Bernt Lorentz GmbH & Co. KG
Heidekoppel 16
D-24558 Henstedt-Ulzburg
Germany
Tel. ++49.4193.7548-0
Fax ++49.4193.7548-29
www.lorentz.de
info@lorentz.de
release 05/04/07
SOLAR WATER
PUMP SYSTEMS
PS200
PS600
PS1200
INSTRUCTIONS FOR
INSTALLATION
OPERATION
SERVICE
2
Open circuit (no-load) voltage above 100V for
PS200-, above 150V for PS600- and above
200V for PS1200 controllers will destroy the
controller. This may occur if the solar array is
wired incorrectly. (See Solar Array Wiring,
Section 5.3.)
Do not attempt to run the Motor without the
PSXXX controller.
Do not attempt to use the controller for any
purpose other than LORENTZ PS-Pump
Systems.
To be installed, connected and serviced by
qualified personnel only. Ensure all power
sources are disconnected when making
connections. Follow all appropriate electrical
codes. There are no user serviceable parts
inside the motor or the controller.
Solar pumps run at low flow rates, and have
closer tolerances than conventional pumps.
Extreme sand or silt concentration (greater
than 2% by volume) may cause the pump to
stop, or the pipe to fill with sand. Do not use
the pumps to clean out a dirty well. (See
Section 6.6. for advice about dirty water.)
Helical rotor pumps are sensitive to heat.
Protect the pump from sunshine or other
source of heat, or it may lock temporarily. If
the water source is, or will be warmer than
72° (22°C), a special model may be required.
(See Section 6.4.)
Undersized wire will cause failure to start.
Do not touch the controller input or pump
wires together to test for a spark.
Do not run the pump dry. Exception: to test
direction of rotation, for maximum 15
seconds
Test the direction of motor rotation before
installing the pump (counter-clockwise looking
down). If direction is reversed, exchange the
connection of any two of the three power
wires to the pump.
When pump is stopped by a shadow or by
action of float switch, it will restart after a 120
seconds.
The low water probe must be submersed, or
the pump will stop for 20 minutes. If the probe
is not to be used, connect the probe terminals
together in the controller box.
Helical rotor models (without a C in the
model #) are not self-draining. If drainage is
required for freeze-protection, install a weep
hole or draining device below freeze level.
1 WARNINGS
Failure to follow
these instructions will void
the warranty.
Install this system in accordance with local
regulations and accepted codes of professional practice.
This manual is the property of the LORENTZ
Pump owner.
Please give it to the owner or maintenance
personnel when you are finished!
Request copies from your pump supplier or
download from www.Lorentz.de
This manual is for controller models
PS1200, PS600, PS200 as illustrated on the
cover. For earlier models (before July 2003)
refer to Version 1 and 2
Copyright © 2002-2005 by BERNT LORENTZ
GMBH & CO KG All rights reserved
3
2 ELECTRICAL INSTALLATION
2.1 Controller and Conduit
WARNING To be
installed, connected and
serviced by
qualified personnel 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.
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.
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 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.
WARNING TEST THE VOLTAGE before
connecting power to the controller. Voltage
(open circuit) must not exceed 100V for
PS200-, 150V for PS600 and 200V for
PS1200 systems. (Even in cloudy weather,
the open circuit voltage will be near maximum.)
WARNING Do not apply a direct connection
or an amp meter between + and – when the
controller is connected. A short circuit
here will cause a strong discharge.
WARNING SOLAR-DIRECT systems only —
Do not connect any electrical load to the
solar array if it is not part of the LORENTZ
Pump system. Connection of a battery
charger, active solar tracker controller, electric
fence charger, or other load simultaneously
with LORENTZ PS systems may “confuse”
the controller and prevent proper operation.
System Wiring Diagram For solar-direct
systems, refer to the System Diagram at the
end of this manual and wire accordingly
POWER IN Ensure that the solar array
DISCONNECT SWITCH (or battery fuse or
circuit breaker)- is OFF. IN case that no
disconnec swtich is used, make shade or
cover the solar array. Connect the power from
the solar array to the input terminals in the
controller box. Observe polarity. If your wires
are not clearly marked +/–, test them using a
DC voltmeter or multitester.
4
3. Wiring Order for Correct Rotation
WARNING If the
pump wires are
in the wrong
order, the motor
will run in
reverse and the
pump will not
function. Damage may result.
Check the
direction BEFORE installing
the pump. The
proper direction
is COUNTERCLOCKWISE
when viewed
from above.
The power wires on the pump are black with
white lettering to indicate L1, L2 and L3.
WRITE DOWN the colors 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 RED,
BLACK and YELLOW colors, use this
sequence:
The power wires on the pump may also be
broun-black-grey for Motors delivered Q2
2005. Then use broun as L1, black as L2
and grey as L3
Testing the pump for direction Helical rotor
pumps will produce water flow only if they are
rotating in the right direction. If you place it in
a water tank or a bucket, you will observe flow
if the rotation is correct. (Submerge at least
75% to observe full flow).
Alternative, dry test If you don’t 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
WARNING When
testing for
direction, do not
run the pump
dry for more
than 15 seconds.
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.
Did you install the pump in the well without
checking the wiring order or the direction?
OR – Is it running but not pumping?
HELICAL ROTOR pump (model number
does NOT contain “C) Turn the pump on.
Observe if air is rising from the pipe. If it isn’t,
reverse any two motor wires and observe
again. If you cannot observe air rise, chose
whichever direction is quieter (less vibration).
There is risk of dry-run damage if it runs too
long in reverse. 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
has been used, it must not be run for more
than about 15 seconds. In many cases, a
pump that is reversed will turn off due to
overload.
CENTRIFUGAL pump (model with C in the
name) In reverse, it will produce no flow (or
very little). This will NOT damage the pump. If
the flow is not normal, reverse any two motor
wires.
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.
DER KCALB WOLLEY NEERG
1L 2L 3L dnuorG
5
4. Battery-Based Systems
PS-XXX pump systems can be operated
from batteries.
Install a jumper wire between terminals 6
and 7 to set the controller to battery mode.
This will de-activate the MPP-Tracking
function and activate the Low Voltage Disconnect.
Wiring: Connect the battery directly to the PSXXX controller and NOT to the load terminals
of the charger. They may not be strong
enough to deliver the load spike during
starting of the pump. The PS-XXX controller
has a Low Voltage disconnect function to
protect the battery from beeing over
discharged.
Some charge controller monitor the capacity
of the battery and regulate the charging
accordingly. That does not work when the
battery is connected to the PS-xxx controller.
In order to provide correct charging the
charger should be set to voltage orientated
regulation. This may require a jumper to be
set in the charger. Check with the manuals of
the charger manufacturer
Overload protection Install a fuse or circuit
breaker near the power source. For either 24
or 48V , use a 25 amp circuit breaker ( PS200
or PS600 Systems) or a time-delay (slow
blow) fuse. The purpose of this protection is
for safety in case of a wiring fault, and to
provide a means of disconnect when installing or maintaining the system. PS-XXX
controllers have electronic over-current
protection against motor overload.
CAUTION The
PS-XXX controller is NOT a
battery charge
controller. A
charge controller
prevents battery
overcharge. It is a
normal part of
any renewable
energy battery
charging system.
Be sure the
charge controller
is appropriate to
the type of
batteries used.
(Sealed batteries
use lower voltage
settings than
liquid-filled
batteries.)
Wire Sizing for the DC circuit Wire must be
sized for no more than 5% voltage drop at 20
amps (starting).
Refer to a wire sizing chart specifically for 24V
or 48V, or follow these examples:
24V SYSTEM:
#10 wire to maximum distance of 30 ft.
Metric: 6 sq. mm to max. 10m
48V SYSTEM:
#12 wire to maximum distance of 22 ft.
Metric: 4 sq. mm to max. 13m
GREATER LENGTHS For each 150% increase, use next larger wire size.
ON/OFF switching You can switch either the
primary power to the controller, or the remote
(float switch) control circuit.
Low-voltage disconnect function. Lead-acid
batteries can be permanently damaged by
over-discharge when the voltage falls below
a critical point. To prevent this, the PS batterysystem controller will turn off at low voltage,
and turn back on only after the battery has
recovered significantly. The set points are:
24V SYSTEM: OFF at 22V ON at 24V
48V SYSTEM: OFF at 44V ON at 48V
A controller in disconnect mode can be reset
manually by turning off/on, but it will quickly
disconnect again if the battery is not gaining
a substantial recharge.
6
5 OPERATING THE PUMP
This explains the function of the switch and
the indicator lights on the pump controller.
SWITCH
POWER ON/OFF
When switched off/on during operation, it resets all
system logic.
Indicator lights
SYSTEM (green)
The controller is switched on and the power source
is present. In low-power conditions, the light may
show even if there is not enough power to run the
pump.
PUMP ON (green)
Motor is turning. Sequence of flashing indicates
pump speed. See below sequence
PUMP OVERLOAD (green changes to red)
SOURCE LOW (red)
The water source dropped below the level of the
low-water probe. After the water level recovers, the
pump will restart, but this light will slowly flash until
the sun goes down, power is interrupted, or the
POWER switch is reset. This indicates that the
water source ran low at least once since the
previous off/on cycle.
TANK FULL (red)
Pump is turned off by action of the remote float
switch (or pressure switch or manual switch,
whichever is wired to the “remote float switch”
terminals.
BATTERY LOW (tank light flashes)
Battery systems only – battery voltage fell to 44 /
22V, and has not yet recovered to 48/24V.
RPM indication: Pump speed can be read off by the
flashing sequence of the Pump ON LED.
LED ON > 900
One flash > 1200
Two flash > 1600
Three flash > 2000
Four flash > 2400
Five flash > 2800
7
Starting the pump Be sure there is not a
closed valve or other obstruction in the water
line. Switch on the array disconnect switch in
the junction box, and toggle the power switch
on the controller. It is normal to leave the
switches on at all times, unless you desire to
have the system off.
A solar-direct pump should start under the
following conditions
1. clear sunshine at an angle of about 20°
or more from the surface of the solar
array
2. cloudy conditions, if the sunshine is
bright enough to cast some shadow
3. low-water probe submersed in the water
source (or bypassed in the controller) –
Water-Low light OFF
4. full-tank float switch is not responding to a
full tank – Tank-Full light OFF
5. battery system only – voltage is higher
than the low-voltage disconnect point (22V
or 44V)
When sunshine is insufficient When
sunshine on the array is present, but too weak
for the pump to run, it will attempt to start
about every 90 seconds. During each attempt,
you will see the PUMP ON light come on.
When pump runs slowly (PUMP ON) under
weak sun conditions
1. PS-Pump models that have “C” in the
model number -– These use a centrifugal
pump end. In weak sun, the pump may
spin without lifting water all the way to the
outlet. This is normal.
2. PS-Pump models that do NOT have “C” in
the model number – These use a helical
rotor (positive displacement) pump end. If
the pump is turning, even slowly, water will
be delivered at a slow rate.
When pump stops from a sudden shadow on
the solar array
If a shadow suddenly passes over the array,
like if you walk in front if it, the controller will
lose track of the input voltage. It may make
rapid on/off noises and a high-pitched noise,
then stop. This does NOT indicate a problem.
The pump will attempt to restart after the
normal delay.
Time delays
1. After pump stops due to insufficient
sunshine – 120 SECONDS
2. After full-tank float switch resets – 2 to 3
SECONDS
3. After low-water probe regains contact with
water in the source -– 20 MINUTES but
the indicator light will slowly falsh for the
rest of the solar day, or until power is
disrupted or the controller is turned off/on.
4. Battery systems – after low voltage
disconnect point is reached, delay to stop
pump – a few SECONDS. After voltage
recovers, delay to re-connect – a few
SECONDS
To force a quick start To test or observe the
system, you can bypass the normal time
delays. Switch the POWER switch off then on
again. The pump should start immediately if
sufficient power is present.
Pump vibration Most PS-Pump models use
a HELICAL ROTOR pump end (those that do
NOT have a “C” in the model number. A slight
vibration is normal with these pumps. If noise
is disturbing, try changing the position of the
pump. PS-Pump models that have a “C” in
the model number use a CENTRIFUGAL
pump end similar to conventional pumps.
They should produce no significant vibration.
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 Watt 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 3 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. See Troubleshooting, Section
9.3 “HIGHER CURRENT”.
Operating the Pump continued
8
6 TROUBLE SHOOTING
Please read this section before calling for
help.
If you call for help, please refer to the model
and serial numbers.
6.1 If The Pump Doesn’t 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.
1. There may be insufficient power reaching
the controller. 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 22V (24V system) or 44V (48V
system).
2. If the pump was recently connected (or
reconnected) to the controller, it may be
running in reverse direction due to wiring
error. See Section 3.
3. If the motor shaft only vibrates and will not
turn, it 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.
4. The pump or pipe may be packed with
mud, clay, sand or debris.
5. Helical rotor models: The pump may have
run dry. Remove the pump stator (outer
body) from the motor, to reveal the rotor. If
there is some rubber stuck to the rotor,
the pump end must be replaced.
6. Helical rotor models: The check valve on
the pump may be faulty or stuck, 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 Watt 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 3 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.
CAUTION DO
NOT REMOVE
THE CHECK
VALVE from the
pump. If you want
to look for dirt
stuck inside the
pump, it is
preferable to
unbolt the pump
body and pull it
from the pump. IF
YOU MUST
REMOVE THE
CHECK VALVE,
use a hardening
adhesive sealant
on the screw
threads when you
replace it. Epoxy
glue is good. The
threads are not
tapered. They will
leak if a hardening sealant is not
used. Teflon tape
will make a good
seal, but it may
not prevent the
joint from unscrewing.
9
7. System Wiring Diagram for Solar-direct (non-battery) System
Power
In
Pump
Ground
Earth
Ground
Red
Black
Yellow
1 2345
Low-water sen sor probe
Low Water
Level Probe
Pump Motor
Submersible
Cable
Splice
For wire size, refer to Sizing Table.
Float Switch
(Optional)
Conn ect to float
switch terminals.
67
To any ground
terminal at
contr oller
Connect to bypass
Not used
L1 L2 L3
If you are not using the
low-water probe, install
a jumper wire between
terminals 1 and 2.
Remote
Float
Switch
NO
com
NC
If you are not using a
float switch, install a
jumper wire between
terminals 4 and 5.
WARNING
max open circuit voltage:
150 VDC !
PV Modules (Solar Panels)
Before connecting the array to the
controller measure the opencircuit voltage. It must be within a
range of
PS200 : 35-90V DC
PS600 : 75-135V DC
PS1200: 110- 180V DC
Float Switch (optional)
Float Switch Kit makes contact on
rise to stop pump.
Connect termins 3 (NO) and 4
(COM) and connect terminals 4
and 5 with jumper wire.
PV-Array 2...8 Panels
10
8 SYSTEM REPORT FORM
System and Components
System Voltage V
Date of Purchase
Purchased from
Battery System? yes no
if not: Quantity of Solar Modules (panels)
Solar Module Brand
Module Model #
Controller Model PS1200
PS600
PS200
other, i.e.:
Controller Serial #
Pump End Model #
Pump End Serial #
Temperature Range
Helical rotor pumps (without C in the model number) work optimally only in a specific
temperature range. Last digit of Pump End Model # indicates temperature class.
If a special temperature range was not specified, the last digit of model number (X) will be 1.
Class 0 32 °F to 54 °F 0 °C to 12 °C
Class 1 46 °F to 72 °F 8 °C to 22 °C Class 1 is the standard class.
Class 2 64 °F to 90 °F 18 °C to 32 °C
Class 3 82 °F to 108 °F 28 °C to 42 °C
Class 4 100 °F to 126 °F 38 °C to 52 °C
See Section 12
for more about
temperature
specifications.
11
Installation Report
Installation Date
by
Well Depth m / ft
Pump depth m / ft
Additional Vertical Lift (up to top of tank) m / ft
Static Water Level m / ft
Drawdown level m / ft
Drop Pipe (vertical from the pump)
Size mm
2
/ inch
Type
Length m / ft
Additional Pipe Length (to tank)
Size mm
2
/ inch
Type
Length m / ft
Submersible Pump Cable
Wire size mm
2
/ AWG
Total Length (controller to pump) m / ft
MAX RPM CONTROL
(See Section 5.6) Factory setting is Maximum.
If this setting was reduced, enter setting here:
System Report Form continued
yes no
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