SOLARJACK PCA 10-30A - REV 0297 User manual

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PCA 10-30A
SDS SUBMERISIBLE
PUMP CONTROLLER
USER’S MANUAL

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OPERATION AND INSTALLATION
MANUAL FOR THE
PCA10-30A
SOLAR ELECTRIC PUMP CONTROLLER
MANUFACTURED BY:
GOLDEN GENESIS CO
SOLARJACK
7812 E. Acoma Dr.
SCOTTSDALE, ARIZONA 85260
UNITED STATES OF AMERICA
PHONE # [phone]
FAX # [phone]
DC# 5223-0001-A
REV 0297
For controllers with serial numbers 18057 and above
Table of Contents
1.0 Introduction
2.0 Product Overview
2.1 Features
2.2 Application
3.0 Installation and Operation
3.1 Location
3.2 Wiring
3.3 Water Sensors
3.4 Adjustment Procedures
4.0 Troubleshooting
5.0 Technical Specifications
6.0 Warranty Statement

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1.0 Introduction
Thank you for selecting the PCA10-30 pump controller. The PCA series of pump controllers are a
high quality, solid state DC power converters designed as the interface between a Solarjack SDS
series pump and a DC power source. The purpose of the controller is to maximize the total daily
water output while providing protection for the pump and the DC power source aswell as providing
interface with other related pumping system equipment. Although the PCA series pump controllers
are easy to use, please read this manual to become familiar with the controller features, functions,
connection points and various configurations. For future reference, keep this manual and other
relevant product information in a safe place.
PRECAUTIONS
• Safety First - Always understand what you are doing when working with any form of electricity.
Guessing at something is not worth the potential of product damage and/or severe personalinjury.
• Shut down all power when working on the system.
• Do not attempt to feed live wires into the PCA or product damage and/or personnel injury may
result.
• Do not exceed the power rating of the controller.
• Do not splash water on the controller when the cover is open.
• When working with batteries, be careful not to short the battery terminals, as thousands of
amperes can flow. Remove all jewelry, use insulated tools and secure all conductors.
• Batteries can produce explosive hydrogen gas. Be sure battery housing is well ventilated.
2.0 Product Overview
The PCA series of controllers are designed to operate with a variety of DC power sources.
Typically these include solar electric modules, wind generators and batteries, or any combination
of the three. When properlyinstalled and configured, the unique features incorporated into thisline
of controllers will automatically control and protect your pump system permitting several years of
dependable, trouble free service.
When used in a solar electric panel direct system or a wind generator direct system, the PCA
series of controllers will provide pump protection from over-voltage and over-current conditions as
well as current boosting in low sunlight conditions or low wind conditions respectively.
In a battery powered system, the PCA series controllers are not to be used as a solar electric
charge regulator between the solar electric panel and the battery bank. However, the PCA
controllers feature a Low Voltage Cut-off function when used on battery-sourced systems. This
feature will prevent excessive battery discharge conditions thereby helping to extend the battery
bank life. In addition, the PCA controllers will provide a degree of protection for your charge
regulator by attenuating inductive voltage spikes generated when pump motors switch on or off.

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2.1 Features
1. Current boosting for matching the load requirements of the pump motor.
2. Voltage regulation of the solar electric array at its maximum power point.
3. Low Voltage Cut-off function for battery-sourced installations.
4. Over-current protection via integrated automatic resetting electronic circuit breaker.
5. Reverse polarity protection (10 amperes maximum).
6. Voltage and current limiting to pump motor.
7. Transient protection and surge suppression.
8. Adjustable pump motor voltage setting for precision system tuning.
9. Adjustable input voltage (solar and wind) for system optimization.
10. System ON/OFF switch.
11. LED indicators - Red = power in, Green = power out, Yellow = over current shutdown.
12. Weather resistant cast aluminum enclosure with hinged door and strain relief connectors.
13. Rising clamp screw terminal blocks - no fork terminals required.
14. User selectable pre-adjusted input voltage configuration and power source selection.
15. Remote switch interface - float switch or remote shutdown - N.O. or N.C. user selectable.
16. Water level electrode interface - user selectable high or low water level cut-off.
17. 2 year limited warranty
2.2 Application
The only application the PCA series of standard controllers are designed to operate on is the
interface between the Solarjack SDS series of pumps and the DC power source as well as
peripheral pump system signal devices. The PCA series controllers are capable of operating with
a variety of DC inputs, including solar electric modules, wind generators and batteries or any
combination of the three. Of these, solar electric modules are the most common.
No other applications or DC power sources are recommended or warranted unless written
approval is provided by Solarjack management.
3.0 Installation and Operation
The following sections are outlined in a step by step format to guide you through the installation,
configuration and system power-up of the PCA series controllers. Read all product manuals and
review all system components to gain physical and electrical familiarity before undertaking the
installation effort. Check all equipment for any product damage. Refer to applicable figure(s) as a
guide during the installation.
The PCA series controllers are limited to a maximum power output of 300 watts, which is 30 volts
at 10 amps. Providing more power to the input of the controller will not increase pump flow rate.
WARNING
Reverse polarity on a battery sourced system or a panel system capable of producing
over 10 amps will result in non-warranted product damage.
NEC compliance and local electrical inspectors

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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.

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Remote Switch
The Remote Switch interface can serve as an automaticsystem shutdown when used with a water
storage tank mounted float switch. It can also serve as a manual system shutdown with a remote
system ON/OFF toggle switch. The majority of installations will use this port for float switch
interface. Both applications are configured and operate the same way. Please refer to the
following operational scenarios for configuration options.
With switch number 5 in the OFF position, the controller is configured to accommodate a Normally
Open (N.O.) float switch or remote toggle switch. In this configuration the controller will operate as
follows:
PUMP ON
float switch open = water tank low = pump ON
PUMP OFF
float switch closed = water tank high = pump OFF
With switch number 5 in the ON position, the controller is configured to accommodate a Normally
Closed (N.C.) float switch or remote toggle switch. In this configuration the
controller will operate as follows:
PUMP ON
float switch closed = water tank low = pump ON
PUMP OFF
float switch open = water tank high = pump OFF
Water Level Electrodes
The water level electrodes interface serve as an automatic system shutdown when properly
installed and configured. The PCA series of controllers are capable of two configurations; high or
low level shutdown. The high level shutdown is typically used to interface with a water storage
tank to achieve the same system control results as a float switch. The low-level shutdown is
intended to monitor the well water level and shutdown the system if the water level in the well
drops to a critical point.
To use this interface, three E-1s brass electrodes must be used. One is for the ground (reference)
, the second is for the low-level point and the third is for the high level point. Please refer to the
system wiring diagrams and the following operation scenarios for configuration options.
With switch number 6 in the OFF position, the controller is configured to interface with electrode
water level sensors for a water level HIGH pump shutdown and a LOW water level pump
activation.
PUMP ON
low and high level electrode exposed = water tank low = pump ON
PUMP OFF
low and high level electrode submerged = water tank high = pump OFF

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With switch number 6 in the ON position, the controller is configured to interface with
electrode water level sensors for a water level LOW pump shutdown and a HIGH water level
pump activation.
PUMP ON
low and high level electrode submerged = well water level ok = pump ON
PUMP OFF
low and high level electrode exposed = well water level critical = pump OFF
3.4 Adjustment Procedures
The PCA series controllers have several adjustment features. Some are system configuration
adjustments are user selectable by a six positions DIP switch located on the face of the controller.
These include pre-adjusted DC source selection, remote switch selection and water level cut-off.
The remaining adjustments are for input and output voltage fine-tuning that are independently
adjustable by high precision multiple turn (brass screw) trimmers.
The pre-adjusted DC source selection allows the user to choose the nominal input voltage and
basic source configuration. These consist of four pre-adjusted voltage settings consisting of solar
panel or battery in nominal 12 volt or 24-volt sources. The first four switches on the DIP switch are
used for this selection. For proper controller operation, only one of these first four switches should
be in the ON position. Please refer to the chart below for the switch position identification and
setting options.
Switch No. Description Setpoint Note
1 12 V. Battery 11.80 V. 1
2 12 V. Panel 13.10 V. 2
3 24 V. Battery 23.60 V. 1
4 24 V. Panel 26.00 V. 2
5 Remote
Switch
HI/LO 3
6 Remote
Switch
HI/LO 4
NOTES:
1. Set-point is Low Voltage Cut-off. The controller will turn off the pump if the battery voltage drops
below set-point preventing excessive battery discharge conditions thereby helping to extend
battery life.
2. Set-point is solar module input constant voltage hold approximately at solar modules maximum
power point. These voltages will work with most standard solar modules available in the
marketplace today. The voltage can be easily adjusted to optimize system performance, see
procedure above. Use the “Panel” selection options when a non regulated wind generator is
utilized as the power source.
3. With switch number 5 in the OFF position, the controller is configured to accommodate a
Normally Open (N.O.) float switch; float switch open = water tank low = pump water or float switch
closed = water tank high = shut off pump. With switch number 5 in the ON position, the controller

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is configured to accommodate a Normally Closed (N.C.) float switch; float switch closed = water
tank low = pump water or float switch open = water tank high = shut off pump.
4. With switch number 6 in the OFF position, the controller is configured to interface with
electrode water level sensors for a water level HIGHpump shutdown and a LOW water level pump
activation. With switch number 6 in the ON position, the controller is configured to interface with
electrode water level sensors for a water level LOW pump shutdown and a HIGH water level pump
activation.
The input and output voltage set-points are calibrated at the factory and typically will not require
end user adjustment for proper system operation. However, if system “fine tuning” is desired for
optimal performance, please refer to the adjustment procedures below.
INPUT VOLTAGE ADJUSTMENT
The purpose of this procedure is to adjust the voltage of the solar electric panel to its peak power
point and thus obtain maximum water delivery from the system. In a solar electric application, this
procedure should be performed with the solar electric panel at its normal operating temperature at
mid-day to match as close as possible the worst case maximum voltage operating point. On a
battery source system, it is not recommended to adjust the input voltage set-point.
1. With the system installed, controller properly configured and pumping water, turn the solar
electric panel away from the sun until the pump flow rate is reduced by approximately 50%. If this
is not possible then shade the panels slightly until the same results are obtained.
2. Connect an accurate DC volt meter to the pump side of the controller (L+ and L-).
3. Slowly turn the “Panel Input Voltage” trimmer located on the face of the controller until the
highest possible output voltage is obtained.
4. Return the solar electric panel(s) to their normal or unshaded position. The pump will then
operate at its maximum output.
NOTE: Counter Clockwise lowers input voltage and Clockwise increases input voltage.
OUTPUT VOLTAGE ADJUSTMENT
The purpose of this procedure is to adjust the output voltage of the controller to reduce the water
flow of the pump. Typically this not recommended as the PCA controllers are factory calibrated for
optimum voltage output for the SDS series of pumps.
A common case scenario as to when the controller might be readjusted for a lower voltage output
would be an installation where the static water level drops rapidly when the pump system is
performing at its peak, thus turning off the pump system. The low water level electrode located in
the well would detect this low water level. The well could take a long time recharge to a water level
high enough (as detected by the high water level electrode located in the well) to reactive the
pumping process. This scenario could cause the pump system to cycle on and off unnecessarily
through out the day and possibly reduce system water production as compared with the following
solution. The solution in this case would be to reduce the controller output voltage to the pump,
thereby reducing water flow to a level where the well can maintain the water level above the low

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water level electrode. This allows a longer pumping duration at a lower rate and probably higher
net water production per day.
1. With the system installed, controller properly configured and pumping water, connect an
accurate DC volt meter to the pump side of the controller (L+ and L-).
2. Slowly turn the “Output Voltage” trimmerlocated on the face of the controlleruntil desired output
voltage and water production is achieved. This process will probably take a few attempts to
“balance” the system for optimum water production.
NOTE: Counter Clockwise lowers input voltage and Clockwise increases input voltage.

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4.0 Troubleshooting
PUMP DOES NOT RUN
1. Check wiring diagram for proper connections. Confirm all electrical terminations are tight and
secure.
2. Check for proper voltage selector switch settings for your DC source input. If the incoming
voltage is less than the set-point voltage, the controller will not turn on.
3. On battery sources systems, make sure the batteries are at a full state of charge and that the
controller voltage selector switch is in the proper position for your nominal voltage input
configuration.
4. Check for proper controller input and output with a volt meter. A quick look at
the LED indicator lights will verify power coming from the DC source supply
going to the controller (red), power going from the controller to the pump
(green) and overcurrent shut down (yellow). If the red LED is on and the
green and yellow LED’s are not, make sure the system on/off switch is on, disconnect the remote
switch and electrode wires, if used, and turn switch #5 and #6 off. If the green LED is still not on,
disconnect the pump wires, L-and L+. If the green light does not turn on then check voltage on L-
and L+ with a volt meter to confirm no output voltage. THEN WHAT?
5. For additional pump test, connect a jumper wire across terminals PV- and
L-. This will bypass the controller and allow the pump to run directly from
the DC source. This step will confirm pump operation. If the DC source is a
solar array, the test must be conducted when full sunlight is available for a valid test.
RED AND GREEN LEDS ARE ON, YELLOW LED IS OFF AND THE PUMP
DOES NOT RUN
To verify power coming out of the controller, connect a DC voltmeter across L+
and L-. If 12 Volts or more is coming out then:
1. Check the splice above the pump for proper connections.
2. Check for broken wire leading to the pump.
Check for open motor winding. With an ohmmeter set on the R x 1 scale, check
between the two pump lead wires. The meter reading should be between .5 to
50 ohms. If the resistance is higher than this, disconnect the pump at the
splice above the pump and check again.
NO VOLTAGE AT THE L+ AND L- TERMINALS
Note: To bypass all remote switching circuits, disconnect all wires from the sensor interface
terminal block in the controller housing (the small terminal block) and switch program switches #5
and #6 to the OFF position.
1. Make sure the system ON/OFF switch is ON.
2. Check to see if the water level is above the top electrode when low water cut-off circuit is being
used.
3. Check to see if the float switch, if used, is functioning properly.
4. Check the controller for proper programming and adjustment. If the voltage setting on the
controller is higher than the incoming voltage, the controller will not turn on, (See controller
adjustment section)

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Make sure the Yellow LED (over-current shut down) is not on. If it is, switch OFF the system
ON/OFF switch, wait a minute and then switch it ON.
EXCESSIVE CURRENT DRAW (More than the rating of the pump, but less than
the rating of the controller)
1. Check wiring diagram for proper connection.
2. Check for skinned wires or faulty underwater splice.
3. Check for locked motor armature. With the pump out of the well, bypass the controller and
connect power directly to the motor leads. If the pump still does not run and the current is over
1.5 amps, the pump is in a locked rotor condition and just be repaired.
5.0 Technical Specifications

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PCA 10-30A Controllers
LIMITED WARRANTY – TWENTY-FOUR MONTHS
SOLARJACK warrants the product to be free from defects in materials and
workmanship under normal applications and service conditions for twenty-four
(24) months from date of sale to the original purchaser, but not to exceed (30)
months from the date of manufacture. SOLARJACK will, at its option, either
repair or replace the product if it fails due to a defect in material or
workmanship during the period of this warranty.
This warranty is extended only to the original purchaser. A completed warranty
card with the pump serial number and the controller serial number must be on
file at the factory to validate the warranty. No warranty performances will he
rendered without a valid warranty card on file at the SOLARJACK factory.
This warranty only covers failures due to defects in materials or workmanship
that occur during normal use. It does not cover damage which occurs in
shipment, or failures which are caused by products not supplied by SOLARJACK or
failures which result from accident, misuse, abuse, neglect, mishandling,
misapplication, alteration, modification or repairs by anyone other than
SOLARJACK, or damage that is attributable to acts of God. Any disassembly
whatsoever of the product voids all warranty.
Warranty limitations
There are no express warranties except as listed above. SOLARJACK shall have no
responsibility for damage to property, persons, animals, or other loss or
injury resulting from the use of this product.
UNDER NO CIRCUMDSTANCES WILL SOLARJACK BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGE, UNLESS OTHERWISE EXPRRESSLY STATED HEREIN. ALL PRODUCTS
ARE SOLD AS IS WITH ALL FAULTS.
Any warranties are limited to the warranty period described above. SOLARJACK’S
maximum liability under any warranty, expressed, or implied, or statutory, is
limited to the purchase price of the product. The purchaser's exclusive remedy
shall be only as stated herein. This warranty is in lieu of all other
warranties expressed or implied. This warranty gives you specific rights; your
state law may provide for additional rights or may affect the time and other
limitations set forth herein.
This Warranty Excludes: Labor, transportation and related costs incurred by the
consumer to make the allegedly defective equipment available to the factory for
inspection, re-installation, costs caused by interruption of service, or lost
profits.
If a problem with the product develops during the warranty period, you may
contact your dealer. If the problem is not handled to your satisfaction,
contact:
Kyocera Solar, Inc. / SOLARJACK, 7812 E. Acoma Drive, Scottsdale, AZ 85260
Telephone [phone] FAX [phone]
E-mail [email protected]
www.kyocerasolar.com