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Many problems can be located by simple
inspection. No electrical experience is
required for this.
Inspect the solar array
1. Is it facing the sun? (See solar array
orientation, Sections 4.4 and 4.5)
2. Is there a partial shadow on the array? If
only 10% of the array is shadowed, it can
stop the pump!
Inspect all wires and connections
1. Look carefully for improper wiring (espe-
cially in a new installation).
2. Make a visual inspection of the condition
of the wires and connections. Wires are
often chewed by animals if they are not
enclosed in conduit (pipe).
3. Pull wires with your hands to check for
failed connections.
Inspect the controller and junction box
1. Remove the screws from the bottom plate
of the controller. Move the plate downward
(or the controller upward) to reveal the
terminal block where the wires connect.
(See Section 5.5.)
2. First, check for a burnt smell. This will
indicate a failure of the electronics. Look
for burnt wires, bits of black debris, and
any other signs of lightning damage.
3. Open the junction box. Is the Power IN
switch turned ON? Pull on the wires to see
if any of them have come loose.
4. Inspect the grounding wires and connec-
tions! Most controller failures are caused
by an induced surge from nearby lightning
where the system is NOT effectively
grounded. Ground connections must be
properly made and free of corrosion. (See
Section 5.2.)
Check the low-water probe system
(See
Section 5.9)
If the controller indicates “SOURCE LOW”
when the pump is in the water, inspect the
low-water probe system. The probe is
mounted on, or near the pump. If inspection is
not feasible, you can bypass the probe or test
it electrically. See Section 9.3 below.
1. If the probe is NOT being used, there must
be a wire between terminals 1 and 2.
2. The probe is a cylindrical plastic device
mounted on or near the pump. It contains
a small float on a vertical shaft. The float
must be able to move up to indicate that it
is submerged, and down to indicate that it
is dry.
3. The probe must be positioned vertically
(within about 10°).
4. The probe or a probe wire may be broken.
Inspect the wires for damage.
5. Does the pump run when the probe is
OUT of the water? This can happen if the
float in the probe is stuck. In surface
water, this can happen from algae, a
snail, or other debris (see Section 5.9).
6. If the pump was purchased before August
2003, it may have a wet-electrode probe.
In case of trouble, it can be replaced with
a new (mechanical float) probe, with no
changes to wiring or controller.
Check the full-tank float switch
(See
Section 5.10)
If the controller indicates “TANK FULL” when
the storage tank is not full, inspect the float
switch system. If your system has a float
switch, it will be mounted in the tank. If
inspection is not feasible, you can bypass
the switch or test it electrically. See Section
9.3 below.
1. If a float switch is NOT being used, there
must be a wire between terminals 4 and
5.
2. Inspect the float switch. Is it stuck in the
UP position?
3. There are two types of float switch,
normally-open and normally-closed.
Check to see that the wiring is correct for
the type that is used. (See Section 5.10)
Force a quick start
If you restore a connection or bypass the
probe or float switch, there is no need to wait
for the normal time delay. Switch the on/off
switch (or the power source) off then on
again. The pump should start immediately if
sufficient power is present.
9.2
Inspect The System
