Sun Pumps PCC-BT-M2 - Manual (Page 13)

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 30 volts. Less
than 30 volts at the input terminals and the unit may show no signs of operation. If you do have at least
30 volts in the right polarity, contact Sun Pumps for further assistance.
2. If the expected voltage is not present, disconnect the panels 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 not blown fuses and no tripped breakers, check the open circuit voltage of your array. If
the open circuit voltage is not correct trouble shoot the array to find the problem. If the open circuit
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 second LED is labeled “Run”. This indicates the pump is running. If it is on, listen for the sound
of the motor. Check for breaks in the pipe. If you cannot find a problem call Sun Pumps for further
assistance.
3. Check the fourth LED, labeled “RS Stop”; this is the remote switch shutdown indicator. If it is on, the
remote circuit is preventing the controller from running the pump. Set the #1 and #2 dip switches to
off and disconnect any remote switches. If the pump starts, troubleshoot the remote switches
individually. If the pump does not start and the LED is still lit, call Sun Pumps for further assistance.
4. Check the fifth LED, labeled “Low Power”; this is the low power shutdown indicator. If it is on, the
controller detected a low power condition. The low power shut down is a common occurrence on days
when clouds which block the sun are momentarily present. First check the input voltage to the
controller. This will be shown on the LCD screen and is labeled DCBUS. Verify that this exceeds 30
volts. If it does not meet or exceed the minimum voltage, you do not have enough power to start your
pump.
Note: To accurately trouble shoot this feature there should be absolutely no clouds blocking
the sun at any time during the following tests. If you have enough input voltage, turn the controller off
then on again to reset this fault. If the low power condition still exists then the controller will start but
shut down again. Verify power using the LCD screen. Wait for the screen to cycle to the power
reading and turn on dip switch # 9. Note the number underneath the “LP” on the display. Cycle the
pump off then on and watch the power reading. If the power reading goes higher than the LP set point,
the controller is shutting down due to low output current or voltage condition. If the number is not
higher than the set point, skip to step 5. Check to verify the pump is not running out of water. If your
pump is not running out of water, call Sun Pumps for further assistance.
5. Verify the current setting of dip switches 3, 4, 5 and 6 are correct. Only one should be on for normal
operation and should coincide with the current rating on your motor. You should reduce the LP Adj
trim pot to the minimum by turning it counter clockwise until it stops. Restart the controller by cycling
the On/Off switch. If the controller again shuts down in low power, call Sun Pumps for further
assistance.