SUNPUMPS SDS Series Specification sheet

OPERATION AND
INSTALLATION
MANUAL
SDS SERIES
SOLAR ELECTRIC PUMP
&
PCA-30-M1 SERIES
PUMP CONTROLLER
MANUFACTURED & SERVICED BY:
SUNPUMPS
325 EAST MAIN STREET
SAFFORD, ARIZONA 85546
UNITED STATES OF AMERICA
PHONE # [phone]
FAX # [phone]
DC# SDS-PCA-30-M1
REV 2001
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.
•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.

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