Sun Pumps PCC-48BLS-M2 - Manual (Page 5)

3.1 Location
As the majority of system installations vary greatly, only general comments can be made about the installation
location. Prior to installing the system, it is suggested to make a system layout plan. During the system layout, take
into consideration physical battery bank size, wire runs, wire size, conduit runs, trenching, controller accessibility,
tank location, pump head etc. There is no substitute for a good plan!
The PCC-series controller can either be mounted indoors or outdoors. Locate all system equipment as close as
possible to each other. The controller is not designed for use in direct sunlight and should be mounted in a shaded
location. The controller must be mounted in a vertical position for proper cooling and to keep the electronics dry.
This general physical layout is conducive to clean installation both aesthetically and electrically.
3.2 Installation 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 battery bank. Wire sized too small will cause a decreased output from the pump. Keep
the distance from the batteries 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%.
2. 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 submersible 4 wire splice kit is recommended for this watertight
connection.
3. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-heating of
the controller.
4. 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.
5. The controller should be grounded to the pump motor housing, the frame of any conductive battery box
and to an 8-foot ground rod. Use only a copper lug to attach the ground wire. The Ant thing which is
cemented in the ground will not provide an adequate ground. SunPumps recommends that you always
use a DC surge/lightning arrestor on the battery side of the controller. (Midnight Solar MN-SPD surge
arrestor is recommended)
6. Do not ground the battery positive or negative electrical wires.
3.3 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. Also be certain that you have the right type of wire for your usage. Any wires
which will be in water must be rated for such an application. SunPumps recommends using stranded wire for all DC
applications.
All other system equipment should be installed before proceeding to wire the controller. Double check polarity and wire
termination tightness before powering up the system.
CAUTION: Batteries are capable of large amounts of current. Install a fused disconnect or circuit breaker
between the batteries and the controller of the pump. Maximum fuse/breaker rating is 50 amps. If using
photovoltaic panels to charge the batteries, remember that they produce DC electricity when exposed to sunlight.
Install a disconnect switch between the solar modules and the charge controller.