Attachment B - TPP+BP Combined Solar - User Manual.pdf

RPS Solar Pumps Tankless Pressure™ & Eco-Steady Booster™

530-240-3825Videos & FAQs RPSsolarpumps.com/help Call or Text: 530-240-3825 Email: service@ruralpowersystems.com

RPS Solar Pumps 40250 County Road 27 Woodland CA 95776

Copyright © 2023.3 Rural Power Systems Inc. All rights reserved.

The contents of this manual may not be reproduced, distributed, sold, or used in any manner whatsoever without the express written permission of Rural Power Systems Inc.

1 RPSsolarpumps.com/help | Call or Text: 530-240-3825 | service@ruralpowersystems.com

RPS Solar Pumps (“RPS Products”) come with an easy to install Do-It-Yourself (“DIY”) kit intended for the consumer to install themselves or with the help of others. THE RISK OF

INJURY AND ELECTRIC SHOCK EXISTS AND COULD RESULT IN SERIOUS BODILY

INJURY OR DEATH. You are the best judge of your own capacity and qualifications to determine whether you can install the RPS Products or if you require assistance.

Only qualified persons should install the products. Turn off power before installing.

By purchasing an RPS Product, you acknowledge the potential risks and agree to assume all such risks of injury, including death.

In some cases, you may decide to hire a professional to complete some or all of the installation. Whether self-installed or professionally installed, RPS Solar Pumps is unable to guarantee or offer any compensation for troubleshooting, replacing parts, pulling pumps or anything else involved in the troubleshooting/ replacement process, regardless of the reason for the warranty claim.

But never fear, RPS Solar Pumps has tens of thousands of customers across the USA who have successfully installed and, in those rare cases, troubleshoot their system with the help of our dedicated RPS Solar Pumps support engineers!

Solar panels and batteries can produce a significant amount of energy, which can cause electric shock. Please exercise caution when installing your well pump and follow the step-by-step instructions in this manual for your safety. Whenever you’re working with electrical wiring or connections, make sure:

• power is set to OFF, other power sources are disconnected

• to remove exposed jewelry or other metallic items

• to ground the system for safety and to prevent damage to equipment

LIMITATION OF LIABILITY

TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT

SHALL RPS SOLAR PUMPS BE LIABLE FOR ANY CONSEQUENTIAL, INDIRECT,

INCIDENTAL, SPECIAL, EXEMPLARY, PUNITIVE, OR ENHANCED DAMAGES, LOST

PROFITS OR REVENUES OR DIMINUTION IN VALUE, ARISING OUT OF, OR

RELATING TO, AND/OR IN CONNECTION WITH ANY BREACH OF THIS AGREEMENT,

REGARDLESS OF (A) WHETHER SUCH DAMAGES WERE FORESEEABLE, (B)

WHETHER OR NOT RPS SOLAR PUMPS WAS ADVISED OF THE POSSIBILITY OF

SUCH DAMAGES, (C) THE LEGAL OR EQUITABLE THEORY (CONTRACT, TORT OR

OTHERWISE) UPON WHICH THE CLAIM IS BASED, AND (D) THE FAILURE OF ANY

AGREED OR OTHER REMEDY OF ITS ESSENTIAL PURPOSE.

IN NO EVENT SHALL RPS SOLAR PUMPS’ AGGREGATE LIABILITY ARISING OUT OF

OR RELATED TO THIS AGREEMENT OF THE RPS PRODUCTS, EXCEED THE TOTAL

OF THE AMOUNTS PAID TO RPS SOLAR PUMPS FOR THE PRODUCTS PURCHASED

BY CUSTOMER.

USER MANUAL

● Ground the system before turning on. Improper grounding may cause shock, burns, damage to property or death

● Abide by local electrical and building codes or ordinances when installing. Follow the National Electrical Code (NEC) and Canadian Electrical Code as required.

● Do not use motor in swimming areas without proper grounding

● Disconnect power to the pump system before installing or performing service

● Do not overpressurize pump system components like the pressure tank or piping. Overpressurizing may result in a serious risk of injury

● Ensure that the electrical supply voltage matches the equipment specifications

● Only use this pump with clear water free of excess sediments. Fine gravel and precipitates from TDS levels exceeding 2000ppm may affect operation

● Install a disconnect switch where required by code

● If powering the pump with a generator you should use a manual or automatic transfer switch. Failure to do so may result in injury.

WARNING

TABLE OF CONTENTS

This manual will...

Answer your questions before you have them!

Enable you to have the tools and equipment you need on the day of installation to help everything proceed quickly and enjoyably

Ensure that you install safely and avoid any damage to your equipment

Make sure you don’t miss anything with highlighted KEY STEPS sections

Give you a resource for troubleshooting in the field, even without cell reception

As always, we are here to help if you still have questions after working through the manual:

Support@ruralpowersystems.com

Text Or Call 530.240.3825

System Components………………………………………………….5 Installation Details..…………………………………………..………7 Plumbing Options………………………………………………………9 Which Pump Do I Have……………………………………..………11 Priming Your Pump………….………………………………………..19 Mounting Your Solar Panels……………………………………..22 Wiring Your Solar Panels……..…………………….……………..23 Battery Wiring…….……………………………...……………………..25 Controller Overview…………………………………..………………27 Pump Operation…………………………………………..…………….34 Winterization…………..……………………….…………..……………38 Controller Troubleshooting………………………………..…….39 Pump Troubleshooting.……………………………………………..40 Support……………………………………………………………………….41 Warranty………………………………………………….…………………42

Did you purchase just the pump? No solar panels, batteries or Controller for now?

You can skip all pages from Mounting Your Solar Panels (pg 22) to Controller Overview (pg 27) along with Controller Troubleshooting (pg 38).

TABLE OF CONTENTS

SYSTEM COMPONENTS

1. PUMP — Your system will come with one of our seven pressure pumps. This pump is designed to produce the required pressure when called for. Make sure to remove the orange cap before proceeding with plumbing. *Appearance Varies **BP3 will include a teal-colored tank

2. SOLAR CONTROLLER — This large sturdy Controller is the brains of the system. It arrives pre-programmed for your pressure pump.

The pump Controller is not waterproof so protecting it from direct sun and weather is required.

3. SOLAR PANELS — Our monocrystalline solar panels have been designed for the optimal voltage of your Controller. Sturdy aluminum frames are designed to clamp to any mounting material of your choice.

4. BATTERIES — Your battery bank consists of either GEL or AGM batteries, 55ah or 160 ah. They come with cables to connect to each other and to the provided battery breaker. Batteries should be stored in a dry location protected from the elements. Keep them out of freezing conditions for maximum performance.

5. SOLAR CONNECTOR WIRES — Two 20’ lengths of solar wire can help provide the extra length needed to connect your solar panels to your Controller with MC4 connectors, making your panel wiring safe and easy. Y-connectors are included in case you need to do any parallel connections with the panels.

6. DC BREAKER -100A or 300A DC Breaker comes included for connection between batteries and Controller. They come with wires to connect to your battery bank and Controller.

1. Find a suitable install location for pump that is protected from the elements (small well or pump house is a good idea), no more than 20 feet from your storage tank/body of water location. If you’re in a frost/ freeze location, ensure that there is proper insulation in the pump house, especially for the 2HP and 3HP models as the inlet face plates are susceptible to cracking if frozen. Ideally, the pump inlet is located as close as possible to the storage tank.

2. Install Solar Panels

3. Install Batteries

4. Connect Solar Panels and Batteries to the Controller

5. Plumb Inlet

6. Plumb Outlet

7. Prime Pump

8. Once you have your pump primed and connected to power, your pump will automatically turn on!

9. Set Pressure by pushing the plus and/or minus, make sure shut off valves are open if you plan on turning on and immediately testing!

10. Allow the pump to run for a bit, check for leaks in plumbing connections and re-seal as needed

11. You’re all set!

QUICK INSTALL CHECKLIST

INSTALLATION DETAILS

Ensure there are no shadows or other obstructions on the solar panels. While shadowing a small corner of a single panel may not seem like a big deal, since the panels are connected in series, a small shadow can limit the power output from all other panels connected in series! This means a small shadow on a single panel could reduce system power by hundreds of watts. Time to get out that chainsaw and trim some trees!

TPP and BP PUMP CONTROLLER — Your Controller is not waterproof and should be located in a dry dust-free location, protected from the sun, freezing temps, the elements and pests such as mice and bugs. Mice love to chew wires and spiders and moths will build nests wherever they can find room. While we understand you cannot eliminate all pests, it might be time to spray some insecticides around your shed and set some mousetraps! There is nothing worse than finding insulation chewed off your electrical wires. *The fan remains running in low power mode at most times to protect the equipment. This fan uses very little power and increases the lifetime of the system.

TPP and BP PUMP - Your pump is designed for use out of the direct elements: sun, rain and snow.

Covering or building a small enclosure around it off the ground is ideal. Since water does expand when it freezes, care should be taken to winterize the system if being used in a climate that experiences hard freezing. If a foot valve is being used, care should be taken in plumbing the intake to ensure tight connections to avoid the loss of prime.

BATTERIES - Unless you already bought a Pressure Pump system that included the appropriate number of RPS 55Ah 12V Deep Cycle GEL batteries, customers will need to supply their own battery bank. RPS recommends 12V AGM / sealed lead acid batteries that are designed for maintenance free operation. More common flooded deep cycle marine or RV batteries can also be used. Batteries should be stored in a dry location protected from the elements.They operate best at room temperature and it is best to keep them out of freezing conditions for maximum performance.

RPS SOLAR PANELS — Solar panels should be mounted on a secure structure. Several ideas can be found at www.RPSSolarPumps.com. Panels should face true South and at an angle appropriate for your latitude. If you are mounting your panels on an already built structure, try to get as close to the correct angle as possible.

http://www.rpssolarpumps.com

With the RPS Tankless Pressure Pump™ or Eco-Steady Booster Pump™ system, you'll get smooth continuous steady reliable water pressure without the need for AC power or the utility grid.

The solar charged battery bank powers your centrifugal booster pump through your Controller.

The pump varies its speed and power based on your demand for water at the exact pressure you set. Quick Connect MC4 clips and 20’ of solar wire allow for the connection of your solar array to your Controller

Pre-attached (+) and (-) wires connect the Controller to your 24V or 48v* battery bank (required to operate)

Once the pump is ready for power and primed with water, the pump’s 3-prong male plug can be inserted directly into the outlet of the Controller.

(Optional) 110v or 220V* power from a generator or the grid can supplement solar in charging the battery bank.

*Your pump may look different and require different power depending on the model!

PLUMBING OPTIONS

Your pressure pump can plumb directly from your storage tank to your main line, no more than 20 ft. The pump will auto-adjust speed to maintain pressure.

* Important: Care should be taken when plumbing to ensure tight connections and maintain prime. We recommend teflon tape and/or pipe DOPE on all connections. Using pipe cement can make it difficult to access the plumbing. . Minor leaks or seepage will cause the pump to cycle and deplete the batteries.

You can also draw water up from a pond, shallow well or cistern (up to 15ft) but you must maintain prime with a foot-valve and tight connections. The foot valve should placed in the body of water the pump is drawing from.

Remember to remove the orange cap on the outlet before plumbing.

No more than 15 ft of lift overall

There are a variety of ways to plumb Pressure Pumps, here’s an example of what you could use.

When plumbing into the inlet of the pump, use a MNPT threaded bushing. A bushing makes it easier if the pump is needed to be worked on down the line. There are bushings with threads on the inside, and other without threads: either type of bushing works and you can adapt the plumbing to what's available locally! Threaded PVC fittings are tighter and will be less likely to leak air or water. For PVC, use minimum Schedule 40 rating.

Install a shut off valve (ball valve, hose bib etc) close to the storage tank. This will allow you to shut off incoming water and troubleshoot the pump if necessary.

For the outlet side, plumb a threaded nipple to the outlet. Within a few feet of the outlet we recommend installing a second shut off valve, that way you can control flow for troubleshooting if needed, or for emergencies.

NOTE: Do not install any sudden rises (like a small hump or hill) near the inlet or outlet, as the shape will cause the pump’s pressure sensor to malfunction and may cause surging or low pressure. If suctioning from a body of water, no more than one elbow on the inlet side is recommended and you MUST use a foot valve to maintain prime.

Straight piping from tank to pump without elbow bends is recommended. If elbow bends are necessary on the inlet side, we don’t recommend using more than two elbows due to positive pressure loss.

BALL VALVE BUSHING

THREADED NIPPLE

ELBOW

WHICH PUMP DO I HAVE?

Pressure Pump

Color Max Pressure

Suggested

GPM

Inlet Size (inches)

Outlet Size (inches)

Controller Battery Bank

TP-750 40psi 15-25 1.25” FNPT 1” FNPT VC3.22 24v

TP-HP 55psi 5-20 1” FNPT 1” FNPT VC3.22 24v

BP05 30psi 5-15 1” FNPT 1” FNPT VC3.11 24v

BP1 40psi 15-25 1.25” FNPT 1” FNPT VC3.11 24v

BP1-HP 55psi 5-20 1” FNPT 1” FNPT VC3.11 24v

BP2 60psi 10-30 1.25” FNPT 1” FNPT VC5.22 48v

BP3 70psi 20-50 1.5” FNPT 1.5” FNPT VC5.22 48v

We have a total of 7 different pressure pumps each with their own characteristics, shown below in the table. Each pump has an assigned color, which will show up in the top right corner throughout this manual. Once you know which color matches your pump, keep an eye out for any pages with that color as it will pertain to your setup.

Eco-Steady Booster

Pump

BP05

High Pressure EcoSteady

Booster Pump

BP1-HP

High Pressure Tankless Pressure

Pump

TPP-HP

EcoSteady Booster Pump

BP1

Original Tankless Pressure

Pump

TP750

Eco-Steady Booster

Pump

BP2

Eco-Steady Booster

Pump

BP3

Max Pressure

30psi 55psi 55psi 40psi 40psi 60psi 70psi

Volume 5-15 GPM 5-20 GPM 5-20 GPM 15-25 GPM 15-25 GPM 10-30 GPM 20-50 GPM

Pump Inlet

(FNPT)

1” 1” 1” 1-¼” 1-¼” 1-¼” 1-1/2”

Pump Outlet

(FNPT)

1” 1” 1” 1” 1” 1” 1-1/2”

Horse-power at

Max Power 0.5hp 1hp 1hp 1hp 1hp 2hp 3hp

Solar Power

Train™ Model

Controller

VC3.11

Or

V35C.11.48V

VC3.11

Or

V35C.11.48V

VC3.22

VC3.11

Or

V35C.11.48V

VC3.22 VC5.22 VC5.22

Input Voltage

(optional)

110V- 120V

110V- 120V

220V- 240V

110V- 120V

220V- 240V

220V- 240V

220V- 240V

Battery Bank

Voltage

24V Or

48V

24V Or

48V 24V

24V Or

48V 24V 48V 48V

MODEL DETAILS

4 Controllers

VC3.11

V35C.11.48V

VC3.22

VC5.22

7 Pumps B05

BP1-HP

BP1

TPP

TPP-HP

BP2

BP3

Inlet

Outlet

Inlet 1.25" FNPT

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50 - 113°F

Max Liquid Temp 60°C, 140°F

Power Range 750 - 1300w

Suction Up to 4M, 15ft (wetted)

Max Current 8 Amps

Pump Dims Box Size

12in x 8in x 10in 16in x 10in x 13in

Weight 8.6kg, 19lbs

TPP-750 PUMP SPECS

Inlet 1" FNPT

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50- 113°F

Max Liquid Temp 60°C, 140°F

Power Range 750 - 1300w

Suction Up to 4M, 15ft (wetted)

Max Current 8 Amps

Pump Dims.

Box Size

15in x 8in x 11in 19in x 10in x 13in

Weight 9.5kg, 21lbs

TP-HP PUMP SPECS

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50 - 113°F

Max Liquid Temp 60°C, 140°F

Power Range 350-750W

Suction Up to 4M, 15ft (wetted)

Max Current 6 Amps

Pump Dims Box Size

13in x 6in x 11in 16in x 10in x 13in

Weight 8.2kg, 18bs

BP05 PUMP SPECS

BP1 PUMP SPECS

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50 - 113°F

Max Liquid Temp 60°C, 140°F

Power Range 750 - 1500w

Suction Up to 4M, 15ft (wetted)

Max Current 12 Amps

Pump Dims Box Size

12.5in x 6.5in x 11.5in 16in x 10in x 13in

BP-HP PUMP SPECS

Inlet 1" FNPT Power Range 750 - 1500w

Outlet 1" FNPT Suction Up to 4M, 15ft (wetted)

Acceptable pH 5 - 8, Water (No Fuel) Max Current 8 Amps

Temp. Range 0 - 40°C, 32 - 104°F Pump Dimensions Box Size

17in x 9in x 11in 19in x 11in x 13in

Max Liquid Temp 90°C, 194°F Weight 10kg, 22lbs

TPP-HP / BP1 PUMP SPECS

TP-750 SPECS

Inlet 1.25" FNPT Power Range 750 - 1500w

Outlet 1" FNPT Suction Up to 4M, 15ft (wetted)

Acceptable pH 5 - 8, Water (No Fuel) Max Current 8 Amps

Temp. Range 0 - 40°C, 32 - 104°F Pump Dimensions Box Size

14in x 12in x 9in 15in x 13in x 11in

Max Liquid Temp 90°C, 194°F Weight 10kg, 22lbs

Inlet 1" FNPT

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50 - 113°F

Max Liquid Temp 60°C, 140°F

Power Range 750-1500W

Suction Up to 4M, 15ft (wetted)

Max Current 8 Amps

Pump Dims Box Size

16in x 6in x 11in 18in x 13in x 16in

Inlet 1.25" FNPT

Outlet 1" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 10 - 40°C, 50 - 113°F

Max Liquid Temp 60°C, 140°F

Power Range 1200 - 2000w

Suction Up to 4M, 15ft (wetted)

Max Current 12 Amps

Pump Dimensions Box Size

14in x 6in x 11in 17in x 10in x 13in

Weight 11kg, 24lbs

BP2 PUMP SPECS

BP3 PUMP SPECS

Inlet 1.5" FNPT

Outlet 1.5" FNPT

Acceptable pH 5 - 8, Water (No Fuel)

Temp. Range 0 - 40°C, 32 - 104°F

Max Liquid Temp 60°C, 140°F

Power Range 1500-3000 w

Suction Up to 4M, 15ft (wetted)

Max Current 16 Amps

Pump Dimensions Box Size

16in x 9in x 10in 24n x 18in x 10in

Weight 19kg, 42 lbs

PRIMING YOUR PUMP

TPP-750, BP1 and BP2 Priming

Priming your pressure pump is essential before operation. If you have access to 110vac or 220vac, you can test the pump before hooking up the panels, batteries, and Controller- just be sure to prime it first. Otherwise, prime the pump after hooking everything up to the Controller except for the pump.

TP-HP, BP-05, and BP-HP Priming

Priming your pressure pump is essential before operation! If you have access to 110vac or 220vac, you can test the pump before hooking up the panels, batteries, and Controller - just be sure to prime it first. Otherwise, prime the pump after hooking everything up to the Controller except for the pump.

ASSEMBLY

**With stainless steel connections, we recommend Thread Sealant and large wrenches.

1) Thread your Tee with Pressure Sensor to the upper outlet of the pump chamber using ample pipe dope/thread sealant.

2) On the left and right sides of the Tee are two openings for small fittings. On one side goes the closed fitting. On the other side you remove the sensor from the small metal fitting, screw the fitting tight, and then reattach the sensor plug to the pump control panel interface.

3) The top of the tee is where the tank will go.

Spin on the tank until tight using ample pipe dope/thread sealant.

4) The tank is assembled and ready for you to add your inlet and outlet connections.

Remember to use adequate pipe dope to ensure a tight, leak proof connection between fittings.

PRIMING

1. Loosen Priming Screw.

2. Create positive pressure in supply line to push water into pump inlet or fill line with water.

3. Once air is completely purged, power on the pump to purge air completely before fully tightening Priming Screw again

4. Adjust Pressure Setting with controls. Pump will adjust speed and smoothly cycle on & off to maintain desired setting.

MOUNTING YOUR SOLAR PANELS

Solar panels should be mounted on a secure structure. Several ideas can be found at RPSsolarpumps.com/mounting

Panels should face true South and at an angle appropriate for your latitude. If you are mounting your panels on an already built structure, try to get as close to the correct angle as possible.

Ensure there are no shadows or other obstructions on the solar panels. While shadowing a small corner of a single panel may not seem like a big deal, since the panels are connected in series, a small shadow can limit the power output from all other panels connected in series! This means a small shadow on a single panel could reduce system power by hundreds of watts. Time to get out that chainsaw and trim some trees!

Scan here to use our tilt angle calculator tool!

If you’re not using steel as part of your mounting, ground those panels! You can wrap some copper through the frame holes of the panels.

TP/BP 4

TP/BP 8

WIRING YOUR SOLAR PANELS

TP/BP 12

Connect the panels in series and parallel based on the diagrams below. Link your solar panels together and connect to the Controller by clipping MC4 connectors from the panels together with the MC4 connectors coming off the controller. Each MC4 connector is either a male end or female end. They simply snap together to make safe and easy connections.

Note: If using your own solar panels do not exceed 90Voc input! Ask an RPS Engineer how to wire if you’re unsure!

Second Note: If you have the BP2 or BP3, refer to the next page!

WIRING YOUR SOLAR PANELS

Your BP2 or BP3 pump may have come with 100w panels or with 370w panels. With either type of panel, connect them in series as shown in the diagrams below. Link your solar panels together and connect to the Controller by clipping MC4 connectors from the panels together with the MC4 connectors coming off the controller. Each MC4 connector is either a male end or female end. They simply snap together to make safe and easy connections.

Note: If using your own solar panels, do not exceed 500Voc input! Ask an RPS Engineer how to wire if you’re unsure!

BATTERY WIRING 24V ONLY

RPS recommends AGM / sealed lead acid batteries that are designed for several maintenance-free years of operation. They should also be stored in a dry location protected from the elements. The batteries operate best at room temperature and it is best to keep them out of freezing conditions for maximum performance. To prevent significant voltage drop, the batteries should be located as close to the Controller as possible. Within 3 feet is ideal. If further than 3ft is required, the wires may be extended using appropriate gauge cables.

For a 24v battery bank, refer to the diagram below to know how many series and parallel connections are needed. Most common is two 12V batteries in series, rest in parallel.

Note: Do not exceed two 12V batteries in series or four 6V batteries in series. For extra battery capacity, add sets in parallel.

In a series connection, batteries are connected side by side, with the positive terminal of one battery connected to the negative of another battery.This increases the voltage of the battery bank.

In a parallel configuration, batteries are connected side by side, with the positive terminals connected to each other and the negative terminals likewise.

BATTERY WIRING 48V ONLY

RPS recommends AGM / sealed lead acid batteries that are designed for several maintenance-free years of operation. They should also be stored in a dry location protected from the elements. The batteries operate best at room temperature and it is best to keep them out of freezing conditions for maximum performance. To prevent significant voltage drop, the batteries should be located as close to the Controller as possible. Within 3 feet is ideal. If further than 3ft is required, the wires may be extended using appropriate gauge cables.

For a 48v battery bank, refer to the diagram below to know how many series and parallel connections are needed. Most common is four 12V batteries in series, rest in parallel.

Note: Do not exceed four 12V batteries in series or eight 6V batteries in series. For extra battery capacity add sets in parallel.

4 Batteries 3 Series Jumpers

8 Batteries 6 Series Jumpers 2 Parallel Jumpers

12 Batteries 9 Series Jumpers 4 Parallel Jumpers

In a parallel configuration, batteries are connected side by side, with the positive terminals connected to each other and the negative terminals likewise.

In a series connection, batteries are connected side by side, with the positive terminal of one battery connected to the negative of another battery.This increases the voltage of the battery bank.

Controller Overview

Controller Model

Battery Bank Needed

PV Array (Solar Panel)

AC Input (optional*)

Which Pump?

VC3.11 24v Less than 90voc 110v

VC3.22 24v Less than 90voc 240v

VC5.22 48v Less than 500voc 240v

Now that solar panels and batteries are set up, it’s time to connect them to the Controller! The model of pressure pump you have determines which model of Controller came with it. Knowing which model you have will help you know how to wire your batteries and solar panels, as well as what kind of backup power it can take.

Your Controller is designed to take solar power and charge your 24v or 48v battery bank. As an optional backup, it is also set-up to accept 110V AC or 220V AC, depending on the model, to both charge your batteries and run your pump directly if desired. AC input can be wired directly into the screw terminals of your Controller, by removing the front cover plate.If your Controller demands 220, you will wire your second Active (L) line into the terminal labeled Neutral (N). You will not use your Neutral wire - only three wires will be used so you can wire out the neutral. Wiring 110v or 220v is only for certified professionals or those familiar with 220v power.

*110V AC or 220V AC INPUT (BACKUP)

Wiring Your Controller

Optional:You can wire in AC here to help charge the batteries.

Wiring shown in previous page.

*The larger model known as the VC5 has the on/off switch and grounding screw on the left side.

The plug to connect to your pump is located here.

The wires from your solar panels will connect to the wires coming out of here

This ON/OFF switch controls when the Controller can output power, meaning lights can still show even if turned off - it just won’t output any power so the pump won’t turn on .

The battery cables from your battery bank will connect to wires coming out of here

A dedicated grounding screw for the Controller.

VC3 Series Solar Power Train™

Compatible Pump VC3.11 - BP05, BP1, BP-HP

VC3.22 - TP-750, TP-HP

Battery Voltage 24 VDC or 48 VDC

Battery Wiring 8AWG or Thicker

Dimensions 15in x 11in x 4in 381mm x 280mm x 102mm

Temp. Range 0 - 40°C, 32 - 104°F

OPTIONAL

AC INPUT

VC3.11 - 110 VAC

VC3.22 - 220 VAC

Weight 13.7bs

Recommended Clearance

Mount with 8 inches of space in all directions

Input Voltage DC 90 VOC

VC5 Series Solar Power Train™

Compatible Pump BP2, BP3

Battery Voltage 48 VDC

Battery Wiring 8AWG or Thicker

Dimensions 16in x 13in x 5in 407mm*321mm*126mm

Temp. Range 0 - 40°C, 32 - 104°F

OPTIONAL AC INPUT 220 VAC Only

Weight 24lbs

Recommended Clearance

Mount with 8 inches of space in all directions

Input Voltage DC 500 VOC

Specs of the Controller can be found on a gray sticker located on the right side.

CONTROLLER DISPLAY

Now that panels and batteries are connected, the display on the top right part of the Controller will turn on. The factory settings of the Controller accommodate almost every install scenario of a Pressure Pump. RPS Engineers recommend leaving them at their default settings to ensure proper operation.

Lights Colors Description

AC/INV Yellow Flashing - AC power is being outputted Steady - only seen in bypass battery mode (AC power is the only input)

CHARGE Green Steady light - charging of batteries completed Flashing -batteries are charging

FAULT Red Steady light - Fault has been detected

These lights can be on even if Controller’s power switch is turned off. Display will go dark after standing by for some time. Press the up or down button for the screen to come back on.

Buttons Description

SET Enter/Exit Settings

UP Previous Choice

DOWN Next Choice

ENT Confirm/Enter Options under current settings menu

ICON BREAKDOWN

ICON BREAKDOWN CONTINUED

As the system operates, you will see multiple data points flash on the screen.

You can press the up and down buttons to scroll through all these to view real time data.

PUMP OPERATION

Your pump will be set to Booster Down/Normal Mode on startup. Press Mode to change if needed.

BOOSTER DOWN/NORMAL:

Used for setups where there is positive pressure aka water is being pushed into the pump.

BOOSTER UP/BOOST:

Used for setups where water is being pulled into the pump aka suction rod into a tank/pond with a foot valve.

FILLING THE TANK/TIMER:

Operates the pump for the specified amount of time and then stops the pump. Most often used for irrigation and filling tanks. Has to be set each day.

Pump Screen can go into standby mode. Press a button or tap on screen to illuminate.

Note: Pump shutoff will become unstable if pressure is set too high. If pump will not shut-off, reduce pressure setting.

Once you have your pump primed and connected to power, it will automatically turn on! Depending on the model, your pump will either have a LED touch screen or physical buttons to press. (The BP3 looks slightly different from both, check pg 36 for that)

A number will appear on the screen - this is the pressure your pump is currently set to (Set pressure). If set to anything other than 0, the pump will start to pressurize and the number on the screen will change to the working pressure. The set pressure can be increased with the (+) button, and can be decreased with the (-) button which will change working pressure accordingly.

Note: the pressure unit is 1 kg/cm² or 1 BAR which is equal to 14.5 psi so change accordingly.

Ex) Setting the pump to 3.0 BAR would mean 3.0 x 14.5 = 43.5 PSI

BUTTONS BREAKDOWN

Button Function Button Function

Selects the working mode;

selects time intervals

Illuminated when power is on

The different modes the pump can operate; the selected mode will be illuminated

Solid: pump is running and working pressure = set pressure Flashing: pump is running but working pressure ≠ set pressure Light off: pump is not running

If Filling the Tank is selected mode, press to select the time interval the pump will run each day.

For Filling the Tank Mode, these are the possible intervals to select.

Light on: selected run time Light off: not in this mode

Press to set and adjust working pressure of pump.

Can also lock/unlock the screen by pressing both at the same time.

Illuminated when pump detects no water running through. Pump will shut off and will restart automatically with proper water supply. Can also show as EMPTY.

Press to manually turn pump on and off.

Abnormal behavior detected; code will appear on display

Enter setting menu and select settings (rarely used)

Illuminated when leak in outlet pipe is detected

BP3 PUMP OPERATION

Once you have your pump primed and connected to power, it will automatically turn on!

A number will appear on the screen. This is the pressure your pump is currently set to (Set pressure). If set to anything other than 0, the pump will start to pressurize and the number on the screen will change to the working pressure.

The set pressure can be increased with the (+) button, and can be decreased with the (-) button which will change working pressure accordingly.

You can manually turn the pump on and off with the middle power button.

BUTTON

MODE Select desired working mode SETTINGS Enter setting menu (not advisable)

TOGGLE View real time pumping data

1) kg/cm^2 = pressure setting

2) m = meters of head

3) r/min = rotations per minute

4) kw = kilowatts, power consumption

OVERRIDE RPM based control/bypass the transducer sensor. PSI setting will turn pump to max speed. Recommended only in case of sensor failure while waiting for a replacement part.

LIGHTS

BOOSTING Illuminates depending on selected mode

TIME Illuminated when running pump at intervals is selected mode of operation

RUN Solid: pump is running and working pressure = set pressure Flashing: pump is running but working pressure ≠ set pressure Light off: pump is not running

MULTI-P Multi-pump. Used exclusively in situations that call for multiple, parallel pumps to achieve higher volumes . Very rare, call RPS for help if you plan on using this feature!

POWER Illuminated when power is on WATER

LESS

Illuminated when pump detects no water running through. Pump will shut off and will restart automatically with proper water supply.

EMERGENCY Abnormal behavior detected;

code will appear on display

Winter Operation If you don’t plan on using the system during the winter season, there are some tips to follow. Your surface pump should be unplumbed, unplugged, and stored in a dry environment much like your Controller and batteries. As for the solar panels, you are able to leave them in place, preferably covered. If you have an adjustable mount, tilt the panels to achieve a steeper angle so snow doesn’t collect on the panels. If not, and you get heavy snowfall, you will want to clear off excess snow from the panels from time to time.

If you’re using the system during the winter, there aren’t many changes to be made. If you’re able to change the tilt angle of your solar panels, change it to a more optimal angle for winter. Make sure the plumbing is kept insulated to prevent freezing. The Controller and batteries should already be in a dry environment but it might be a good idea to add some insulation to add extra protection from cold temperatures. With wintertime, batteries may take a little longer to recharge due to there being less sun - for those urgent moments of operation, you can hook up 110/220 VAC to the Controller or directly to your pump!

CONTROLLER TROUBLESHOOTING

Your Controller is not waterproof and should be located in a dry dust-free location, protected from the sun and the elements and pests such as mice, moths and bugs.

*The fan remains running in low power mode at most times to protect the equipment. This fan uses very little power and when running, increases the lifetime of the system.

If the fault light is turned on, there should be a 2 digit number showing in the top-center of your screen.

Below are some common alarms and how to proceed. For those rare instances where a code not listed below comes up or if the error still persists, give a RPS Engineer a call/text at 530-240-3825!

VOLTAGE CHECK

Take a DC Voltage Reading of each battery. Battery voltages range from 11.5VDC (dangerously low) to 14.4VDC (fully charged) depending on the state of charge. Low voltages? Charge for 8 hours in full sun.

SOFT RESET

Press and Release Power Switch. Turn back on after 60 seconds.

HARD RESET

Disconnect Batteries and Solar Panels for 60 seconds. Reconnect.

01,04 Battery Undervoltage

Controller is detecting not enough voltage from battery bank to operate. Make sure wiring matches requirement of Controller (24v or 48v). Allow time for batteries to recharge and have Controller power switch set to off so no output is being generated.

06 Battery OverVoltage Controller is detecting higher voltage from battery bank than needed. Make sure wiring matches requirement of Controller (24v or 48v).

Battery not connected

Make sure wiring matches requirement of Controller (24v or 48v). Do a voltage check of batteries. Check if battery breaker has tripped.

PV OverVoltage

Check DC voltage of solar panels, make sure VDC is not higher than Controller requirements (pg 27)

Fan Failure

Check if the fan is not turning or if it’s blocked by foreign object.

PUMP TROUBLESHOOTING

No Lights On Pump Low or no power To pump

Check Connections, Soft Reset of Controller, Check batteries for low voltage

Pump Doesn’t Start Pipe is blocked Ensure valves are open to clear airlocks

Pump Doesn’t Stop Leak Light is on

Check for leaks, Turn down pressure

Small leaks in plumbing are the most common, check around outlet cover, Turn down pressure setting

Pump Sputters Pump not properly primed or air entering system

Prime pump and remove all air from system, check inlet pipes for leaks, Install foot valve for suction applications

Settings may have been changed Reset to factory defaults Press and hold “MODE” for three seconds

E01 Low input voltage Check input voltage, Check battery voltage

E02 Over voltage input Ensure input voltage is less than 280V AC

E03 Pressure sensor error Hard Reset, Replace pressure sensor

E04 Pump over temperature Remove pump from direct sun, Improve ventilation

E05 Pump Overload Ensure water is fairly clear (no mud or large debris)

E06 Display over temperature or sensor failure

Remove from direct sun, Improve ventilation, Hard reset, Contact RPS

E07 Not Used n/a, Hard Reset

E08, E09 Motor phase mismatch, Over current

Motor not operating at commanded speed, check for obstructions, check for stuck impellers

E10 Startup fault Hard Reset, Contact RPS to check for impeller obstructions

E11 Motor communication error Check for damage to motor wires, Hard Reset, Contact RPS

E12 Not used n/a, Hard Reset

E13 Display communication error Hard Reset, Contact RPS

Hard Reset Unplug pump, wait 60 seconds, plug pump back in.

The pressure pumps have their own set of faults that can appear on the screen and will always start with the letter E.

Run Light is Flashing:

pump is running but working pressure ≠ set pressure

SUPPORT

Need additional help getting your system running?

We’re here to help!

If you're having issues getting your system operating we have videos on each section of the setup. Find us at youtube.com/rpssolarpumps

NEW

Text our Engineers!

We’re committed to making sure you get water. Our Engineers are standing by to help with any issues.

Call or TEXT (questions, notes, observations & photos encouraged!)

530–240–3825

SYSTEM WARRANTY

Product Warranty: 2-Year System Warranty Rural Power Systems Inc. (RPS Solar Pumps) warrants to the owner for a period of twenty-four (24) months from the date of purchase (“Warranty Period”) such RPS Products will be free from material defects in material and workmanship. During the Warranty Period, RPS Solar Pumps will repair or replace any defective part(s) at no cost to the owner.

During the Warranty Period, in the event of a malfunction, the purchaser must return the defective product to receive a replacement. The warranty is limited to the repair or replacement of the defective product purchased from RPS Solar Pumps. YOUR USE OF THE SERVICES AND RPS PRODUCTS IS AT YOUR OWN RISK. RPS SOLAR PUMPS DISCLAIMS ALL WARRANTIES UNLESS EXPRESSLY PROVIDED IN THESE TERMS, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY, NON-INFRINGEMENT, AND FITNESS FOR A PARTICULAR PURPOSE. The above remedies shall be the sole and exclusive remedies and RPS Solar Pumps’ sole liability for any breach of the limited warranty set forth above.

This warranty does not apply when the RPS Product has not been installed according to the instructions or damage has occurred through abuse, carelessness, negligence, improper installation, connecting to an improper voltage (most commonly, connecting too many panels in series for your controller) or degraded wells. Your warranty is linked to your product’s serial number, which is on record at RPS Solar Pumps. RPS Solar Pumps will quote all replacements not covered by warranty or outside the warranty period.

For a complete list of other available warranties and guarantees visit: www.rpssolarpumps.com/terms/

RETURNS AND REFUNDS

Return Policy: 30 days Customer shall inspect the RPS Product within 30 days of receipt and will be deemed to have accepted the RPS Product unless you notify RPS Solar Pumps of your intent to return the product. You may return the RPS Products purchased, for any reason, for a full refund up to thirty (30) days after the date of purchase. The RPS Products must be unused, in new condition, and you must pay the return shipping or return the product to RPS Solar Pumps in person. For your convenience, we are happy to email printable return shipping labels and deduct the cost (often a discounted rate vs. the retail store rate) from your refund amount.

After 30 days and up to sixty (60) days after purchase, a full refund is not available, but transferrable store credit is available for returned product. We do not accept returns past 60 days and are unavailable to offer refunds;

however, your product warranty is transferable in event the system is sold during the Warranty Period.

NOTES

RPS Solar Pumps 40250 County Rd 27 Woodland CA 95776

530-240-3825 Call or Text