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
5
1

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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2

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.
3

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
1
2
3
4
5
6
OR
4
7 8 910 11 12 13

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
5

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.
6

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
7

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
8

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!
9

USER MANUAL
WIRING YOUR
SOLAR PANELS
Your panels will have two MC4 connectors on the back,
male and female. You will use these connectors to connect
each panel as shown, as well as to connect them to the
DC disconnect shut off switch. After that you will use the
MC4 connectors from your DC Disconnect and connect
into your controller. Below is a diagram for connecting the
1.5HP controller to the panels.
PRO 1500 (1.5HP) Wiring Diagram
In general this is how you will wire each of your panels. In
cases where you will need more than 10 panels you will
need to add another DC Disconnect which goes into the
second set of MC4 connectors in your controller.
10
Pro 500
(1/2HP)
Pro 750
(3/4HP)
Pro 1000
(1HP)
Pro 1500
(1.5HP)
Pro 2000
(2HP)
Pro 3000
(3HP)
Pro 5000
(5HP)
8 10 12
6 8 10 20
SOLAR PANEL SYSTEM GUIDE
SYSTEM
100W
350+W
*WIRES SHOWN RED AND BLACK FOR ILLUSTRATION PURPOSES ONLY, ACTUAL WIRES WILL BE BLACK

USE ALL 4
CONNECTORS!
Remember only use a
maximum of 10 Solar
Panels per pair of
MC4 Connector Pairs
5 HP ONLY
WIRING
DIAGRAM
11
*WIRES SHOWN RED AND BLACK FOR ILLUSTRATION PURPOSES ONLY, ACTUAL WIRES WILL BE BLACK

USER MANUAL
USING EXISTING SOLAR PANELS
Are my existing solar panels compatible with RPS Solar Pumps?
Most Common Sizes
“12V Panels” “24V Panels”
Each panel is different
but in general..
Vmp is 16v - 20v
Voc is ~20v - 23v
Example
RPS 100w Panels
Vmp = 18.6v
Voc = 21.8v
Each panel is different
but in general..
Vmp is 30v to 37v
Voc is ~38v to 45v
Example
RPS 290w Panels
Vmp = 32.1v
Voc = 38.8v
P = I x V (Power = Current x Voltage)
1 horsepower (hp) = 745 watts
Min Solar
Array Voltage
120v DC
Max Solar
Array Voltage
360 Vmp
410 Voc
Optimal Solar
Array Voltage
Examples Arrays
260-320 Vmp
Examples
16x 100w 12v in series (288 Vmp)
10x 290w 24v in series (320 Vmp)
Pump Wattage /
Coefficient
Recommend 1.3x or more
Battery Bank
Voltage
Not designed for batteries. Use
backup of generator or grid 1 Ph 220v.
12
RPS PRO SERIES REQUIREMENTS
1) Stats from the sticker on the back of your solar
panels Total Power (watts), Vmp (volts), Voc (volts)
2) The total number of panels you have
Solar Panel Sticker
(on reverse side under junction box)
Stats you’ll need from the sticker..
Total Power ( Pm, Watts )
Voltage Maximum Power ( Vmp, Volts DC )
Voltage Open-Circuit ( Voc, Volts DC )
Optional stats:
Current Maximum Power ( Imp, in Amps )
Short-Circuit Current ( Ioc, in Amps )
Example: RPS 100w “12v Panel”

“Series” “Parallel” “Series / Parallel”
Add voltage of every solar panel or
battery in series, current stays the
same. All the solar panels must be the
same.
40v +40v + 40v + 40v + 40v = 200v
Add current of every solar panel or
battery in parallel, voltage stays the
same. All the solar panels must be the
same.
40v // 40v = 40v
Add voltage of every solar panel or
battery in series, voltage stays the
same when other sets connected in
parallel.
40v + 40v // 40v + 40v = 80v
Rough Panel Specs Pro Series
Voc Max 410V (Ideally 400v)
350 Watts
40 Vmp
45 Voc
“72 Cell Panels”
Wired in Series
1) Check Voc: 45v * 4 < 410V ✅
2) Check Vmp: 40v * 4 = 160Vmp > 120Vmp ✅
3) Array Specs: 350w * 4 = 1400w @ 160Vmp
Just over Pro 1000 performance. Probably not higher.
MAX: Could add as many as 8 in series.
45 * 8 < 410V
200 Watts
30 Vmp
36 Voc
“60 Cell Panels”
Wired in Series
1) Check Voc: 36v * 8 < 410V ✅
2) Check Vmp: 30v * 8 = 240Vmp > 120Vmp ✅
3) Array Specs: 200w * 8 = 1600w @ 240Vmp
Right around Pro 1500 performance. Maybe Pro 1000 with 8.
MAX: Could add as many as 8 in series.
36 * 11 < 410V
13

USER MANUAL
1
2
3
4
SYSTEM
GROUNDING
Controller grounding is required for system
safety and helps protect your system. It is
very important that you ground your controller.
To do this locate the grounding screw (as noted
by the symbol in image 1) on the side of your
controller’s heat sink. Take the grounding lug
(located in your pro-series accessory bag) and
secure it to your controller using the grounding
screw.
Once the lug is secured to your controller
loosen the crimping screw and insert your
copper grounding wire, then tighten down the
crimping screw.
A dedicated ground rod should be pounded into
the ground as deep as possible to achieve a
good ground.
Run your copper wire to a copper grounding
rod,and then secure the bare copper wire using
the bolt on the grounding clamp as shown in
image 4.
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 unhooked from the panels
• 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.
14

STEP 1
Remove the 4 nuts on the top of your pump motor.
You will need a ½” wrench for this step.
STEP 2
Remove the two screws on the wire protector located on
the pump end. You will need a medium sized philips head
screwdriver for this step.
STEP 3
Place the pump end onto the pump motor allowing the bolts to pass
through each of the holes. Be sure to align the wire groove on the
pump end with the wiring harness coming out of the pump motor.
Secure the nuts you previously removed. Hand tighten until snug
and secure. The exact torque value is 10 lb-ft (14 Nm)
PUMP
ASSEMBLY
15

USER MANUAL
STEP 4
Run the wires from
the pump motor up
along the side of the
pump end where the
wire cover will go.
PRO TIP: To make the
installation of the wire
cover easier make sure the
wires lay flush along the
pump end.
STEP 5
Install the wire cover by fastening the two screws
previously removed.
PRO TIP: The top of your wire cover is
outfitted with a lip that fits securely over the
sheath of your pump end. Secure this lip
before fastening the screws to ensure proper
fit.
16
PUMP ASSEMBLY CONT.

Connecting to a tank
To connect to a storage tank without using a check valve, make
sure the pipe from your pump fills the tank from the top of the tank
and not the outlet on the bottom to prevent creating a siphon back
out of the tank when the pump stops. If you’re using a check
valve, you can connect to the bottom or top of your storage tank.
In a later section, we’ll install the tank sensor and connect it to the
controller.
If you’re planning to use a mechanical float valve on the tank to
shut off the pump, or if you are pumping into a pressure tank.
Well seals
You may already have a well seal, or you may be using a pitless
adapter, which allows you to keep plumbing below ground. If not,
you’ll want to procure a well seal that allows your pipe, wires, and
safety rope to exit the well while preventing any debris from falling
into the well. This can be installed last, after testing and final
installation of the system.
Check valves
For long runs of pipe, you may want to install a check valve. For
any system using a pressure switch, a check valve is
recommended. You’ll need a 1 ¼ - 2” stainless threaded nipple
to connect a stainless check valve to the outlet of the pump. The
barb or your own plumbing will thread into the upper part of the
check valve. Ensure the arrow is in the direction of flow.
Check valves are frequently made of brass and your pump
is made of stainless steel; to prevent electrolysis, in this
case use a PVC threaded nipple and a PVC barb for brass
check valves.
Torque arrestors and spacers
Some traditional well installers are accustomed to using
torque arrestors, but because RPS systems feature a
slow-start and slow-stop, they don’t create strong torque
like an AC pump. For this reason, spacers and torque
arrestors are far less commonplace in this setting. They
can be used if you prefer, but are usually omitted during
installation.
Debris filters
While some well owners choose to place a non-degradable
well sock/mesh over their pump, this is unnecessary. All
RPS pumps feature a filter screen that will prevent
anything large from entering and clogging your pump.
The amount of total pump head (shown in feet) increases due to friction over long horizontal distance of poly pipe depending on the diameter of the pipe.
Smaller diameter pipe adds more head to the system.
5 GPM 50 GPM
Tank float
The tank float switch included in your kit is optional but
very useful; when the water level in your tank rises to the
level of the sensor, it sends a signal to the controller to
shut down the pump and prevent your tank from
overflowing. You can install this sensor at the top of your
tank or wherever you want the water level to stop rising.
Extend as necessary with 16-22 gauge 2 strand wire.
Calculating pump head
OTHER CONSIDERATIONS
17

USER MANUAL
At this point in the process it is important to prep a few
items for later steps. If you take these extra steps in
preparation you will thank yourself later.
Attach a safety rope through either of the two holes (or
both) in the top of your Pro-Series pump. Polypropylene
rope is best since it will not decay however you can use a
chain or stainless-steel cable if desired.
PLUMBING &
SAFETY LINE
What you choose to use for the piping for your pump is
completely up to you. We recommend poly pipe. If you are
using poly pipe you are going to want to unspool the piping
now. This step is especially important if the piping, or the
surrounding weather is cold. Laying out the pipe now will
make it so you don’t have to fight against the pipes natural
curvature while lowering down the pump.
After the pipe is laid out, run your heavy duty submersible
flat jacket pump wire and your safety rope along the length
of the pipe. Once this is done adhere the three lengths
together using electrical tape and wrapping two to three
times about every ten feet.
PRO TIP: Leave a little extra slack in the
wiring and safety pop as polypipe can stretch
up to 1% in the well. That's equal to 1 foot for
every 100 feet of poly pipe.
18

WELL PUMP PLUMBING
WITH POLY PIPE
If your installation requires a check-valve, (for example installs that
also have pressure systems) you will need to install all three of
these plumbing pieces: a threaded nipple, check-valve, and the
hose barb, in that order.
Your RPS Pro-Series submersible pump already has an internal
check-valve installed, but it is recommended to install a dedicated
check valve when used in a pressure system and other
installations where you want to ensure no leakage.
For other open discharge applications you can install the hose barb
directly to the outlet of your pump.
Hose
Barb
Check-valve
Make sure to install your
check-valve with the arrow
pointing with the flow of water
(away from the pump.)
Threaded
Nipple
When installing any of the following plumbing pieces to
your pump be sure to use 3+ wraps of teflon tape around
the threads. Stainless steel can be more difficult to seal,
so extra tape or pipe dope can help. Doing this will ensure
that your fittings are secure and provide peace of mind.
PRO TIP: When wrapping teflon tape on
any threads, wrap the tape going clockwise
to avoid the tape being unraveled when
threading on additional plumbing.
19
Optional
Connecting the pump to the drop pipe
Using the hose barb included in your kit and Teflon tape,
screw the male thread of the hose barb coupling into the
female NPT pipe thread outlet of the pump. Thread the
hose clamps over the pipe and out of the way, then insert
the end of your poly pipe over the hose barb end of the
coupling. In cold weather to make the tightest connections
possible, apply even heat from a heat gun to warm up the
poly pipe; this increases malleability and allows the pipe
to fit snugly over the barb. While the poly pipe is warm,
tighten the hose clamps over the poly pipe and barb.
Pro tip: use a socket set on the hose clamps instead of a
screwdriver for a tighter fit.