Sun Pumps PCA-30M1D - Manual (Page 7)

3.4 Pump Installation
1. The well should be clean and disinfected before the pump is installed. You should always clean and
develop a new 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. And will
aide in any troubleshooting which may be necessary.
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 shaded side of
the solar module rack mounting pole is usually a convenient place.
5. Install the poly male adapter, supplied with the pump, into the pump discharge head. Consult your pump
supplier for other available adapter materials. Do not use galvanized connections with 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. For poly pipe,
compression fittings are recommended.
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. If the drop cable does
not have the same color wires as the pump, be sure 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. Now connect the
safety rope to the I-bolt located on the top of the pump.
7. You can now lower the pump into the well. Set the pump at least 10’ off the bottom (see 3.2 System
Design Basics #4). Never rest the pump on the bottom of the well. Never lower the pump by the
submersible pump cable.
8. Attach the drop pipe, drop cable and safety rope together every ten feet with 2” 10 mil PVC pipe wrap
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, if used, to the eye-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.
3.5 Wiring
Prior to connecting any wires to the controller, be sure you have a system wiring diagram to use as a reference
(see figure 2). 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. Wire gauge being too small will cause excessive voltage
losses to the motor and will reduce the flow rate of the pump.
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 a non-opaque material before wiring. Or you can install a disconnect switch or a
circuit breaker between the solar modules and the controller so you are not wiring hot. However a
disconnect switch is not absolutely necessary for these low power applications. You can cover the solar
modules or disconnect one of the MC connectors, if available, until you finish wiring.