SUNPUMPS SCS HP SERIES Specification sheet

OPERATION AND
INSTALLATION
MANUAL
SCS ½ HP SERIES
SOLAR ELECTRIC PUMP
&
PCA-60-M1 SERIES
PUMP CONTROLLER
MANUFACTURED & SERVICED BY:
SUNPUMPS
325 EAST MAIN STREET
SAFFORD, ARIZONA 85546
UNITED STATES OF AMERICA
PHONE # [phone]
FAX # [phone]
DC# PCA-60M1
REV 2001

Table of Contents
Introduction ………………………………………………………………………... 1.0
Precautions
Product Overview …………………………………………………………………. 2.0
Controller 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 Diagram
Wiring ………………………………………………………………………………. 3.5
Figure 3: Solar Panel Wiring Diagrams (Generic)
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 SCS series solar pump system. The SCS series pump and PCA series
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, wildlife and stock
watering problems without violating the environment.
SunPumps SCS series pumps are multi-stage centrifugal, DC powered, submersibles constructed of high
quality marine bronze and stainless steel. These pumps were designed specifically for water delivery in
remote locations.
The PCA-series controllers are micro-processor-based, solid-state DC power converters designed as the
interface between a solar module array and a DC pump motor. The purpose of the controller is to
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 SCS series pump systems are easy to install, please read this manual to become
familiar with the 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 PC-series controller or product damage and/or
personal injury may result.
•Do not exceed the voltage and power rating of the controller.
•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 Solar Pump Contractor.
2.0 Product Overview
SunPumps PCA series controllers were primarily designed for the ½ HP SCS-series, brushless DC
submersible pump. However, they will operate various brush-type DC motors as well. 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.
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. 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 pump motor voltage control for precision output flow.
8. Adjustable input voltage for system optimization or solar modules.
9. System ON/OFF switch.

10. 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.
11. Weather resistant cast aluminum enclosure with hinged door.
12. Rising clamp screw terminal blocks – no fork terminals required.
13. User selectable pre-adjusted input voltage configuration and power source selection.
14. Remote switch interface – float switch or remote shutdown –Normally Open or Normally
Closed user selectable.
15. Sensor-less Low Water Cut-Off circuit
2.2 Application
The only application the PCA-60-M1 controllers are designed for is the interface between a solar
module array and a DC motor as well as various peripheral pump system signal devices.
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 SCS series pump and PCA series controller. The procedure for installing the SCS
submersible pump is the same as a standard AC submersible 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 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 panel system capable of producing over 10 amps will result in
non-warranted product damage. Please check polarity before connecting power to the
controller.
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!
The PC-series controller 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 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 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. As a rule of
thumb use 1” for up to 8 GPM, 1 ¼” for up to 25 GPM and 1 ½” for up to 40 GPM.
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. Due to the aggressive action of DC power, it is essential that any under-water splice 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.
4. Never rest the pump on the bottom of the well (bore hole). This can cause the pump to fill with
mud and damage the impellers. Suspend the pump five feet (1.5 meters) or more above the
bottom of the well (bore hole). If possible, install the pump above the well casing perforations.
This will allow any sand intrusion to settle below the pump.
5. Never install a pump in a well that has had an oil-lubricated line shaft turbine in it without
cleaning it first. Any drip oil remaining in the water may damage the pump shaft bearing
sleeves.
6. On deep wells, a check valve should be installed every 200’ of vertical lift.
7. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-
heating of the controller.
8. Never lay the controller on the ground or mount the controller in a horizontal position. The
controller should be mounted in a vertical position only. A convenient place to mount the
controller is on the north side (shaded side) of the solar module array.
9. The controller should be grounded to the pump motor housing, the frame of the solar modules
and to an 8-foot ground rod. 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.
10. Do not ground the positive or negative electrical wires.
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).

3.4 Pump Installation
1. The well should be clean and disinfected before the pump is installed. You should always develop the well
before installing the pump.
2. Write the pump 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.
3. Inspect all components for shipping damage and insure that you have all the components that are required
for a complete installation.
4. Select a well-ventilated, shaded location in which to vertically mount the control box. The north side of the
Solar Panel Tracker mounting pole is usually a convenient place.
5. If using unthreaded discharge pipe install a stainless steel or brass adapter fitting into the pump discharge
head. Consult your pump supplier for other available adapter materials. Do not use galvanized
connections on stainless steel or bronze discharge heads as galvanic corrosion will occur. Connect the
drop pipe, safety rope and sand shroud (if used) to the pump. Barbed type connectors should always be
double clamped.
6. Splice the drop cable to the motor lead using an under water splice kit. (See wire splicing instructions
provided with splice kit.) Match the drop cable wire colors to the pump motor leads or identify the leads to
insure correct connections at the controller. (Red is positive, Black in negative and Green is ground).
7. You can now lower the pump into the well. Set the pump at least 10’ off the bottom. Never rest the pump
on the bottom of the well. Never lower the pump by the wires.
8. Tie the drop pipe, drop cable and safety rope together every ten feet with plastic wire ties or high quality
electrical tape. Make sure that the tape does not loosen as it will block the pump suction if it falls down the
well. The use of the safety rope is at the discretion of the installer.
9. 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.
10. Finish lowering 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 1 System Installation Layout

Figure 2 Top of Pole Mount Rack Diagram
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. Please refer to a DC voltage
loss table or call your SunPumps dealer for assistance.
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.
CAUTION : Photovoltaic panels produce DC electricity when exposed to sunlight. Cover the panels with
a blanket or with an opaque material before wiring. Install a disconnect switch between the solar
modules and the controller.

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 (-), black conductor to controller terminal labeled “LD-”.
6. Connect pump motor positive (+), red conductor to controller terminal labeled “LD+”.
7. Connect the DC source supply negative (-), black 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 (+), red 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. If you have a volt meter check the open circuit voltage
and the module polarity before connecting power to the controller.
11. Switch the disconnect 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.

Figure 3 Solar Panel Wiring Diagram
(Generic)