14
5 ELECTRICAL INSTALLATION
5.1 Controller, Junction Box, and Conduit
WARNING To be
installed, con-
nected and
serviced by
qualified person-
nel only. Ensure
all power
sources are
disconnected
when making
connections to
the controller.
Follow all
appropriate
electrical codes.
There are no
user serviceable
parts inside the
motor or the
controller.
CAUTION Loose connections are the most
common cause of system failures.
Pull on each connection to confirm that it is
secure.
Location Place the controller close to the
solar array, not the pump. This will reduce the
risk of lightning damage.
Explanation — The controller’s input circuitry
is more sensitive to surges than its output. It
is safest to minimize the length of the input
wiring.
Protection from solar heat Electronic
devices are most reliable when they are
protected from heat. Mount the controller in
the shade of the mid-day sun. An ideal
location is directly under the solar array, on
the north side of the mounting pole. If shade
is not available, cut a piece of sheet metal
and bolt it behind the top of the controller.
Bend it over the controller to provide shade.
This is especially important in extremely hot
locations. Extreme heat may trigger a thermal
switch in the controller and cause it to turn off.
Location of controller Mount the controller
vertically to keep out rainwater. It is preferable
to mount it ON THE NORTH SIDE of a pole or
other structure, to help reduce solar heating.
This may also allow easiest access without
hitting your head on the lower (south) edge of
the array.
Junction Box (optionally) A pre-wired
junction box is available for your system. The
junction box terminals will handle pump wires
as large as #6 (13 sq. mm). If large wires
cannot be accommodated easily in the box,
you can join them to smaller wires in the
junction box. #12 (4 sq. mm) or larger is
acceptable for this very short length. Do NOT
remove terminal screws. If the key to the
junction box gets lost, it can be opened with a
screwdriver.
Mounting the controller and junction box
to a pole See photos on the following page.
The controller can be mounted onto the solar
array support pole using materials available
from your local electric supply store. The best
mounting hardware is “slotted strut” (Unistrut
®
or equivalent) with matching conduit clamps to
fit around the mounting pole. This makes a
very strong assembly that is easy to adjust. In
North America, these materials are commonly
available from electric suppliers.
Electrical conduit is recommended We urge
you to use electrical conduit (pipe) to protect
outdoor wiring from the weather, from human
activities, and from chewing animals. See
photos on the following pages. If you don’t
use conduit, use strong, high-quality outdoor
cable. Where cables enter the junction box,
install sealed strain-relief cable clamps.
Keep the controller and junction box sealed
Unused holes must be sealed to keep out
animals, insects, water and dirt. Each hole is
supplied with a rubber plug that can be kept
in place for this purpose.
Battery system Batteries must be in a cool
location for best longevity, and in a protective
enclosure for cleanliness and safety. Place
the controller near the batteries but NOT in
the same enclosure. They must be safely
isolated from the battery terminals and from
corrosive gasses.
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