Sun Pumps PCC-48BLS-M2 - Manual (Page 14)

4.0 Troubleshooting
Sun Pumps, Inc. is dedicated to its customers and will gladly help you trouble shoot any problems with your system.
However, especially during the busy summer pumping season, we may not be able to help you right away. Using
this trouble shooting guide as your first resource when your system is not working properly can save you valuable
time in getting your system fully functional. If at any time however, you are not comfortable performing any of
these tasks, or do not fully understand the system, it is better to call than to guess. Before calling please go
through the section below labeled “Before Calling Sun Pumps” and complete the steps there.
CONTROLLER DOES NOT TURN ON
1. 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 is correct. If it is not on, verify that the controller is
properly wired, including polarity, and that the input terminals have at least 35 volts. Less than 35 volts at the
input terminals and the unit may show no signs of operation. If you do have at least 35 volts in the right
polarity, contact Sun Pumps for further assistance.
2. If the expected voltage is not present, disconnect the battery bank from the controller using the disconnect, and
check any fuses and breakers in the system. Replace blown fuses and reset tripped breakers.
3. If there are no blown fuses and no tripped breakers, check the voltage of your battery bank. If the battery bank
voltage is not correct troubleshoot it to find the problem. Double check all of the terminal connections for
integrity. If the battery bank voltage is correct, call Sun Pumps for further assistance.
CONTROLLER TURNS ON BUT PUMP DOES NOT RUN
1. Make sure the On/Off switch is in the up position. (On)
2. The third LED is labeled “Battery Ready”. This light must be on for the controller to start the pump. If this
light is off, it is generally caused by insufficient input voltage or if the sufficient voltage timer has not recorded
enough time at the sufficient voltage to run. If the Low Voltage LED is lit, the 30 seconds of sufficient voltage,
49 V, has not been achieved. If both the Low Voltage and Over Current LED are lit it indicates a Dead Battery
Condition. Then a 30 second timer of sufficient voltage, 49 V, must timeout as well. Cycle the on/off switch.
This will bypass the timers and reset the dead battery condition. If 49 volts or more are present, the Battery
Ready light should light and the pump will start. If the Battery Ready light does not turn on, check the input
power. This may be done on the display screen, input voltage is labeled “DC BUS”. If it is below 49 volts you
must charge your batteries or use the Input Voltage Threshold Adjustment procedure under Controller Settings
in this manual. If the voltage is above 49 V and the “Battery Ready” light does not turn on or the pump does
not run, check the other lights for errors. If the voltage is higher than 64 V, your batteries are over charged and
the controller will not attempt to start the pump. Discharge your batteries until the bank reads less than 64 V. If
you cannot find any problems contact Sun Pumps for further assistance.
3. The second LED is labeled “Run”. This indicates the pump is running. If it is on, check the power reading on
the LCD screen of the controller. If it is greater than 50 watts, go to the pump and check for the sound of the
motor. Check for breaks in the pipe. If you cannot find a problem call Sun Pumps for further assistance.
4. Check the fourth LED, labeled “RS Stop”; this is the remote switch shutdown indicator. If it is on, the remote
circuit or low water cutoff circuit is preventing the controller from running the pump. Check the display to see
if the controller has shut down for a Remote Switch error or Low Water error. Set the #1 and #2 dip switches to
off and disconnect the remote switch and low water cutoff depending on the error displayed on the screen.
Cycle the on/off switch. If the pump starts, troubleshoot the remote switch or low water cutoff accordingly. If
the pump does not start and the LED is still lit, call Sun Pumps for further assistance.
5. If the sixth LED, labeled “Over Current” is on, the controller has exceeded its current limit and shut down.
Turning the controller off then on again will reset this fault. If the controller continues to need high current, it
will turn itself off again. Check the pump for a short to ground using an ohm meter and call Sun Pumps for
further assistance.
6. If the seventh LED, labeled “Fault Condition”, is on, this indicates a motor or ground fault fuse error. Check the
controller display for the type of fault. Check motor wiring and connections. If the screen displays “GF FUSE
OPEN” the ground fault fuse has been blown. Check your system for ground loops and replace the fuse with a
500 VDC 1A rated fuse. If this does not solve the issue, contact Sun Pumps for further assistance.