Okay, I understand you're having trouble with the wiring from your battery to the pump, controlled by the Hunter DC irrigation controller and a pump start relay, and including an on/off switch to bypass the controller. Let's break this down and figure out the correct connections.First, let's clarify the pump start relay pin numbers. Standard pump start relays are usually numbered like this. Let me know if these pin numbers are different. Pin 85 Coil Positive (+) Pin 86 Coil Negative (-) (Ground) Pin 30 Common (Connect to Battery Positive) Pin 87 Normally Open (Connect to Pump Positive) Pin 87a Normally Closed (Not Used)Now, here's how to wire it all together:1. Battery Connections



Battery Positive (+)

Connect one side of the ON/OFF switch

in + to the Battery Positive. Battery Negative (-)

Connect to the Hunter controller's common wire.2.

ON/OFF Switch



Out +

Connect the other side of the ON/OFF switch

out + to Relay Pin 30 Out -

Do not use this connection.3.

Pump Start Relay Connections



Relay Pin 30 (Common)

Connect to the out + on the ON/OFF switch

Relay Pin 87 (Normally Open)

Connect to the

Red wire of the pump. Relay Pin 85 (Coil Positive)

Connect to the Hunter controller's master valve wire.

Relay Pin 86 (Coil Negative)

Connect to the Battery Negative (-). Or you can connect it to the Hunter controller's common wire.4.

Pump Connection



Red Wire

Connect to Relay Pin 87.

Black Wire

Connect to the Battery Negative (-)5.

Hunter Controller Connections



Master Valve Wire

Connect to Relay Pin 85.

Common Wire

Connect to the Battery Negative (-)

Explanation and Troubleshooting Tips



How it Works

When the Hunter controller activates the master valve, it sends power to Relay Pin 85, energizing the coil. This closes the connection between Relay Pin 30 and Relay Pin 87, allowing power from the battery (via the ON/OFF switch) to flow to the pump and turn it on.

Bypass Switch Function

When the ON/OFF switch is turned on, power flows directly from the battery to the relay. When it's off, the relay doesn't receive power, and the pump won't run, even if the controller is trying to activate the master valve.

Important Safety Note

Always disconnect the solar panel input to the battery before working on any wiring. Also, label all wires clearly before you start disconnecting anything.

Troubleshooting



Pump Doesn't Run at All

Check the battery voltage. Check all connections. Make sure they are clean and secure. Check the fuse (if there is one) in the circuit. Make sure the ON/OFF switch is in the on position. Test the pump by directly connecting it to the battery (carefully!) to see if it's functional.

Pump Runs Constantly

The relay might be stuck in the closed position. Try tapping it gently to see if it releases. If not, you may need to replace the relay. The Hunter controller might be stuck on. Double-check your wiring to ensure you didn't accidentally create a direct connection from the battery to the pump.

Pump Only Runs When Controller is On

This is the desired behavior when the ON/OFF switch is off. When the ON/OFF switch is on, the pump should run constantly.

Important Considerations



Wire Gauge

Make sure you're using appropriately sized wire for the current draw of the pump. Undersized wires can overheat and cause a fire. Check the pump's specifications for its current (Amps) rating.

Fuse

Install a fuse in the positive wire close to the battery. The fuse rating should be slightly higher than the pump's running current. This protects the battery and wiring in case of a short circuit.

Voltage Matching: Ensure the battery voltage matches the operating voltage of both the pump and the controller. Using the wrong voltage will damage the components.

Disclaimer: Electrical work can be dangerous. If you are not comfortable with wiring, consult a qualified electrician. The information provided here is for guidance only, and I am not responsible for any damages or injuries resulting from your wiring.Please confirm the pump relay pin numbers and wire gauges used. If you have any other questions, just ask! Flag for review