SUNPUMPS SDS Series Specification sheet

OPERATION AND
INSTALLATION
MANUAL
SDS SERIES
SOLAR ELECTRIC PUMP
&
PCA-30-M1D SERIES
PUMP CONTROLLER
MANUFACTURED & SERVICED BY:
SUNPUMPS, INC.
325 EAST MAIN STREET
SAFFORD, ARIZONA 85546
UNITED STATES OF AMERICA
PHONE # [phone]
FAX # [phone]
Made in the U.S.A.
DC# SDS-PCA-30-M1
REV 2011

Table of Contents
Introduction ………………………………………………………………………... 1.0
Precautions
Product Overview …………………………………………………………………. 2.0
Features ……………………………………………………………………………. 2.1
Application ………………………………………………………………………... 2.2
Installation and Operations ………………………………………………………… 3.0
Location …………………………………………………………………………… 3.1
System Design Basics ……………………………………………………………… 3.2
Well Measurements ……………………………………………………………… 3.3
Pump Installation …………………………………………………………………… 3.4
Figure 1: System Installation Layout
Figure 2: Top of Pole Mount Rack Installation
Wiring ………………………………………………………………………………. 3.5
CE Compliance
Figure 3: Solar Panel Wiring Diagram
Figure 4: Controller Wiring Diagram
Auxiliary Control Features ………………………………………………… 3.6
Remote Switch
Output Voltage Control Circuit
Low Water Cut-off Circuit
Adjustment Procedures ……………………………………………………………… 3.7
Output Voltage Adjustment
Low Water Cut-Off Adjustment
Troubleshooting …………………………………………………………………….. 4.0
Pump does not run
Red and green lights on
Amber Light off
No voltage at the LD+ and LD- Terminals
Technical Specifications ……………………………………………………………. 5.0
Pump
Controller
Dimensions and weights
Warranty Statement ………………………………………………………………… 6.0
Phone [phone] Fax [phone]

1.0 Introduction
Thank you for selecting a SunPumps SDS series pump system. The SDS series pump and PCA series
controller are the key components to a high quality submersible pump system. Their stand-alone, pollution
free and low noise operation makes them an ideal solution for remote homes, wildlife and stock watering
problems without violating the environment.
SunPumps SDS series pumps are positive displacement, low voltage, DC powered, submersibles
constructed of high quality marine bronze and stainless steel. These pumps were designed for corrosion
free service in clean potable water.
The PCA series controllers are solid-state DC power converters designed as the interface between and SDS
series pump and a DC power source. The purpose of the controller is to maximize the total daily water
output while providing protection for the pump and the DC power source as well as providing interface
with other related pumping system equipment.
Although these SDS 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 attempt to feed live wires into the PCA series controller or product damage and/or
personal injury may result.
Do not exceed the power rating of the controller. Max input voltage 45. 30-M1D Max amps
out 5. 30-M1 Max amps out 8. If more than 200 total watts are applied, the controller may
shut down on over current during full sun conditions.
Do not splash water on the controller when the cover is open.
Mount the controller in a shaded, well vented, vertical position.
When working with batteries be careful not to short battery terminals as hundreds of
amperes can flow. Remove all jewelry, use insulated tools and secure all conductors.
Batteries can produce explosive hydrogen gas. Be sure battery housing is well ventilated.
2.0 Product Overview
The SDS series pumps and PCA series controllers are designed to operate with a variety
of DC power sources. The most common of these are solar electric modules and
batteries. When properly installed and configured, the unique features incorporated into
this stand-alone system will automatically control and protect your pump system
permitting several years of dependable, trouble free service.
When used as a solar electric panel direct system the PCA series controllers will provide
pump protection from over-voltage and over-current conditions as well as current
boosting in low sunlight conditions.
In a battery-powered system, the PCA series controllers are not to be used as a solar
electric charge regulator between the solar electric panel and the battery bank. However,
the PCA controllers feature a Low Voltage Cut-off function when used on battery-
sourced systems. This feature will prevent excessive battery discharge conditions thereby
helping to extend the battery bank life. In addition, the PCA controllers will provide a
degree of protection for your charge regulator by attenuating inductive voltage spikes
generated when pump motors switch on or off.

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
3. Low Voltage Cut-off function for battery sourced installations.
4. Over-current protection via integrated electronic circuit breaker, with manual or
automatic reset features
5. Reverse polarity protection (10 amperes maximum) on the input terminals
6. Voltage and current limiting to pump motor
7. Transient protection and surge suppression
8. Adjustable pump motor voltage control for precision output flow
9. Adjustable input voltage for system optimization or solar modules
10. System ON/OFF switch
11. LED indicators; Red = power in, Green = power out, Amber 1 = Remote
switch shutdown, Amber 2 = over current shutdown and Amber 3 = Low Water
Cut-Off
12. Weather resistant cast aluminum enclosure with hinged door
13. Rising clamp screw terminal blocks –no fork terminals required
14. User selectable pre-adjusted input voltage configuration and power source
selection
15. Remote switch interface –float switch or remote shutdown –Normally Open or
Normally Closed user selectable
16. Sensor-less Low Water Cut-Off circuit
2.2 Application
The only application the PCA-30-M1 controllers are designed for is the interface
between the SunPumps SDS series of pumps and the DC power source as well as
peripheral pump system signal devices. The PCA-30-M1 controllers are capable of
operating with two different DC inputs, solar electric modules or batteries. Of these,
solar electric modules are the most common.
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, configuration and system power-up of the SDS pumps and the PCA-30-M1
controllers. Before installing the pump system, read all product manuals and 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 battery sourced system or a panel system capable of producing
over 10 amps will result in non-warranted product damage.
Open circuit voltage of over 45 volts on the input of the controller will result in non-
warranted product damage.

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 and etc. There is no substitute for a good plan!
The PCA series controllers can either be mounted indoors or outdoors. Locate all system
equipment as close as possible to each other. Generally the controller is mounted on the
north side of a pole which has solar electric modules mounted on top of it. The pole
should be located close to the well (bore hole). This general physical layout is conducive
to clean installation aesthetically and electrically.
3.2 System Design Basics (Read carefully before installation)
1. 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.
2. Make sure the discharge pipe is sized properly for the length of run. Friction
loss in a pipeline over a long distance will add head to the pump and thus reduce
the flow rate. Consult your SunPumps distributor if there is any question.
3. Never rest the pump on the bottom of the well (bore hole). This can cause the
pump to fill with mud and damage the diaphragm. Suspend the pump five feet
(1.5 meters) or more above the bottom of the well (bore hole). If possible
mount the pump above the well casing perforations. This will allow any sand
intrusion to settle below the pump.
4. Use no larger than ½” drop pipe for SDS-D series pumps and ¾” drop pipe for
SDS-Q series pumps. Because of the low flow rates of the SDS series pumps,
the water velocity is not fast enough to carry any sand and sediment to the
surface. These small particles may settle inside the pump as well as the drop
pipe causing pump damage. If there is a known sand problem, a sand shroud or
a screen is required. The minimum casing diameter for an SDS-D series pump
with a sand shroud is 5” (12.7 cm) and for and SDS-Q series pump it is 6” (15
cm). Sand damage to an SDS series pump is not covered under warranty. It is
therefore highly recommended that sand shrouds be installed on all SDS series
pumps in an unproven well (bore hole).
5. Due to the aggressive action of DC power, it is essential the wire splice at the
pump be made correctly. This splice must be watertight. Improper sealing of
the splice will cause poor pump performance and may cause damage to the
system. A SunPumps splice kit S-703 is recommended for this watertight
connection.
6. Never install the pump over 50 feet (15 meters) under the static water level.
Excessive water pressure on the pump housing may cause seal damage and
allow water to enter the motor housing.
7. Never chlorinate a well while the pump is installed. Heavy concentrations of
chlorine will damage the diaphragm and seals.

8. Never install the pump in a well that has or has had an oil-lubricated line shaft
turbine in it. Any drip oil remaining in the water may damage the diaphragm
and seals.
9. If the pump is used in a well over 100 feet (30 meters) deep, install a check
valve above the pump. This will help relieve some of the pressure on the
internal check valves and will keep any sediment from entering back into the
pump.
3.3 Well Measurements
Before installing the pump measure the depth of the well (bore hole) and static water
level. The static water level is the distance from the top of the well casing to the water
level in the well (bore hole). This information is necessary in determining the pump
setting. (See Figure 1).
It is important the “Total Dynamic Head” does not exceed the rating of the pump.
Section 5.0 lists the specifications for each pump.
Figure 1 System Installation Layout

3.4 Pump Installation
1. Connect the drop pipe, safety rope and sand shroud (if used) to the pump. Splice the
drop cable to the motor lead using an under water splice kit. (See wire splicing
instructions provided with splice kit.) Unroll the drop cable, drop pipe and safety rope
and lay them on the ground in a straight line.
(Care must be taken not to get dirt inside the drop pipe while stretching it out on
the ground. If a saw is used to cut the drop pipe, make sure to remove the saw
cuttings from the inside of the pipe before assembly.)
2. Make the length of the drop pipe the distance of the anticipated draw down of the water
level plus a minimum of two feet (.6 meters). Never install the pump deeper than
necessary.
NOTE: Never install the pump over 50 feet (15 meters) below the static water level.
This will cause excessive pressure on the pump and may cause water leakage into the
motor housing.
3. Tie the drop pipe, drop cable and safety rope together every ten feet with plastic wire
ties or high quality electrical tape. Slide the well seal over the discharge end of the pipe,
connect the discharge fitting, pull the drop wire through the well seal and connect the
safety rope to the I-bolt on the inside of the well seal.
4. Lower the pump and pipe assembly into the well (bore hole) positioning the well seal
over the top of the casing. Connect the discharge pipe to the fitting on top of the well
seal and run the pump wires to the controller.
Figure 2 Top of Pole Mount Rack Installation

3.5 Wiring
Prior to connecting any wires to the controller be sure you have a system wiring diagram to
use as a reference. Generic system wiring diagrams are included in this manual for your
convenience. (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. As a quick
rule use 12 gauge (4 mm2) wire up to 100 feet (30 meters) and 10 gauge (6 mm2) wire up to
250 feet (76 meters). If distances greater than this is required please refer to a DC voltage
loss table or call your SunPumps dealer.
All other system equipment should be installed before proceeding with wiring the controller.
Pre-configure the controller switches prior to wiring. . (See Figure 4) Refer to
“Adjustment Procedures” for details. Double check polarity and wire termination tightness
before powering up the system.
1. Switch the controller to the OFF position.
2. Connect ground rod conductor to the controller chassis ground block.
3. Connect solar module frame ground conductor to controller chassis ground block.
4. Connect pump ground conductor to controller chassis ground block.
5. Connect pump motor negative (-) conductor to controller terminal labeled “LD-”.
6. Connect pump motor positive (+) conductor to controller terminal labeled “LD+”.
7. Connect the DC source supply negative (-) conductor to the controller terminal labeled
“PV-“. (NOTE: If a fused disconnect is used, the power should be connected to it first
and then to the controller).
8. Connect the DC source supply positive (+) conductor to the controller terminal labeled
“PV+“. (NOTE: If a fused disconnect is used, the power should be connected to it first
and then to the controller).
9. Refer to the next section for “Remote Control” connections and “Adjustment
Procedures” for configuration (if applicable) and then return to this point.
10. At this point, all system components are installed and wired, double check conductor
polarities, wire termination tightness and controller configuration.
11. Switch the disconnect, if used, on and if the polarity is correct the red light will be on.
12. Turn the “ON/OFF” switch to the ON position. The system should be operational. If
the system is not working refer to the “Troubleshooting” section.
For CE Compliance
Appropriate watertight cable glands must be used to keep the controller sealed. Only
one power wire may be attached to each terminal block screw. Wires may not be
doubled up except for signal and control wires. Wiring must conform to HO7RN-F
specifications and must be installed in accordance with all national and local
regulations.
PE ground wires must be Green/Yellow with a color ratio of 50/50, not less than 70/30,
and must be of a size equal to or larger than the pump primary wire. All stranded PE
ground wires connected to the controller case must use a crimped ferrule over the wire
for protection from the set-screw.

Figure 3 Solar Panel Wiring Diagram
(Generic)

Figure 4 Controller Wiring Diagram
3.6 Auxiliary Control Circuits
The PCA-30-M1 controllers feature remote peripheral interface functions with easy
programming. The remote switch interface supports float switches (storage tank level),
pressure switches or a remote system “ON/OFF” toggle switch. Use only “Shielded
Wire” to run from the remote switch to the controller. Induced voltages from
lightning storms or two-way radio transmissions could damage the controller.