Sun Pumps PCC-BT-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 any potential shading of the solar electric 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 the output of the entire array and thus reduce or completely stop the
output of the pump. There is no substitute for a good plan!
The PCC–BT series controller can either be mounted indoors or outdoors. Locate all system equipment as
close as possible to each other. For top of pole mount racks, the controller is usually mounted on the north
side (shaded side) of the mounting pole. The controller must be mounted in a vertical position for proper
cooling and to keep the electronics dry. The pole should be located close to the pump installation. 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 solar modules. Wire sized too small will cause a decreased output
from the pump. Keep the distance from the solar modules 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 wire splice be made correctly.
This splice must be watertight if it is to be submerged. Improper sealing of the splice will cause
poor pump performance and may cause damage to the system. Wire splicing must be done in
accordance to local, state and national electrical codes. A submersible 3 wire splice kit is
recommended for watertight connections.
3. Never install the controller in direct sunlight. Direct sunlight on the controller may cause over-
heating of or damage to 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. A convenient place to mount the
controller is on the north side (shaded side) of the solar module array.
5. The controller should be grounded to the pump motor housing, the frame of the solar modules
and to an 8-foot ground rod. The cemented support structure pole will not provide an adequate
ground. Do not ground the positive or negative electrical wires. Always use a DC
surge/lightning arrestor on the panel side of the controller. (Midnight Solar MN-SPD surge
arrestor is recommended)
6. Do not ground the array 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 1). 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. Install a disconnect
switch between the solar modules and the controller.