SOLARJACK PCB-90 User manual

PCB-90
DC SUBMERISIBLE
PUMP CONTROLLER
USER’S MANUAL

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PCB-90C SERIES
SOLARJACK'S HIGH VOLTAGE PC SERIES PUMP CONTROLLERS
SOLARJACK’S PC series controllers are state-of-the-art solid state power
converters designed as an interface between a SOLARJACK pump and the DC power
source. The purpose of this controller is to maximize the total daily water
output while providing protection for the pump as well as the power source.
The unique features incorporated in this controller will protect the pump system
insuring many years of dependable, trouble free service. When used in a solar
panel direct system it provides protection for the pump from over-voltage and
over-current conditions and will provide current boosting in low sunlight
conditions.
PCB-90 SPECIFICATIONS 1 HP
Input Voltage 45-130V (Open Circuit)
(Six Panels in Series Max)
Maximum Output Current 10 AMPS
Maximum Surge Current 16 AMPS
Maximum Output Power 900 Watts (90V @ 10A)
FEATURES
1.) Current Boosting for matching the load requirements of the pump.
2.) Voltage Regulation of the PV array around its maximum power point.
3.) Built in controller protection:
A. Output current limiting
B. Voltage surge protection
4.) Voltage output adjustment (Optional)
5.) Remote float switch circuit
6.) Low water cut-off circuit with adjustable set points
7.) High water cut-off circuit with adjustable set points
8.) Electrode logic reversal switch
Remote switch logic reversal switch
9.) Power in indicator light (Red),
Power out indicator light (Green)
Remote switch / electrode turn off indicator light (Amber)
10.) Fuse protection on the output
11.) Weather-tight enclosure

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WIRING THE PCB-90 SERIES CONTROLLER
The PCB-90 Series controllers are limited to a maximum of six 17 volt panels
connected in series for the 90 volt systems. However, more panels may be
connected in parallel.
This controller has a 4 position preset input voltage selector switch designed
for various solar module arrangements. Please refer to the selection chart for
the switch position for your system.
CAUTION- Only one of the 4 preset switches should in the on position at one
time. These preset voltage settings will work with the majority of the standard
solar modules on the market. If you need to change the voltage set point the
"panel voltage adjusting pot" will allow you to do so. (Refer to the controller
adjusting procedures). CAUTION If you change the voltage setting using the
adjusting pot, it will change the set points on all 4 selector switches. It is
highly recommended you do not adjust this pot.
SELECTOR SWITCH SETTINGS
Switch Used For
1 Electrode Logic off for High Water Cut-off
On for Low Water Cut-off
2 Remote Switch Logic Off-Make Contact for Turn-off
On-Break Contact for Turn-off
Switch Used For No. Series Modules Set Point
3 45 Volt Panel Direct 3 41 Volts
4 60 Volt Panel Direct 4 55 Volts
5 75 Volt Panel Direct 5 68 Volts
6 90 Volt Panel Direct 6 82 Volts
LARGE WIRE TERMINAL BLOCK
1 PV- NEGATIVE WIRE from the PV array.
2 LD- NEGATIVE WIRE to the pump or load
3 LD+ POSITIVE WIRE to the pump or load.
4 PV+ POSITIVE WIRE from the PV array.
SMALL WIRE TERMINAL BLOCK
5 LO LOW WATER ELECTRODE
6 HI HIGH WATER ELECTRODE
7 GRD/RS LOW WATER GROUND AND REMOTE SWITCH GROUND REMOTE ON-OFF
CIRCUIT is used to turn the pump on and off from a remote
location.
8 RS REMOTE SWITCH
ELECTRODE CIRCUIT
Switch # 1 on the dip-switch is the electrode logic circuit. This circuit was
designed for use with three electrodes; a high-water, a low-water and a ground
electrode.
With switch #1 in the ON position it becomes a low water cut-off circuit (well).
This keeps the pump from running dry in a low yield well. The electrodes are

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generally attached to the drop pipe above the pump in a well. When the water in
the well draws down below the high water electrode it does nothing. As it
drops below the low water electrode it turns the pump off. As the water raises
again and passes the low water electrode it stays off. When it reaches the high
water electrode it turns the pump on again. This differential keeps the pump
from rapid cycling.
It is recommended that the ground electrode be placed 2 inches above the pump,
the low water electrode be placed 2 inches above the ground electrode and the
high water electrode be placed from 2 to 5 feet above the low water electrode
depending upon the desired draw down.
As a general rule it is recommended that the low water electrode circuit be used
only when absolutely necessary. About 70% of the LWC systems work flawlessly and
30% seem to have problems. Water with a high mineral content has a tendency to
build up mineral deposits on the electrodes causing false triggering. Cascading
well water may create a current path between electrodes causing the pump to stay
running in low water conditions. Please be advised that this circuit does not
work in all situations.
With switch #1 in the OFF position it becomes a high water cut-off circuit (tank
fill). This keeps a storage tank from over-flowing. The electrodes are generally
taped together -and dropped into a tank. A small pipe or rod can be installed in
the tank and the electrodes can then be taped to the pipe or rod.
When the water in the well draws down below the high water electrode it does
nothing. As it drops below the low water electrode it turns the pump on. As the
water raises again and passes the low water electrode it stays on. When it
reaches the high water electrode it turns the pump off again.
It is recommended that the ground electrode be placed 2 inches above bottom of
the tank or the ground wire can be attached to the tank if the tank is metal.
The low water electrode should be placed at the desired turn-on point and the
high water electrode should be placed at the desired turn-off point.
REMOTE SWITCH CIRCUIT
The purpose of the remote switch circuit is to turn the pump on and off from a
distant location without having to switch the main power lines from the solar
modules to the pump. This circuit uses a low voltage, micro-amp circuit to bias
the FET in the controller. This low power switching circuit allows the use of
small gauge wire to run over a thousand feet to control the pump.
Since this is such a sensitive circuit it requires the use of a high quality,
shielded, 2-conductor cable. The shield over the wires should then be attached
to the ground terminal in the controller. This in turn is attached to a ground
rod.
Switch #2 in the on position allows the pump to run when terminals 7 and 8 are
connected. This is generally used in conjunction with a float switch or a
pressure switch which makes contact to run the pump.
Switch #2 in the off position allows the pump to run when terminals 7 and 8 are
disconnected. This is generally used in conjunction with a float switch which
breaks contact to make the pump run.

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CONTROLLER ADJUSTING PROCEDURE
CAUTION: THIS PROCEDURE SHOULD ONLY BE PREFORMED BY A QUALIFIED SOLAR ELECTRIC
TECHNICIAN. THIS PROCEDURE IS NOT NECESSARY IF STANDARD 16.5 TO 17 VOLT SOLAR
MODULES ARE BEING USED.
This procedure will not work on a centrifugal type pump such as an SCS
submersible. It is only for positive displacement type pumps.
The purpose of this procedure is to adjust the voltage of the PV array to its
peak power point and thus obtain the maximum water delivery from the pump. This
procedure should be performed with the panels at their normal operating
temperature at mid-day.
(Option 1) For panel voltage adjustment at the maximum power point.
1. With the system installed and pumping water, turn the panels 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 you have obtained the
same results. This puts the controller in a current boosting mode so this
adjustment can be made.
2. Connect a DC volt-meter to the pump side of the controller. (LD+ and LD-)
3. Turn the small brass adjusting screw on the "Panel Voltage Adjusting Pot",
located on the front of the controller, until the highest possible voltage
is obtained. (If this controller is used on a Jack Pump system using a
flywheel, there will be a slight delay from the time you make an adjustment
to when a change in voltage will be noticed.)
4. Return the panels to their normal position. The pump will then operate at
its maximum output.
(Option 2) For estimated panel voltage adjustment.
1. With the system installed and pumping water, turn the panels 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 you obtain the same results.
2. Connect a DC volt meter to the panel side of the controller. (PV+ and PV-)
3. Estimate the proper voltage by multiplying the voltage rating of the panel’s
times the number of panels connected in series and deduct 20%. Example:
6-60 Watt panels @ 17.1 Volts ea. = 103 Volts - 20% x (103 Volts) = 82 Volts
4. Turn the small brass adjusting screw on the "Panel Voltage Adjusting Pot",
located on the front of the controller, until the estimated voltage is
obtained.
5. Return the panels to their normal position. The pump will then operate at
its maximum output.

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TROUBLESHOOTING
PUMP DOES NOT RUN
If the pump does not run, first make sure the on/off switch is in the up
position. Then look at the row of lights to check the status of the system. The
red light (indicating power in) and the green light (indicating power out) are
the only ones that should be on. All other lights indicate that the controller
has been turned off for a specific reason.
1. Check wiring diagrams for proper connections. If the solar panel wires are
connected in reverse polarity the controller will short to ground. CAUTION:
If a battery system or a high amperage panel system is used and the polarity
is reversed, damage to the controller will result. This is not covered under
warranty.
If the motor polarity is reversed on a brush type motor the motor will
simply run backwards. If the polarity is reversed on an SCS brushless DC
motor a diode in the motor will block any current flow. The result would be
an open circuit and this will not damage the motor.
2. Check for proper panel and controller voltage and current.If a DC volt and
amp meter is available the best way to test for proper power is to check
input voltage and current and output voltage and current. This will indicate
where to start looking for the problem.
If a volt and amp meter is not available then a quick look at the indicator
lights will verify voltage coming from the panels going to the controller
(red) and power from the controller going to the pump (green). The other
three lights will also indicate the controller being turned off for low
voltage (yellow), over-current (orange) or a remote switch turn-off (amber).
If the red light is on and all other lights are off take a DC volt meter and
check for the correct open circuit voltage. Typical open circuit voltage
ranges from 18 to 20 volts per panel. Multiply this voltage times the number
of panels wired in series. Check to see if this calculated voltage
corresponds to the measured voltage.
For an array short circuit current test, disconnect the array wires from the
controller and short the wires together through a DC amp meter. Check this
current against the short circuit current rating of the solar panels. The
current in a series string should be the same as the rating for a single
panel. If the current in a string is low, run the same test for each
individual panel to identify the defective one.
3. Check for the proper panel voltage set point. Make sure the proper panel
voltage selector switch is on for your panel arrangement. (Switches 4-6 on
the dip-switch.) Note: If the incoming voltage is lower than the set point
voltage, the controller will not turn on.
IF THE RED AND GREEN LIGHTS ARE ON, WITH ALL OTHER LIGHTS OFF, AND THE PUMP DOES
NOT RUN: (IN GOOD SUNLIGHT)

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4. Check for proper controller output voltage. Connect a DC volt meter across
terminals 2 LD- and 3 LD+ on the large terminal block. If no voltage is
indicated check the fuse. If the fuse is good and there is no voltage on the
output, the controller has an internal problem and must be sent back to the
factory for repairs.
If the voltage on the output terminals is about the same as the open circuit
voltage then check for an open circuit between the controller and the pump
motor. Check the wiring and the wire splice. If there is open circuit voltage on
the pump side of the splice and the motor does not run, then there is an open
circuit in the motor. This indicates the motor has an internal problem and must
be sent back to the factory for repairs.
If the voltage on the output terminals is very low then disconnect the pump
wires and check again. If the voltage goes to open circuit then a high current
load is indicated. Usually a high load will trigger the over-current circuit and
will turn the controller off and at the same time turn the orange light on. To
reset this circuit, turn the on/off switch off and back on again
5. Testing an SCS Brushless DC Motor.
To check an SCS Brushless DC motor, take an ohm meter and set to a meg-ohm
scale. Connect the negative lead on the meter to the positive lead on the motor
and the positive lead on the meter to the negative lead on the motor. The
reading should be over 10 meg-ohms if measuring through the drop wire with the
motor in the well. If measuring a dry motor only at the surface it should read
over 100 meg-ohms. This test is for the polarity protection diode.
To check the FETS connect the positive meter lead to the positive motor lead and
the negative meter lead to the negative motor lead. If the FETS are shorted to
ground the meter will read around 2000 to 5000 ohms and steady. If they are not
shorted it will read about 1 to 5 meg-ohms at first and as the internal
capacitor charges it will drift higher.

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PCA and PCB Series Pump Controllers
LIMITED WARRANTY – TWENTY-FOUR (24) 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 act 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