth as a result of treating customers
with respect and standing by our products.
No Pressure. Ever. Our sales team is not on commission—we think this is important.
Their role is to match you with the right pump for your well. If we don’t have a pump
that will suit your needs, we’ll help you find a solution elsewhere. Our job is to help get
you water, not sell you something that isn’t a good fit.
We pledge to bring you reliable water! All manufactured products have occasional
issues and we can’t claim to be perfect. Well water varies in pH, iron level, and sand
content. With that said, we are extremely proud of our 100% track record in getting our
customers water. That’s right, every single one of our customers is now successfully
pumping water with an RPS system. This starts with making sure we supply you with
the right pump for your land, and if issues do arise, we will immediately provide
technical support and replacement parts so you can get up and pumping again as
quickly as possible.
Sincerely,
The RPS Family
OUR PLEDGE TO YOU
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USER MANUAL
TABLE OF CONTENTS
This manual
will...
Answer your questions before
you have them!
Enable you to have the tools
and equipment you need on the
day of installation to help
everything proceed quickly and
enjoyably
Ensure that you install safely
and avoid any damage to your
equipment
Make sure you don’t miss
anything with highlighted KEY
STEPS sections
Give you a resource for
troubleshooting in the field,
even without cell reception
As always, we are here to help
if you still have questions after
working through the manual:
[email protected]
Text Or Call
530.240.3825
System Components…………………………………………………
Things You Will Need…………………………………………..……
System Overview..…………………………………………..………..
Controller Overview………………………………………………….
Mounting Solar Panels……………………………………..………
Wiring Solar Panels………….…………………………………….
5HP Wiring Diagram………………………..…………
Using Existing Panels……………………………………….…….
System Grounding……………………………………….…….…...
Well Pump Assembly………………..…………………….……...
Plumbing & Safety Line…….……………………………...……
Well Pump Plumbing…………………………..………
Dewatering Plumbing…….……………….………….
GB Booster Plumbing….……………………..………
Surface Irrigation Plumbing………………………
Priming Surface Pumps…………………………………..……..
Pro Controller Wiring….…………………………………..….…..
Connecting AC power…………………………………………..….
Dewatering Wiring…………..……………………….…………..…
Surface Pump Wiring…………………………………………..….
Bucket Test.………………………….……………………………..…..
CHECKLIST: Ready To Lower Your Pump?..............
Shut O Sensor….……………………………………….………….
Indicator Lights………………………………………………………
System Keypad………………………………………………....…...
How Pressure Switches Work………………….……………
Winterizing………………………………………………………….…..
Warranty………………………………………………….………………
Support ……………………………………………………………………
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Warning: Risk of Electric Shock
Solar panels and batteries can produce a significant amount of energy, which
can cause electric shock. Please exercise caution when installing your solar well
pump and follow the step-by-step instructions in this manual for your safety.
Whenever you’re working with wiring or connections, make sure:
• the controller is set to OFF
• solar panels are covered
• there are no exposed wires
Be sure to ground the system for safety and to prevent damage to equipment.
Remember, safety first! RPS is not liable for damage or injuries that result from
improper installation technique. If you’re unsure about the safety aspects of any
step in this manual, please consult an RPS Engineer.
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USER MANUAL
SYSTEM COMPONENTS
1. PUMP — Your system will either come with one of our Well Pumps, Surface
Pumps, or Dewatering pumps. In the case of our well pumps you will have a motor
and a pump end that will need to be assembled.
2. PUMP CONTROLLER — This large sturdy controller is the brains of the system.
Arrives pre-programmed for the specific HP your pump and motor and will adjust
the speed of the pump’s motor based on available power from the sun. The pump
controller is waterproof but protecting it from direct sun and weather is still
encouraged. We suggest mounting underneath the shade of the solar panel array.
3. FLOAT SWITCH — This can be used in a storage tank to tell controller to stop
pumping when the tank is full. Wires can be extended with any two strand wire.
Wire gauge is not important, as they are signal wires but common wire gauges are
between 16 to 24 gauge.
4. HOSE BARB AND HOSE CLAMPS — Submersible Well Pumps Kits Only. The
corrosion-resistant stainless steel fitting allows for the connection to poly pipe. Use
minimum of 160 psi poly for up to 300’ and 250 psi for lengths up to 500’. Mos
recommend rigid plumbing after that.
5. SOLAR CONNECTOR WIRES — 2 wires with MC4s. These will connect your
panels to your DC Disconnect. There are 2x 20 foot lengths of solar extension
cable to connect the panels.
6. DC DISCONNECT SWITCH — An instant shut off switch rated for the DC power.
This switch allows the power from your solar array to be shut off from your
controller. NOTE: in some larger systems you may receive multiple.
PRO SERIES ACCESSORY KIT— Every Pro Series kit will come with most of the
accessories you need. In your accessory kit your will find: 7) Mounting & Grounding
Kit 8) Pump Splice Kit 9) Tank Sensor Splice Kit 10) Electrical Tape & Teflon
Tape 11) Keypad and wire for advanced use only 12) Plug connector for Pump
Wires & Optional AC Input 13) Tank Sensor Plug & Pigtail
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Necessary equipment
●Pump wire extension: Use 10 gauge 4-strand wire (4
conductors, often called 3+Ground) to extend the pump wire to
your desired depth. More details are provided in the next section.
●Tank sensor wire extension: To extend the available in the
Communications / Home Security section of your local hardware
store. Between tank and controller.
●Drop pipe: Black poly pipe is most common and easiest to work
with; this attaches to your pump end. PVC and steel pipe may
also be used. More details are provided in the next section.
●Polypropylene rope: Cut to desired depth and attach to the pump
as a safety line. The drop pipe will hold the pump, but the rope will
support the pump in case the drop pipe breaks or is damaged.
●Grounding rod: To ground your controller and panels. Clamp and
6’ of copper wire
Recommended equipment
● Something to seal the top of your well casing, well seal,
● Solar panel mount: RPS offers 8-panel adjustable top-of-pole mount and Scalable Ground Mount kits that are compatible with
4.5”OD Schedule 40 Steel Pipe (for the 8-panel) the Scalable Ground Mount that mounts on a 2” substructure for up to 40+
panels (rpssolarpumps.com/mounting). This pipe and cement are not included as it is too bulky to ship with kits. Alternatively,
use any mounting design of your choice—creativity is encouraged!
Tools
Here’s a list of the tools you’ll want to have on hand during installation:
● Wire stripper/crimper
● Screwdrivers (flat and Phillips head)
● Electrical tape (for attaching wire to drop pipe)
● Teflon tape for tight thread connections (recommended)
● Two adjustable wrenches
● Heat gun or butane torch for heat-shrink sleeves
● Multimeter (highly recommended)
● Large bucket or barrel for testing the system
For an extended
start-to-finish installation
video, visit
RPSsolarpumps.com/
pro
THINGS YOU WILL NEED
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USER MANUAL
Well Pumps Dewatering Pumps Surface Pumps
1-¼ to 2”
Outlet
2 to 3”
Outlet
1-½” to 3”
Outlet
PRO TIP: At the top of each
page you will see one or more
colored dots, each of these
colors correlate with one of our
products. Well Pumps in blue,
Dewatering Pumps in black,
and Surface Pumps in red.
AC or
Generator
(Optional)
Tank Full or
Pressure Sensor
(Optional)
or GB Booster
RPS Systems are designed for a wide range of pump styles and sizes.
Some components are universal (like the Controller, Mounting, AC
Input Wiring, Pump Wiring, Sensor Wiring) and some plumbing and
wiring will be specific to your pump and system size. We’ll indicate that
throughout the user manual with colored dots in the top right corner.
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PUMP CONTROLLER OVERVIEW
The RPS Pro Series Controller is the brains of your setup. This highly intelligent apparatus is pre programmed and will regulate the
power coming from your panels and run your pump correctly. Each proseries controller is constructed of heavy duty metal and is
water resistant. They weigh in at ~20 LBS and have the following inputs and outputs.
AC Backup Power Input MC4 Solar Panel Input Expansion Port (not used) Sensor Input AC Output (to pump)
Systems requiring more than one DC
disconnect will have more than one
set of MC4 connectors
6”
6.5” 5HP
10”
12”
14 LBS
Mounting - The mounting plate on the backside of the controller can be detached, positioned and
mounted in place with the included hardware. The controller hangs on the mounting plate with set
screws on the side to prevent it from coming loose. The controller should be set as vertically as
possible with at least 12 inches on all sides to provide ample room for cooling.
Simply unfasten the screws on the side of the heat sync, and remove the mounting plate, then
use the holes in the plate to fasten the plate onto whatever you are mounting too, then refasten
the controller to the plate by replacing the screws on the side of the heat sync. The self drilling
screws are great for metal and wood posts.
23 LBS
17” 5HP
14.5” 5HP
5HP
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USER MANUAL
RPS22PRO RPS40PRO
Compatible Systems
Pro 500, 750, 1000, 1500, 2000, 3000
(Well, Submersible, Irrigation, Effluent, and
Sewage)
Pro 5000, Pro 3000 1PH AC Conversion
(Lakemakers, Well, Submersible, Irrigation,
Effluent, and Sewage)
Solar Min Voltage 100VDC 200VDC
Solar Max Voltage
Max Current DC
450VDC
12A DC
450VDC
24A DC
MC4 Connectors 1 set (1 male + 1 female) 2 sets (2 male + 2 female)
Power Range 800w - 3200w 3200w - 6400w
AC Input Compatible 220V Single Phase 60hz, 9-15A 220V Single Phase 60hz, 24-30A
Motor Compatibility 220V 3 Phase, 220V Single Phase (3 Wire
only)
220V 3 Phase, 220V Single Phase (3 Wire only)
Minimum Generator Size 6kW min (varies based on waveform output
quality)
10kW min (varies based on waveform output
quality)
Temp. Range -25 to 60°C, -13 ℉ to 140 ℉-25 to 60°C, -13 ℉ to 140 ℉
Weight 14lbs 23lbs
Height / Diameter
12 in x 10 in x 6 in
300mm x 255mm x 137mm
17 in x 14.5 in x 6.5 in
410mm x 360mm x 154mm
PUMP CONTROLLER Specifications
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MOUNTING YOUR SOLAR PANELS
Solar panels should be mounted on a secure structure,
ground mount or top of pole mount. Several ideas can be
found at RPSsolarpumps.com/mounting
Panels should face true South and at an angle appropriate
for your latitude. If you are mounting your panels on an
already built structure, try to get as close to the correct
angle as possible.
Ensure there are no shadows or other obstructions on the
solar panels. While shadowing a small corner of a single
panel may not seem like a big deal, since the panels are
connected in series, a small shadow can limit the power
output from all other panels connected in series! This
means a small shadow on a single panel could reduce
system power by hundreds of watts. Time to get out that
chainsaw and trim some trees!
Scan here to use our tilt
angle calculator tool!
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