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Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
PS150C
Instructions for Installation, Operation and Service
for Controllers from serial # 10070901
1 Introduction
Thank you for purchasing a LORENTZ PUMP. LORENTZ has
set a new standard for quality and economy in solar pumping. It incorporates the best solar pump technologies that
were very expensive until its introduction in 2002.
PS150 is a highly efficient pump system which is economical for (drip-) irrigation, livestock, dugout floating pump, water transfer to remote places and many other applications.
PS150C is a submersible pump with a centrifugal pump
end. The PS150 brushless DC motors are specially made
for this system. The motor is using very advanced raw earth
magnet technology, hand made wiring for highest copper
density and does not need wearing brushes. This results in
an exceptional high efficiency with low temperature dissipation.
PS150 can either be used in a battery system with voltages
of 12 V or 24 V or alternatively it can be operated as a solar-direct system using the same Controller PS150.
The solar battery is charged up during daylight hours using
a separate charger. The charger works effectively during reduced sunlight conditions when direct pump operation is
not possible. The energy stored in the battery is available
to operate the pump at any time, day or night and during
periods of bad weather. Extended bad weather periods
with water demands of up to 10m
3
per day will be reliably bridged due to the high system efficiency even with low
capacity batteries.
The pump is manufactured from non-corrosive material
(stainless steel).
Before you begin, check the model numbers of all the components of your system, and verify that they are the items
that you ordered. Also check against the pump specifications and performance charts to be sure the system is appropriate for your application. If you think you may have
the wrong pump for your application, call your supplier
immediately.
Please fill in the System Report. This will be essential information if any problems occur.
3 System Dimensions
Dimensions Packing
L A B D E S packaging shipping
volume
net
weight
gross
weight
[mm] [mm] [mm] [mm] [mm] [mm × mm × mm] [m
3
] [kg] [kg]
Pump Unit
C-SJ5-8
593 408 185 100 98 G 1 1/2 in 650 × 160 × 150 0.0160 12.0 12.5
Controller
PS150
see drawing 320 × 240 × 160 0.0123 1.2 1.8
Symbols
Warning
Disregard might lead to injury or damage the
installation
Caution
Recommended to avoid disfunction or premature ageing of the pump etc.
v110801
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Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
Safety Directions for Maintenance, Inspection
and Assembly Work – It is the user’s responsibility
to make sure that all maintenance, inspection and assembly work is performed exclusively by authorized and
qualified experts sufficiently informed through careful
perusal of the Operating Instructions.The accident prevention regulations must be observed. Basically, all work
on the machine is to be performed while the machine is
not in operation. The sequence for shutting the machine
down described in the manual must be strictly observed.
Pumps or pump units handling hazardous liquids must
be decontaminated. Immediately upon completion of
the work, all safety and protective equipment must be
restored and activated.
Unauthorized Changes and Manufacturing of
Spare Parts – Any conversion or changes of the machi-
ne may only be undertaken after consulting the manufacturer. Original spare parts and accessories authorized
by the manufacturer guarantee operational safety. Using
non-authorized parts may void any liability on the part
of the manufacturer in case of consequential damage.
Unauthorized Operation – The operational safety of
the machine delivered is only guaranteed if the machine
is used in accordance with the directions contained in
manual. Limits stated in the data sheets may not be exceeded under any circumstances.
Cited Standards and other Documentations – DIN
4844 Part 1 Safety marking; Safety symbols W 8, Supplement 13; DIN 4844 Part 1 Safety marking; Safety
symbols W 9, Supplement 14
Transportation and Intermediate Storage – Pro-
longed intermediate storage in an environment of high
humidity and fluctuating temperatures must be avoided.
Moisture condensation may damage windings and metal parts. Non-compliance will void any warranty.
Failure to follow these instructions will
void the warranty.
Before beginning installation procedures, these installation and operating instructions should be studied carefully.
The installation and operation should
also be in accordance with local regulations and accepted codes of good
practice.
This Instruction Manual contains maintenance information, and is the property
of the pump owner. Please give this manual to the pump owner or maintenance
personnel when the installation is finished.
2 Warnings
The manual contains basic instructions which must be
observed during mounting, operation and maintenance.
Therefore the manual should be carefully read before
installation and start-up by the person in charge of the
installation as well as by all other technical personnel/
operators and should be available at the installation site
at all times.
Personnel Qualification and Training – All person-
nel for the operation, maintenance, inspection and installation must be fully qualified to perform that type of
job. Responsibility, competence and the supervision of
such personnel must be strictly regulated by the user.
Should the available personnel be lacking the necessary
qualification, they must be trained and instructed accordingly. If necessary, the operator may require the manufacturer/supplier to provide such training. Furthermore
the operator/user must make sure that the personnel
fully understands the contents of the manual.
Dangers of Ignoring the Safety Symbols – Igno-
ring the safety directions and symbols may pose a danger to humans as well as to the environment and the
machine itself. Non-observance may void any warranties.
Non-observance of safety directions and symbols may
for example entail the following: Failure of important
functions of the machine/plant; failure of prescribed
methods for maintenance and repair; endangerment
of persons through electrical, mechanical and chemical
effects; danger to the environment because of leakage
of hazardous material; danger of damage to equipment
and buildings.
Safety-oriented Operation – The safety directions
contained in the manual, existing national regulations
for the prevention of accidents as well as internal working-, operational- and safety-regulations of the operator/user must be observed at all times.
General Safety Directions for the Operator/User
– If hot or cold machine parts pose a danger, such parts
must be protected by the operator/user against contact
with personnel. Protective covers for moving parts (e.g.
coupling) must not be removed when the machine is
running. Leakages (e.g. at the shaft seal) of hazardous
pumping media (e.g. explosive, toxic, hot liquids) must
be disposed of in such a way that any danger for personnel and the environment is removed. All government
regulations must be observed at all times. Any danger
to persons etc. by electrical energy must be excluded.
(For details see e.g. regulations of VDE and the local
utilities).
v110801
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Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
3 Installation of the Controllers
3.1 Controllers Functions
Controlling and monitoring of the motor
Integrated MPP-tracking and LVD battery protection
LVD protection (low voltage disconnect) for 12 V and
24 V batteries
High-run battery function to avod cycling of battery
LED display of the the operating status
Two control inputs for float- or pressure switches,
remote control, etc.
92% max. efficiency (motor + controller)
Adjustable maximum RPM setting
3.2 Warnings to the Installer
Motor cable strain relief: Submersible
motors must use a safety rope or cable
to act as a strain relief for the motor
cable and to avoid losing the pump in
the well if the pipe breaks.
Open circuit (no-load) voltage above
50 V DC will destroy the controller. This
may occur if the wrong PV modules (so-
lar panels) are used, or if the solar array
is incorrectly wired. Measure the array voltage before connecting to the controller. A 12 V DC (nominal) array should produce an open circuit voltage
around 22 – 25 V under any daylight conditions.
Some thin-film PV modules might produce a higher
open-circuit voltage when they are new. If it is
higher than 50 V, do not connect the controller.
Contact your dealer!
Do not run the motor without the cont-
roller.
To be installed, connected and serviced
by qualified personnel only. Ensure all
power sources are disconnected when
making connections to this unit. Follow
all appropriate electrical codes. There are no user
serviceable parts inside the motor or the controller.
Install proper grounding for safety and
lightning protection.
Do not touch the controller input or mo-
tor wires together to test for a spark.
3.3 Mechanical Installation
Location Place the controller close to the solar array, not
the pump. This will reduce the risk of lightning damage. If
it is outdoors, mount the controller in a vertical position to
assure that rain will not enter the box.
Protection from 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 or in a nearby shaded location. An alternative is to fold a piece of sheet metal so that it mounts
behind the controller and curves over it to provide shade.
This provides protection in extremely hot climates.
Battery system Place the controller near the batteries but
safely isolated from the battery terminals and from corrosive gases. Batteries must be in a cool location for best longevity and enclosed for cleanliness and safety.
Connect the battery (12 V or 24 V) directly with the + and
– terminal of the controller. Do not use the load terminals
of the charge controller as they maybe not strong enough
to allow the start current to flow. The PS150 controller has
a low voltage function to protect the batteries from deep
discharge. An additional charger is needed for charging the
batteries.
3.4 Electrical Installation
Power IN For PV-direct systems, a two-pole disconnect
switch may be installed between the solar array and the
controller. Switch it off to prevent shock and arc burn hazard during installation and maintenance, or if the system
will be shut down for the season. For battery systems a
30 A slow blow fuse must be installed between the controller and the battery.
Ground Connect the ground wire to the ground connection in the controller. Grounding helps to prevent shock hazard if there is a fault in the motor.
L1-L2-L3 The motor requires four-conductor (fourwire)
cable between the controller and the motor. The three wires
L1, L2 and L3 carry power. The fourth wire carries ground.
To reverse direction of rotation reverse any two wires.
No disconnect switches must be installed
in power wires between motor pump
controller. Connecting the motor wire to
the switched-on controller might
irreparably damage it. Such damages are
excluded from the warranty.
No. 1 and 2 In order to protect a pump from being dama-
ged by dry running connect one well probe cable to each
terminal. If dry run protection is not needed, short cut these
two terminals.
No. 3, 4 and 5 Connect any kind of external switch (NO
or NC type) for remote control of the controller. In case no
switch is used the terminals No. 4 and 5 have to be connected with a short cable (factory setting). In case a NOswitch is used (connected to the terminals No. 3 and 4) the
short cable (connecting the terminals No. 4 and 5) must
remain installed.
No. 6 and 7 Connect these two terminals to switch the
controller to battery mode. The motor will be switched OFF
by the controller if the input voltage is below 11 V for a
12 V battery system and 22 V for a 24 V battery system in
order to protect the battery. If the battery voltage increases
to 12 V or 24 V the motor will be switched ON automatically. (For High-run mode at 13.3 V and 26.6 V.)
Table 1: Technical Data of Controller
system PS150C
motor power [W] 250
max. power input of PV module (Vmp)* [V DC] >17
open circuit voltage (Voc) [V DC] 50
input voltage battery [V DC] 12/24
battery low voltage disconnect [V DC] 11/22
battery restart voltage [V DC] 12/24
output 4 – 36 V EC PWM 3-phase
enclosure type
controller IP54 weatherproof (NEMA type 3R)
motor IPX4 weatherproof (NEMA type 3)
ambient
temperature
storage [°C] –30 to +55
operation of controller [°C] –20 to +50
operation of pump [°C] 0 to +50
*) PV modules at standard test condition: AM = 1.5, E = 1,000 W/m2, cell temperature: 25 °C
v110801
4
Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
3.5 Monitoring the System
System switched on (SYSTEM)
Green light indicates SYSTEM ON
Pump running (PUMP ON)
Green: MOTOR / PUMP ON
Red: Motor OFF caused by overload protection
PUMP SPEED
Pump speed is indicated by the blinking sequence of the
PUMP ON LED:
LED is on > 700 min
-1
1 flash > 1,200 min
-1
2 flashes > 1,600 min
-1
3 flashes > 2,000 min
-1
4 flashes > 2,400 min
-1
5 flashes > 2,800 min
-1
Dry-running protection (SOURCE LOW)
Red light: Water level is low. After recovering the motor will
start within 20 minutes. Red light will remain ON to indicate low water level has occurred. For “Reset” press the ON/
OFF switch.
TANK FULL
Red light: The motor has been switched OFF by remote
switch.
BATTERY LOW
Red light flashing: “LOW VOLTAGE DISCONNECT” when
battery is empty (in battery mode only)
LEDs for Monitoring
The power wires on the pump are black with white lettering to indicate L1, L2 and L3. WRITE DOWN the colours
that you splice to L1/L2/L3 so you can match them with the
L1/L2/L3 terminals in the pump controller.
If your pump cable has the standard GREY, BROWN, BLACK
and GREEN-YELLOW colours, use this sequence:
GREY BROWN BLACK
YELLOW-
GREEN
L1 L2 L3 Ground
The power wires on the pump may also be brown-blackgrey for motors delivered from Q2 2005 on. Then use
brown as L1, black as L2 and grey as L3.
Testing the pump for direction Centrifugal pumps will produce water flow even when the turn backwards. However,
the backwards pumping flow will be considerably less and
the lift ability lower. Make sure that the pump turns counter
clockwise as indicated on the pump and motor body. If you
place it in a water tank or a bucket, submerge at least 75%
to observe flow.
Alternative dry test If you do not have a water vessel to
test the pump in, you can test it dry by watching the pump
shaft and running it for only a few seconds. The metal label
on the pump has an arrow to indicate the proper direction
of rotation. If the pump is new from the factory, it is lubricated so it can run dry for about 90 seconds without risk. If
the pump is not new, it can be run dry safely for about 15
seconds. Either way, this is more than enough time to observe the direction of the shaft.
If you did not write down the color match (or the wind
blew your note away) connect the three power wires to the
controller in ANY random order. Apply power. Observe the
pump shaft rotation, then turn the power off. If the direction is wrong, exchange ANY TWO of the power wires at
the controller. In any case, when you are finished connecting the pump to the controller, test it to assure the proper
direction.
Question The motor shaft is hard to turn by hand, and
moves in a bumpy manner. Is this normal?
Answer YES. This is caused by permanent magnets in the
motor. It is especially hard to turn when it is connected to
the controller, or if the pump wires are connected together.
WARNING If the pump wires are in the
wrong order, the motor will run in reverse and the pump will not function. Da-
mage may result. Check the direction
BEFORE installing the pump. The proper direction is
COUNTERCLOCKWISE when viewed from above.
WARNING When testing for direction, do
not run the pump dry for more than 15
seconds.
3.6 Wiring the Motor
v110801
5
Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
4 System Wiring
4.1 12 V Battery System
12V system Voltage from panels will read 22-25 V when
disconnected (open circuit). Connect the pump controller
directly to battery bank.
Remote Tank Float Switch Connect float switch to terminals 4-5 of the pump controller when it breaks contact
on rise, to turn the pump OFF. Otherwise use terminals 3-4
for opposite function.
Grounding Connect either battery minus or solar minus to
ground, never connect both to ground!
Solar Tracking Use stranded wire for flexibility. Secure
the wires to tracker with plenty of tape. Leave a good slack
loop to allow free motion of tracker.
4.2 24 V Battery System
24 V system Wiring scheme shows serial wiring for a sys-
tem of 24 V nominal. Voltage from panels should read 45 V
when disconnected (open-circuit).
Remote Tank Float Switch Connect float switch to terminals 4-5 of the pump controller when it breaks contact
on rise, to turn the pump OFF. Otherwise use terminals 3-4
for opposite function.
Grounding Connect either battery minus or solar minus to
ground, never connect both to ground!
Solar Tracking Use stranded wire for flexibility. Secure
the wires to tracker with plenty of tape. Leave a good slack
loop to allow free motion of tracker.
2 batteries 12 V
in series
external
charge controller
external
charge controller
1 battery 12 V 1 PV module 12 V
2 PV modules 12 V
in series
low water sensor
low water sensor
fuse
30 A
fuse
30 A
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Jmp2
Jmp3
Jmp1
SYSTEM
PUMP ON
OVERLOAD
WELL DRY
TANK FULL
BATTERY LOW IF FLASHES
1234567
low-water
sensor
probes
connect
for battery
mode
remote
float switch
NO
Com
NC
Max. 50V
Do not connect
this terminal
www.LORENTZ.de
T1
T2
T3 T4
T5
T7
V8
Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
Solar direct system Voltage from panels will read 22 – 45 V
when disconnected (open circuit). Use the left power terminals to connect the solar array with the controller.
The jumper wire on terminal 6 and 7 must be taken out for
solar direct mode.
Remote Tank Float Switch Connect float switch to terminals 4-5 of the pump controller when it breaks contact
on rise, to turn the pump OFF. Otherwise use terminals 3-4
for opposite function.
Solar Tracking Use stranded wire for flexibility. Secure
the wires to tracker with plenty of tape. Leave a good slack
loop to allow free motion of tracker.
4.3 System Wiring for 12 V – 24 V Systems in PV-direct Operation
4.4 Jumper Setting for PS150C Mode
Before start-up check that jumper Jmp2
is set to PS150C mode, cf. sketch on the
right.
4.5 High-run Mode
In order to set the battery high-run mode set the jumper
Jmp1 as shown in above picture. This will increase the Low
Voltage Disconnect (LVD) settings to 12.3/24.6 V and the
re-start voltages to 13.3/26.6 V to allow pumping only
when the batteries receives charging current from the solar
array. The lifetime of the battery will be increased considerably as cycling is avoided.
4.6 Power Control for PV-direct Operation
PS150 pumps require different current depending on speed
and lift. When low light conditions are present, the PV
array cannot supply the required current. If you dont use
a controller the voltage will drop to nearly zero, and the
pump will “stall” (like a truck trying to start in 4th gear).
The pump controller, also called linear current booster (LCB)
including Maximum Power Point Tracking (MPPT) acts like
a “gear box” in your car. This device will match the power
source to the load by transforming the voltage down while
increasing the current delivered to the motor (like an automatic transmission).
1 PV module 12 V or
2 PV modules 12 V in series
Jumper Jmp1
Set to activate High-run Mode
Jumper Jmp2
Make sure the two left pins are
connected for PS150C mode
low water sensor
v110801
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Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
5 Trouble Shooting
Please read this section before calling for help. If you call
for help, please refer to the model and serial numbers.
If The Pump Does Not Run
Most problems are caused by wrong connections (in a new
installation) or failed connections, especially where a wire
is not secure and falls out of a terminal. The System ON
light will indicate that system is switched on and connected
to the controller. It indicates that VOLTAGE is present but
(in a solar-direct system) there may not be sufficient power
to start the pump. It should attempt to start at intervals of
120 seconds.
Pump attempts to start every 120 seconds but
doesn’t run.
The controller makes a slight noise as it tries to start the
pump. The pump will start to turn or just vibrate a little.
There may be insufficient power reaching the control-(1)
ler. A solar-direct (non-battery) system should start if
there is enough sun to cast a slight shadow. A battery
system should start if the supply voltage is greater
than 12V (12V system) or 24V (24V system).
If the pump was recently connected (or reconnected) (2)
to the controller, it may be running in reverse direction
due to wiring error. See section 4.7
If the motor shaft only vibrates and will not turn, it (3)
may be getting power on only two of the three motor wires. This will happen if there is a broken connection or if you accidentally exchanged one of the power
wires with the ground wire.
The pump or pipe may be packed with mud, clay, sand (4)
or debris.
The check valve on the pump may be faulty or stuck, (5)
allowing downward leakage when the pump is off.
This can prevent the pump from starting.
Pump Overload
PUMP ON – light shows red instead of green. The system has shut off due to an overload. This can happen if
the motor or pump is blocked or very difficult to turn and
is drawing excessive current (hard to turn). Overload detection requires at least 250 W output of the solar array.
This can be caused by a high concentration of solids in the
pump, high water temperature, excessive pressure due to
high lift or a restriction in the pipe, or a combination of
these factors. The controller will make three start attempts
before shutting down the system. The System ON LED will
be OFF and the red OVERLOAD LED ON. The system will
not reset until the ON / OFF switch is turned OFF and ON
again.
6 Warranty
2 years warranty in material and workmanship.
Details in separate warranty document.
v110801
8
Sun. Water. Life.
BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
Errors excepted and possible alterations without prior notice.
Date of installation
Installer
(full contact details)
Well depth m | ft
Pump depth m | ft
Additional vertical lift (to top of tank) m | ft
Static water level m | ft
Drawdown level m | ft
Drop pipe (vertical from the pump)
Size mm2 | in
Type
Length m | ft
Additional pipe length (to tank)
Size mm2 | in
Type
Length m | ft
Submersible pump cable
Wire size mm2 | AWG
Length (controller to pump) m | ft
Max. RPM control
Factory setting is maximum. yes no
If this setting was reduced,
enter setting here:
Date of purchase
Dealer
(full contact details)
System voltage V
Battery system yes no
Quantity of solar modules
Solar module brand
Module model #
Controller model PS150
Controller serial #
Pump end model #
Pump end serial #
Motor model #
Motor serial #
7 System Report
System und Components Installation
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