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3.1 Location
As the majority of system installations vary greatly, only general comments can be made as
to 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 and etc.. There is no substitute for a good plan!
The PCA series controllers can either be mounted indoors or outdoors. Locate all system
equipment as close as possible to each other. Generally the controller is mounted to the
side of a pole which has solar electric modules or wind generator mounted atop of it. The
pole is the located a few feet from the well head. This general physical layout is
conducive to clean installation, not only aesthetically, but also electrically.
3.2 Wiring
Prior to connecting any wires to the controller be sure you have a system wiring diagram to
use as a reference. Generic system wiring diagrams are included in this manual for your
convenience. Guessing at polarity and connection points is not worth the risk of potential
product damage and/or personal injury. Furthermore, ensure the wire sizes are of adequate
diameter (gauge) to minimize voltage drop.
All other system equipment should be installed before proceeding with wiring the controller.
Pre-configure the controller switches prior to wiring. Refer to “Adjustment Procedures” for
details. double check polarity and wire termination tightness before powering up the
system.
1. Turn “ON/OFF” switch to the OFF position.
2. Connect ground rod conductor to controller chassis ground block.
3. Connect frame ground conductor to controller chassis ground block.
4. Connect pump ground conductor to controller chassis ground block.
5. Connect pump motor negative (-) conductor to controller terminal labeled “L-”.
6. Connect pump motor positive (+) conductor to controller terminal labeled “L+”.
7. Connect DC source supply negative (-) conductor to controller terminal labeled “PV -”.
8. Connect DC source supply positive (+) conductor to controller terminal labeled “PV +”.
9. Refer to the next section for “Water Sensors and Remote Control” connections and
“Adjustment Procedures” for configuration (if applicable) and then return to this point.
10. At this point, all system components are installed and wired, double check conductor polarities,
wire termination tightness and controller configuration.
11. Turn “ON/OFF” switch to the ON position. The system should be operational. If the system is
not working refer to the “Troubleshooting” section.
3.3 Water Sensors and Remote Control
The PCA series controllers feature remote peripheral interface functions with easy programming.
These include two independent ports. First is a remote switch interface which supports float
switches (storage tank level) or a remote system “ON/OFF” toggle switch. The second peripheral
is a water level electrode interface that requires three E-1s brass electrodes. Refer to sample
system wiring diagrams as a guide during hook-up.
