Model MTR BLM-SB-073S-60 - Brushless Submersible Motor Brochure

Table of ContentsIntroduction …………………………………………………………. 1.0Product Overview ……………………………………………………. 2.0Controller Features ………………..…………………………………. 2.1Application …………………………………………………………... 2.2Installation and Operations ………………………………………..… 3.0Location ……………………………………………………………… 3.1System Design Basics …………………………………………..…… 3.2Well Measurements …………………………………………………... 3.3Figure 1: Solar Pump System Terms and Head CalculationsPump Installation ……………………………………………………... 3.4Wiring …………………………………………………………………. 3.5Figure 2: Controller Wiring Diagram (Power Connections)Figure 3: Controller Wiring Diagram (Auxillary)Figure 4: Dip Switch SettingsController Settings …………….……………………………………… 3.6Auxiliary Control Circuits …………………………………..…...……… 3.7Over-Current Shut-Down CircuitSensor Low Water CutoffRemote SwitchLow Water Shut-Down CircuitLow Power Shut-Down CircuitOutput Power Limit CircuitTroubleshooting ……………………………………………...……….. 4.0Controller does not turn onController turns on but pump does not runPump is running but the output is lowPump draws excessive currentBefore Calling Sun PumpsBefore Calling SunPumps ………………….………………………... 4.1Technical Specifications ……………………………………………. 5.0PumpControllerDimensions and WeightsWarranty Statement ………………….……………………………… 6.0Phone (928) 348-9652 Fax (928) 348-96531.0 IntroductionThank you for selecting a SunPumps SCS series solar pump system. The SCS seriespump and PCA series pump controller are the key components to high quality solarpowered pumping systems. Their stand-alone, pollution free and low noise operationmakes them an ideal solution for remote homes, wildlife and stock watering problemswithout violating the environment.SunPumps SCS series pumps are multi-stage centrifugal, brushless, sensorless threephase DC powered, submersibles constructed of high quality stainless steel. These pumpswere designed specifically for water delivery in remote locations.The PCA-series controllers are micro-processor-based, solid-state DC power convertersdesigned as the interface between a solar module array and a brushless, sensorless threephase DC pump motor. The purpose of the controller is to maximize the total daily wateroutput while providing protection for the pump as well as providing an interface withother related pumping system equipment.Although these SCS series pump systems are easy to install, please read this manualto become familiar with the controller features, functions, connection points andvarious configurations. For future reference, keep this manual and other relevantproduct information in a safe place.PRECAUTIONS? Safety First – Always understand what you are doing when working with anyform of electricity. Guessing at something is not worth the potential ofproduct 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 productdamage 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 PumpContractor.2.0 Product OverviewSunPumps PCA series controllers were primarily designed for the 24V, 48V, 60V, and120V SCS-series, brushless, sensorless three phase DC submersible pump. Whenproperly installed and configured, the unique features incorporated into this stand-alonesystem will automatically control and protect your pump system permitting many yearsof dependable, trouble free service. SunPumps has produced multiple versions of thiscontroller. The differences between the versions are certain set points and electrical characteristics whichare detailed in the table on the next page.Table 1Controller Model MinVoltage1MaxVoltageMinPowerMaxPowerLowWaterCutoffMinLowWaterCutoffMaxNominalVoltagePCA-60BLS-M22 30 V 100 V Set byLWC840 W 50 W 300 W 60 VPCA-120BLS-M22 90 V 200 V Set byLWC1000 W 50 W 500 W 120 V1Min Voltage is the minimum voltage which the unit must see in order to start the pump. If thisvoltage is not obtained, the unit will not attempt to start the pump. Voltages lower than this willnot hurt the unit.2Both controller models have the same operating features, functionality and setup. Voltage andpower tolerances are the only differences of concern to the end user. This manual will onlydifferentiate when necessary for clarity.2.1 Controller Features1. 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. System ON/OFF switch.9. LED indicators; 1. Power In, 2. Motor Run, 3. MPPT, 4. RS Stop, 5. LowPower, 6. Over-Current, 7. Fault Condition.10. Weather resistant cast aluminum enclosure with hinged door.11. Rising clamp screw terminal blocks – no fork terminals required.12. Remote switch interface – float switch or remote shutdown –Normally Open orNormally Closed user selectable.13. Sensor and sensor less “Low Water Cutoff” circuit14. Low Power Shut Down circuit2.2 ApplicationThe only application the PCA series controllers are designed for is the interfacebetween a solar module array or battery bank and a brushless, sensorless three phaseDC motor as well as various peripheral pump system signal devices.No other applications or DC power sources are recommended or warranted unlesswritten approval is provided by the SunPumps factory.3.0 Installation and OperationThe following sections are outlined in a step-by-step format to guide you through theinstallation of a PCA series controller. Before installing any pump system, read allproduct manuals and review all system components to become familiar with thephysical and electrical layout. Check all equipment for any product damage. Refer toapplicable figure(s) as a guide during the installation. Controller door must be closedduring normal operation.WarningReverse polarity on a panel system capable of producing over 10 amps will result innon-warranted product damage. Please check polarity before connecting power to thecontroller.3.1 LocationAs the majority of system installations vary greatly, only general comments can be madeas 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 solarelectric 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 theoutput of the entire array and thus reduce or completely stop the output of the pump.There is no substitute for a good planThe PC-series controller can either be mounted indoors or outdoors. Locate all systemequipment as close as possible to each other. Generally the controller is mounted on thenorth side of a pole which has solar electric modules mounted on top of it. The controllermust 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 isconducive 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 forthe length of run between the pump and the solar modules. Wire sized too smallwill cause a decreased output from the pump. Keep the distance from the solarmodules to the pump as short as possible. Refer to a DC wire loss chart forproper sizing. It is recommended to keep the voltage drop under 3%.2. Due to the aggressive action of DC power, it is essential that any under-watersplice be made correctly. This splice must be watertight. Improper sealing ofthe splice will cause poor pump performance and may cause damage to thesystem. A SunPumps splice kit S-703 is recommended for this watertightconnection.3. Never install a pump in a well that has had an oil-lubricated line shaft turbine init without cleaning it first. Any drip oil remaining in the water may damage thepump shaft bearing sleeves.4. Never install the controller in direct sunlight. Direct sunlight on the controllermay cause over-heating of the controller.5. Never lay the controller on the ground or mount the controller in a horizontalposition. The controller should be mounted in a vertical position only. Aconvenient place to mount the controller is on the north side (shaded side) of thesolar module array.6. The controller should be grounded to the pump motor housing, the frame of thesolar modules and to an 8-foot ground rod. If the well casing is steel it may beused as the ground rod. Drill and tap a hole in the casing or weld a bolt to thecasing for the ground lug. Use only a copper lug to attach the ground wire. Thecemented support structure pole will not provide an adequate ground. Do notground the positive or negative electrical wires.7. Do not ground the positive or negative electrical wires.3.3 Well MeasurementsBefore installing the pump measure the depth of the well (bore hole) and static waterlevel. The static water level is the distance from the top of the well casing to the waterlevel in the well (bore hole). This information is necessary in determining the pumpsetting (See Figure 1).Figure 1 Solar Pump System Terms & Head CalculationsDrawDownStatic Water LevelVerticalLiftPump LevelPump SettingSCS Submersible PumpPumping Level _____________FeetVertical Lift _____________FeetFriction Loss _____________FeetTotal Dyn. Head _____________FeetTotal Dynamic Head = PL + VL + FLWater TankSubmersible Pump CableSanitary Well SealDrop Pipe ++=(See Friction Loss Chart)Determining Total Dynamic HeadPumping LevelPumping level is the vertical distance in feet from the discharge pipe at the well head to the water levelin the well while pumping at the specified flow rate.Vertical LiftVertical lift is the vertical distance in feet from the discharge pipe at the well head to the discharge pipeat the top of the water tank.Friction LossFriction loss is the resistance to flow through a pipeline measured in PSI drop and converted to headfeet. The amount of loss depends on the diameter of the pipeline, the length of the pipeline, the flow rate,the number and type of fittings and the coefficient of friction of the pipeline material. Refer to frictionloss tables for your specific application. (There is a Friction Loss Program on the SunPumps web site inthe engineering section at www.sunpumps.com.)3.4 Pump Installation1. The well should be clean and disinfected before the pump is installed. You shouldalways clean and develop a new well before installing the pump.2. Write the pump, motor and controller model number and serial number in the spaceprovided on the last page in this Instruction Manual. This information will be neededwhen filling out the Warranty Card. And will aide in any troubleshooting which may benecessary.3. Inspect all components for shipping damage and insure that you have all the componentsthat are required for a complete installation.4. Select a well-ventilated, shaded location in which to vertically mount the control box.The shaded side of the solar panel rack mounting pole is usually a convenient place.5. If using unthreaded discharge pipe install a stainless steel or brass adapter fitting into thepump discharge head. Consult your pump supplier for other available adapter materials.Do not use galvanized connections on stainless steel or bronze discharge heads asgalvanic corrosion will occur. Connect the drop pipe, safety rope and sand shroud (ifused) to the pump. Barbed type connectors should always be double clamped. For polypipe, compression fittings are recommended.6. Splice the drop cable to the motor lead using an under water splice kit. (See wiresplicing instructions provided with splice kit.) Match the drop cable wire colors to thepump motor leads. If the drop cable does not have the same color wires as the pump, besure to record which colors go to the various colors of the motor lead and label them.The motor can run in reverse if not connected properly.7. You can now lower the pump into the well. Set the pump at least 10’ off the bottom (see3.2 System Design Basics #4). Never rest the pump on the bottom of the well. Neverlower the pump by the submersible pump cable.8. Tie the drop pipe, drop cable and safety rope together every ten feet with 2” 10 mil pvcpipe wrap tape. Make sure that the tape does not loosen as it will block the pump suctionif 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, pullthe drop wire through the well seal and connect the safety rope, if used, to the eye-bolton the inside of the well seal.10. Finish lowering the pump and pipe assembly into the well (bore hole) positioning thewell seal over the top of the casing. Connect the discharge pipe to the fitting on top ofthe well seal and run the pump wires to the controller.3.5 WiringPrior to connecting any wires to the controller be sure you have a system wiring diagram touse as a reference. Generic system wiring diagrams are included in this manual for yourconvenience. (See Figures 2 and 3) Guessing at polarity and connection points is not worththe risk of potential product damage and/or personal injury.Ensure the wire sizes are of adequate diameter (gauge) to minimize voltage drop. Pleaserefer 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.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 adisconnect switch between the solar modules and the controller.Figure 2 Controller Wiring Diagram(Power Connections)1. Switch the controller to the OFF position.2. Connect ground rod conductor to the controller chassis ground block (See Figure 2).3. Connect solar module frame ground conductor and the pump ground conductor tocontroller chassis ground block (See Figure 2).4. Connect pump motor leads to the lower terminal block. Red leg to “R”, yellow leg to“Y” and black leg to “B” (See Figure 2).5. Connect the DC source supply negative (-), black conductor to the controller terminallabeled “PV-“. (NOTE: If a fused disconnect is used, the power should be connected toit first and then to the controller see Figure 2).6. Connect the DC source supply positive (+), red conductor to the controller terminallabeled “PV+“. (NOTE: If a fused disconnect is used, the power should be connected toit first and then to the controller see Figure 2).7. Connect the remote switch and the low water cutoff sensor to the upper terminal block(See Figure 3). Refer to the next section for “Remote Switch” and “Sensor Low WaterCutoff” connections and configuration (if applicable) and then return to this point.8. At this point, all system components are installed and wired, double check conductorpolarities, wire termination tightness and controller configuration. If you have a voltmeter check the open circuit voltage and the module polarity before connecting power tothe controller.9. Switch the disconnect on. If the polarity is correct the red light will be on.10. Turn the “ON/OFF” switch to the ON position. The system should be operational. Ifthe system is not working refer to the “Troubleshooting” section.Figure 3 Controller Wiring Diagram(Auxillary)Figure 4 Dip Switch SettingsSwitch SwitchDescription Function Default SettingNumber Position1 OFF Remote Switch Logic Turns pump off when terminals connect. OFF1 ON Remote Switch Logic Turns Pump on when terminals connect. OFF2 OFF Low Water Cutoff Logic Turns pump off when terminals connect. OFF2 ON Low Water Cutoff Logic Turns pump on when terminals connect. OFF3 ON 10 Minute Delay Increases turn on delay to 10 minutes OFF4 ON 30 Minute Delay Increases turn on delay to 30 minutes OFF5,6,7,8 OFF Not used at this time Must be in the off position for properoperation OFF3.6 Controller SettingsThe PCA series controllers have several settings (see figure 3). Most features includesystem configuration adjustments, some of which are user selectable by an eight positionDIP-switch located on the face of the controller.Switch 1 is the Remote Switch Logic. With this switch off (down), terminals “RS+” and“GND” must be connected to turn the controller off. With this switch on (up), terminals“RS+” and “GND” must be connected to turn the controller on.Switch 2 is the Low Water Cutoff Logic. With this switch off (down), terminals “LW”and “GND” must be connected to turn the controller off. With this switch on (up),terminals “LW” and “GND” must be connected to turn the controller on.Switches 3 and 4 are delay timer adjustments. The delay timer is used for the remoteswitch and the low water cutoff. This timer by default is set for one minute. Switch 3will increase the timer to 10 minutes; Switch 4 will increase it to 30 minutes. SeeRemote Switch and Low Water Cutoff for more information.Switches 5, 6, 7 and 8 are not used at this time and should remain down.3.7 Auxiliary Control CircuitsThe auxiliary control circuits are configured and controlled with the “Dip Switches”, “LPAdj.”, “Speed Control” and the “RS”, “LW” and “GND” terminals. (See Figure 3)These circuits offer expanded capability and are described here. The remote switchcontrol is for float switches (storage tank level), pressure switches or a remote system“ON/OFF” toggle switch. The motor speed control is for adjusting the flow rate of thepump. There is also the low water cutoff, low power shut down and over currentprotection circuits. See each corresponding detailed description below.NOTE: Use only “Shielded Wire” to run from the remote switch to the controllerand the ground wire must be grounded to the controller side only. Induced voltagesfrom lightning storms or two-way radio transmissions could damage the controller.Over-Current Shut Down CircuitThe over-current shut down circuit will turn the controller off any time the currentexceeds the current limit of the controller. When it turns the controller off it will remainoff for 3 minutes and then turn on again. When it turns off an error light will light and thedisplay will say Over-Current. When it turns on again, if it is still pulling excessivecurrent it will continue to shut down for 3 minutes and try to restart.Sensor Low Water Cutoff CircuitThe sensor type low water cutoff circuit is designed as a safety feature to protect yourpump from running dry or your tank from over flowing. The “LW” terminal of thecontroller should be attached to a low water sensor electrode which is mounted in yourtank or well. The system can be used to detect low water or to detect high waterdepending on the position of switch 2 on the dip switch. When dip switch 2 is in the offposition, the low water cutoff circuit expects not to touch water. If water comes intocontact with it, and completes the circuit to ground, the pump will shut off until the wateris removed and the delay timer times out. A three minute timeout is default for thisfeature but is modifiable by switches 3 and 4 to 10 or 30 minutes respectively. Thistimeout applies to remote switch and low water cutoff.Remote SwitchThe Remote Switch interface can serve as an automatic system shutdown when used witha water storage tank mounted float switch, a pressure switch or it can also serve as amanual system shutdown with a remote system ON/OFF toggle switch. The remote logiccircuit allows the use of standard “Pump-Up or Pump Down” float switches. Please referto the following operation scenarios for configuration options.With switch number 1 in the OFF position, the controller is configured to accommodate aNormally Open (N.O.) float switch or remote toggle switch. In this configuration thecontroller will operate as follows:PUMP ONfloat switch open = water tank low = pump ONPUMP OFFfloat switch closed = water tank high = pump OFFWith switch number 1 in the ON position, the controller is configured to accommodate aNormally Closed (N.C.) float switch, pressure switch or remote toggle switch. In thisconfiguration the controller will operate as follows:PUMP ONswitch closed = water tank low = pump ONPUMP OFFswitch open = water tank high = pump OFFA one minute minimum timeout is default for this feature but is modifiable by switches 3and 4 to 10 or 30 minutes respectively. At certain times the controller may be off for upto 14 minutes depending on various factors in the controller program. This timeoutapplies to remote switch and low water cutoff.Low-Power Shut-Down/Sensorless Low Water Cut-Off Circuit (LPLW)The Low-Power Shut-Down/ Low Water Cut-Off Circuit (LPLW) turns the pump off anytime the controller output power drops below a functional level. This may be caused bylack of power from the solar panels or from running out of water. This protects the pumpin stall conditions and saves wear on the system when no or very little water is beingpumped. This feature must be adjusted for your specific application.This feature is always monitoring the output of the motor. If you are not interested inusing this feature turn the “LP Adj” trim pot fully counter-clockwise. This will give thepump the minimum low power set point possible.LPLW AdjustmentThe Low Water Cut-Off Circuit and the Low Power Shut-Down circuit are adjusted usingthe same trim pot labeled “LP Adj.” on the controller. The default is the arrow pointingstraight up. This is sufficient for most systems but adjustment will maximize the life andoutput of your system. Follow the steps below to adjust this feature.1. Turn the “LP Adj.” trim pot fully counter clockwise.2. Turn the “Speed Control” trim pot counter clockwise until the pump is pumpingthe desired minimum flow. This may be down to 0 gal/min but is notrecommended for proper pump cooling.3. Turn the “LP Adj.” trim pot clockwise until the pump shuts off.4. Reset the “Speed Control” trim pot back to the desired position.Motor Speed ControlThe Output Power Limit Control circuit is used to control the speed of the pump motorand thus the flow rate of the pump. It is primarily used for low producing wells where thepump output is matched to the production rate of the well. However it can also be usedany time specific flow rates are required.Motor Speed Control AdjustmentThe purpose of this procedure is to adjust the output power of the controller and thusreduce the water flow of the pump. If tests have shown the pump will out produce thewell capacity, then the controller “Speed Control” feature can be used to match the flowrate of the pump to the production of the well.1. With the system installed and controller properly configured, allow the pump to run atfull power at mid-day until the pump starts surging.2. Slowly turn the “Speed Control” trim pot located on the face of the controller counterclockwise until the pump stops surging. This is the point where the pump flow rateequals the well production. This process will probably take a few attempts to“balance” the system for optimum water production. If maximum water is not acritical issue you may want to reduce the pumps flow rate an additional 5% to 10% toinsure the pump will not run dry.(NOTE: The trim pot has a10- turn range. It usually takes many complete turns in acounter-clockwise direction before you will notice any change in water output ormotor speed).4.0 TroubleshootingSun Pumps, Inc. is dedicated to its customers and will gladly help you trouble shoot anyproblems with your system. However, especially during the busy summer pumpingseason, we may not be able to help you right away. Using this trouble shooting guide asyour first resource when your system is not working properly can save you valuable timein getting your system fully functional. If at any time however, you are not comfortableperforming any of these tasks, or do not fully understand the system, it is better to callthan to guess. Before calling please go through the section below labeled “BeforeCalling Sun Pumps” and complete the steps there.CONTROLLER DOES NOT TURN ON1. Check the LED’s on the face of the controller. The top LED, labeled “Power In”,should be on. This indicates power is connected to the controller and the polarity iscorrect. If it is not on, verify that the controller is properly wired, including polarity,and that the input terminals have at least 30 volts. Less than 30 volts at the inputterminals and the unit may show no signs of operation. If you do have at least 30 voltsin the right polarity, contact Sun Pumps for further assistance.2. If the expected voltage is not present, disconnect the panels from the controller usingthe disconnect, and check any fuses and breakers in the system. Replace blown fusesand reset tripped breakers.3. If there are no blown fuses and no tripped breakers, check the open circuit voltage ofyour array. If the open circuit voltage is not correct trouble shoot the array to find theproblem. If the open circuit voltage is correct, call Sun Pumps for further assistance.CONTROLLER TURNS ON BUT PUMP DOES NOT RUN1. Make sure the On/Off switch is in the up position (On). The second LED is labeled“Run”. This indicates the pump is running. If it is on, go to the bore hole and listenfor the sound of the motor. Check for breaks in the pipe. If you cannot find a problemcall Sun Pumps for further assistance.2. Check the fourth LED, labeled “RS Stop”; this is the remote switch shutdownindicator. If it is on, the remote circuit or low water cutoff circuit is preventing thecontroller from running the pump. Set the #1 and #2 dip switches to off anddisconnect the remote switch and low water cutoff. Turn the switch off then back on.If the light goes out and the pump starts, troubleshoot the remote switch and lowwater cutoff individually. If the pump does not start and the LED is still lit, call SunPumps for further assistance.3. Check the fifth LED, labeled “Low Power”; this is the low power shutdown indicator.If it is on, the controller detected a low power or low water condition. The low powershut down is a common occurrence on days which have clouds which block the sunmomentarily. First check the input voltage to the controller. Verify that this exceedsthe minimum voltage in Table 1. If it does not meet or exceed the minimum voltage,you do not have enough power to start your pump. Note: To accurately trouble shootthis feature there should be absolutely no clouds blocking the sun at any time duringthe following tests. If you have enough input voltage, turn the controller off then onagain to reset this fault. If the low power or low water condition still exists then thecontroller will start but shut down again. Turn the blue pot labeled “LP Adj” all theway counter-clockwise. Cycle the pump off then on. If the pump does not shut down,the low water cutoff was causing the error. If you want to use this feature, readjust thelow water cutoff as seen earlier in this manual. If the does not run properly, skip tostep 7. Check to verify the pump is not running out of water. If your pump is notrunning out of water, call Sun Pumps for further assistance.4. If the sixth LED, labeled “Over Current” is on, the controller has exceeded its currentlimit and shut down. Turning the controller off then on again will reset this fault. Ifthe controller continues to need high current, it will turn itself off again. Verify thenominal voltage of your array. If the calculated Vmp for your array is higher than200 V, the controller may go into over current. Remove one series panel from eachstring and try again. Check the pump for a short to ground using an ohm meter andcall Sun Pumps for further assistance.5. If the seventh LED, labeled “Fault Condition”, is on, this indicates a motor or groundfault fuse error.. Check motor wiring and connections. Also check the ground faultfuse, it may have been blown. Check your system for ground loops and replace thefuse with a 500 VDC 1A rated fuse. If this does not solve the issue, contact SunPumps for further assistance.6. Check for proper dip switch settings on your controller. Switches 5, 6, 7, and 8 mustbe in the off position for proper operation.7. Check for proper controller input voltage. If the pump is not running, the inputvoltage should be the array open circuit voltage, (Voc). Verify that this voltage isbelow the maximum input voltage allowed for your controller (model dependent seeTable 1). Check the Voc on the label on the back of the solar modules and multiplythis figure times the number of modules that are connected in series. This numbershould be + - 10% of the measured reading. If it is not then confirm all electricalterminations are tight and secure. Use a DC volt meter to check each solar module forproper open circuit voltage (Voc). A single bad module can drop the voltage andcurrent of an entire string of panels.PUMP IS RUNNING BUT THE OUTPUT IS LOW1. Make sure you have full sun light at midday, that there are no clouds and no shadowson any part of the array. Then verify power going into the controller by measuring thevoltage and current. Check this against the pump chart for your specific application.2. If the power is correct for your pump model and array size then make sure the pumpwires are connected to the proper terminals. If two wires are reversed the motor willbe running in reverse. It may still pump but not at the full rated output.3. If the wires are correct verify that your system does not have any leaks where watercan be lost. If you cannot determine the problem, contact Sun Pumps for furtherassistance.PUMP DRAWS EXCESSIVE CURRENT (More than the rating of the pump, but lessthan the rating of the controller)1. Check wiring diagram for proper connection.2. Check for skinned wires or faulty underwater splice.3. Check for locked motor armature. With the pump out of the well, remove the pumpend from the motor (if this is not feasible skip this step and contact Sun Pumps).Allow the controller to attempt to start the motor. If the motor still does not run,contact Sun Pumps for further assistance.4.1 BEFORE CALLING SUNPUMPSIf at all possible when calling Sun Pumps for technical support there are a few thingswhich will help to speed up the process and help us determine the cause of and solutionto the system failure. The best way to get help is to call while you are physically at thelocation of your pump, have good sunlight, and have a multimeter and a screwdriver withyou.Furthermore, please fill out the form below before calling. This information will provideus with most of the preliminary information we need to help you. If you cannotphysically be at the site, filling out the worksheet is a must.Pump Model Number: ____________________Pump Serial Number: ____________________Motor Serial Number: ____________________Controller Model Number: ____________________Software Version ____________________Date Purchased: ____________________Solar Module Specifications:Model Number ____________________Rated Watts ____________________Voc ____________________Vmp ____________________Isc ____________________Imp ____________________Solar Modules Connected in Series _________ X Voc _______ = _________ Array VocSolar Modules Connected in Series _________ X Vmp _______ = _________ ArrayVmpSeries Strings Connected in Parallel_________ X Isc _________= _________ Array IscSeries Strings Connected in Parallel_________ X Imp _________= _________ ArrayImpWell Specifications:Well Depth ____________________Well Diameter ____________________Static Water Level ____________________Pumping Level ____________________Pump Setting ____________________5.0 Technical SpecificationsModel Max Input Voltage Max PowerPCA-60BLS-M2 100 840PCA-120BLS-M2 200 1000Maximum ambient temperature is 120 F.Controller Dimensions and WeightWidth Height Length WeightModel Inches cm Inches cm Inches cm Pounds kgPCA-60BLS-M2 6.3 16.1 4.2 10.7 7.7 19.5 4.2 1.9PCA-120BLS-M2 6.3 16.1 4.2 10.7 7.7 19.5 4.2 1.9For future reference, please list your system data before installing the pump.Installation Date______________________ Static Water Level_______________________Pump Model_________________________ Pumping Level_________________________Pump Serial No.______________________ Additional Vertical Lift___________________Controller Model_____________________ Pump Depth___________________________Controller Serial No.___________________ Total Dynamic Head____________________Warranty Card No.____________________ Well Depth___________________________Warranty StatementPCA Series Pump ControllersLimited Warranty – Twenty-Four MonthsSunPumps warrants to the original consumer that its products shall be free from defects inmaterial and workmanship under normal applications and service conditions for a period oftwelve (24) months after the original date of purchase, but not to exceed eighteen (30) monthsfrom the date of manufacture.At its option, SunPumps will repair or replace any SunPumps product, which has failed due toa defect in material or workmanship during this warranty period. A PCA series controllermust be installed in conjunction with the pump to validate the warranty. This limited warrantyshall not apply if the SunPumps product has been damaged by unreasonable use, accident,negligence, mishandling, misapplication, alteration, modification, abrasion (sand damage topump), shipping, service or modification by anyone (other than by SunPumps), or failurewhich are caused by products not manufactured by SunPumps, or should the products serialnumber being altered, or by damage that is attributable to an act of God, or by any othercauses unrelated to defective materials or workmanship. Any disassembly whatsoever of theproduct voids all warranty.The original purchaser MUST complete and send in the warranty registration card, with thepump serial number and the controller serial number for warranty validation. No warrantyperformance will be rendered without a valid warranty card on file at the SunPumpsfactory.There are no express warranties except as listed above. SunPumps shall have noresponsibility for damage to property, persons, animals, or other loss or injury resulting fromthe use of a SunPumps product. The purchaser’s exclusive remedy shall be only as statedherein. This warranty is in lieu of all other warranties expressed or implied.Except for the warranty that the products are made in accordance with the specificationstherefore supplied or agreed to by customer, SunPumps makes no warranty expressed orimplied, and any implied warranty of merchantability or fitness for a particular purpose whichexceeds the forging warranty is hereby disclaimed by SunPumps and excluded from anyagreement made by acceptance of any order pursuant to this quotation.UNDER NO CIRCUMSTANCES WILL SUNPUMPS BE LIABLE FOR ANYCONSEQUENTIAL OR INCIDENTAL DAMAGES, LOSS OR EXPENSE ARISING INCONNECTION WITH THE USE OF OR THE INABILITY TO USE ITS GOODS FOR ANYPURPOSE WHATSOEVER. ALL PRODUCTS ARE SOLD AS IS WITH ALL FAULTS.SUNPUMPS MAXIMUM LIABILITY SHALL NOT IN ANY CASE EXCEED THEPURCHASE PRICE FOR THE GOODS CLAIMED TO BE DEFECTIVE OR UNSUITABLE.SunPumps is not responsible for labor, transportation, and related costs incurred by thecustomer to make allegedly defective equipment available to the factory for inspection re-installation, lost profits or costs caused by interruption of service. SunPumps is notresponsible for loss or damage to products, owned by customer and located on SunPumpspremises, caused by fire or other casualties beyond SunPumps control.This equipment is not to be used for anything other than the purpose stated in this manual.