PDS23 Solar Pump Controller
User Manual
Version code：PDS23-EN-602000561-1702
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Preface
Thank you for using PDS23 series products. This manual provides you with relevant
operation instructions and detailed description of parameters. Please read this
manual carefully before installation, running, maintenance or inspection.
Please make sure the wiring and the pump’s rotation direction is correct before use.
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Content
Preface ............................................................................................................... - 1 -
Notes for Safe Operation .................................................................................. - 4 -
Chapter 1 How It Works ............................................................................... - 6 -
1.1 Features.................................................................................................................... - 8 -
Chapter 2 General Information .................................................................. - 10 -
2.1 Inspection .............................................................................................................. - 10 -
2.2 Descriptions and Features ...................................................................................... - 10 -
2.3 Protection Features ................................................................................................ - 11 -
2.4 PDS23 Solar Pump Controller Model Description ................................................. - 12 -
2.5 Outline &Installation Dimensions .......................................................................... - 17 -
Chapter 3 Mechanical and Electrical Installation ....................................... - 20 -
3.1 Mechanical Installation .......................................................................................... - 20 -
3.2 Electrical Installation ............................................................................................. - 21 -
Chapter 4 Start-up and Operation ............................................................. - 27 -
4.1 Keypad Description ............................................................................................... - 27 -
4.2 Keypad Operation Process ..................................................................................... - 28 -
4.3 Trial operation ........................................................................................................ - 29 -
4.4 Running status panel display parameters ............................................................... - 30 -
4.5 User Definable Parameters ..................................................................................... - 31 -
Chapter 5 Diagnostics and Troubleshooting .............................................. - 37 -
5.1 Fault Codes ............................................................................................................ - 37 -
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5.2 Common Faults and Remedies ............................................................................... - 41 -
Chapter 6 Regular maintenance ................................................................. - 43 -
6.1 Controller and Pump .............................................................................................. - 43 -
6.2 Solar panels............................................................................................................ - 43 -
6.3 Cable ...................................................................................................................... - 43 -
Chapter 7 Backup AC power ...................................................................... - 44 -
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Notes for Safe Operation
■ Before Installation
WARNING
Do not install or operate the controller that is damaged or has missing parts. Otherwise, it
may result in equipment damage or harm life.
■ Installation
CAUTION
◎ Hold the bottom of the controller when installing or moving the controller, can not just
hold the shell to prevent the injured or broken controller.
◎ Install the controller on nonflammable material like metal. Otherwise it may cause a
fire.
◎ When the controller is mounted in a protective cabinet, the cabinet need to set vents to
ensure ambient temperature is below 40℃, otherwise it may be damaged because of high
temperature.
◎ When install the controller, you should avoid direct sunlight, can be installed under the
PV array.
WARNING
◎ Ensure only qualified personnel to operate. Otherwise it can cause an electrical shock or
damage of the controller.
◎ Make sure the controller is isolated from power supply by the circuit breaker. Otherwise it
may cause a fire.
◎ Make sure that the ground terminal is grounded correctly.
◎ Do not touch the power input terminals of the controller and the pump’s terminals .
Otherwise it may cause an electrical shock.
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■ Operation
CAUTION
◎ Do not open or remove the front cover when operation. Otherwise it may cause an
electrical shock.
◎ Before testing the pump must be installed; can not make the pump dry-run for a long time.
In order to test the pump, the maximum dry-run time is not more than 15s
◎ If the pump turning is reversed, it can change any two lines of the pump’s three power
lines.
◎ When the water pump is due to the light shadow, it will restart the operation after 120s.
◎ If a water level probe is installed in the well, when the water level is below the level of
water shortage, the water pump will stop. If there is no water level probe, it will need to be
short. If a water level probe is not used, the controller terminal must be short.
■ Maintenance and check
WARNING
◎ Only qualified or authorized professional personnel can maintain, replace and inspect the
controller. Otherwise it may cause damage and injury.
◎ Wait at least 10 minutes after the power failure, or make sure that is no residual voltage
before carry out maintenance and inspection, otherwise it may cause damage.
■ Others
WARNING
◎ If failing to follow these instructions, resulting in damage to the machine, can not enjoy
the warranty service.
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Chapter 1 How It Works
The PDS23 solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable. The controller can
convert DC from the PV array to AC，and drive kinds of pumps. In sunny days, the
PDS23 solar pumping system can continuously pump water. The system without
batteries and other energy storage devices, it is recommended to take water pumped
to a reservoir for later use and water sources are those natural or special such as river,
lake, well or waterway, etc. A float switch can be installed in the water tower to
control the pump operation. And install a low-level probe in well to detect the well
water so that when the water shortage pump is stopped. Figure 1 shows a typical
diagram of a PDS23 solar pumping system. The major parts and components in the
system are listed after the diagram.
Figure 1 PDS23 solar pumping system
The PDS23 solar pumping system is designed which consists of:
A. Solar Array
B. DC Breaker or Disconnect Switch
F. Water Tower
Float Switch
E. Well
Level Switch
D. Pump
A. PV Array
C. PDS23 Solar Pump Controller
B. DC Breaker
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C. PDS23 series Solar Pump Controller
D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)
The PDS23 solar pump controller runs at variable speed while match the changing
power provided by the solar array. Variable speed operation means there is no
in-rush or surge of energy during the pump/motor start-up, helping to eliminate wear
on the motor and pumping system.
Pump Check Valve Requirements
Notice: In order to ensure maximum system reliability and water delivery, check
valves must be installed in the drop pipe. The first check valve must be installed at
the pump and additional check valves should be installed every 30m (100 ft) of
vertical pipe after the pump.
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1.1 Features
System Diagnostics
The PDS23 solar pump controller continuously monitors system performance and
detects a variety of abnormal conditions. In many cases, the controller will
compensate as needed to maintain continuous system operation; however, if there
is high risk of equipment damage, the controller will protect the system and display
the fault condition. If possible, the controller will try to restart itself when the fault
condition subsides. See Diagnostics and Troubleshooting section for a list of Fault
Codes and corrective actions.
Motor Soft-Start
Normally, when there is a demand for water and power is available, the PDS23
solar pump controller will be operating. Whenever the PDS23 solar pump
controller detects a need for water, the controller always “ramps up” the motor
speed while gradually increasing motor voltage, resulting in a cooler motor and
lower start-up current compared to conventional water systems. Due to the
controller’s soft-start feature this will not harm the motor.
Over Temperature Foldback
The PDS23 solar pump controller is designed for full power operation from a solar
array in ambient temperatures up to 45 °C. In excess of 45 ℃ temperature
conditions，the controller will reduce output power in an attempt to avoid shutdown.
Full pump output is restored when the controller temperature cools to a safe level.
Level Control Switch
The PDS23 solar pump controller can access two water level switch detects
remotely control the pump automatically. Level switch for PDS23 solar pump
controller is optional, not mandatory.
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Switching to Backup AC Power
The PDS23 solar pump controller’s input power terminal may be switched manually
to a backup AC power source.
Note: Depending on the model number, PDS23 solar pump controllers support
power input either 220VAC single phase, or 380VAC three phase, Please contact
controller manufacturer or authorized agencies for details.
When the system is running on back-up AC power, please check for sufficient DC
primary source power every 30 minutes. If the primary DC power is available, shut
down the controller, switch back to primary power and attempt to run on DC
power supply.
NOTICE : A DC circuit switch and a generator power switch must be installed, and
these two switches must be mechanically interlocked each other to prevent
switching on together resulting the solar PV and the generator being connected to
the solar PDS23 solar pump controller simultaneously! Please check if the design is
in accordance with all applicable national and local electrical codes.
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Chapter 2 General Information
The PDS23 solar pump controller is a variable speed motor drive designed to run
any IEC three-phase asynchronous motor. The PDS23 solar pumping system
provides water to remote locations by converting high voltage, direct current from a
solar array into alternating current to run a standard three-phase asynchronous motor.
When solar power is not available, the controller can be switched manually to an
alternate single-phase or three-phase AC input such as a generator or inverter from
battery, if available. The controller provides fault detection, motor soft start, and
speed control. The PDS23 solar pump controller is designed to provide these
features with the plug and play ease of installation.
The PDS23 solar pump controller is designed with the high standard of reliability
expected of products. The controller attempts to drive the pump and motor to deliver
water even under adverse conditions, reducing output as necessary to protect the
system components from damage, and only shutting down in extreme cases. Full
operation is restored automatically whenever abnormal conditions subside.
2.1 Inspection
Before you begin, receive and inspect the PDS23 solar pump controller unit. Verify
that the part number is correct and that no damage has occurred during transit.
NOTE: PDS23 solar pump controller is one component of a PDS23 solar pumping
system which has other two optional components, solar array and AC pump with
motor.
2.2 Descriptions and Features
The PDS23 solar pump controller is based on a standard PDS23 platform controlling
a standard three-phase asynchronous motor driving a pump powered by a solar array
or an optional AC generator backup.
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The PDS23 solar pump controller continuously monitors system performance and
incorporates a number of features for pumping system protection. In the event of a
fault, the PDS23 solar pump controller will indicate the type of fault through the
LED display mounted on the front cover of controller.
The PDS23 solar pumping system is optimized for pumping under adverse input
power conditions unique to solar arrays：
• Internal diagnostics will tolerate a lower input voltage.
• Whenever possible, the controller attempts to drive the pump load by maximizing
power output from the solar array.
An easy to use interface is provided to enhance configurability and enable remote
system monitoring.
• A LED display provides a detailed indication of system status.
• A small keypad offers flexibility for selection of user options.
2.3 Protection Features
Electronic monitoring gives the controller the capability to monitor the system and
automatically shut down in the event of:
• Dry well conditions – with low level switch
• Bound pump – with auto-reversing torque.
• High Voltage Surge
• Low Input Voltage
• Open motor circuit
• Short circuit
• Over heat
NOTE: This controller provides motor overload protection by preventing motor
current from exceeding rating current and by limiting the duty cycle in the event of
low water level. This controller does not provide over temperature sensing of the
motor.
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2.4 PDS23 Solar Pump Controller Model Description
2.4.1 Model Description
PDS 23 - 4 T 5R5
① ② ③ ④ ⑤
Segment
Description
Options
①
PDS series
②
Series ID
2: Series of 2nd generation.
3: Apply to three-phase induction motor
③
Rated Output Voltage
2: 220V three phase; 4: 380V three phase
④
Input Voltage
S: 310VDC rating, MPPT range 280VDC ～360VDC(Note 1)
T: 540VDC rating, MPPT range 500VDC ～600VDC(Note 2)
⑤
Motor Power Rating
004:4kW; 5R5:5.5kW; R: decimal point
Note 1: Supporting Alternating Current input, with voltage rating of 220VAC single phase connected
to terminal R&T.
Note 2: Supporting Alternating Current input, with voltage rating of 380VAC three phase connected to
terminal R, S and T.
2.4.2 PDS23 Solar Controller General parameters
General Parameters
Protection
Surge Protection
Integrated
Overvoltage Protection
Integrated
Undervoltage Protection
Integrated
Locked pump Protection
Integrated
Open circuit Protection
Integrated
Short circuit Protection
Integrated
Overheated Protection
Integrated
Dry Run Protection
Integrated
Communication
MODBUS Communication Card
Optional, RS-485 Isolated
Others
Ambient Temperature Range
-20°C ～60°C; >45°C, Derating as Required
Cooling Method
Fan Cooling
Ambient Humidity
≤ 95%RH
Standard Warranty(month）
18
Certificates
IEC/EN 61800-5-1,IEC/EN 61800-2:2004,IEC/EN 61800-3:2004,CE
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2.4.3 PDS23 Solar Controller Input and Output Data
PDS23-2SXX Input and Output Data
Controller Model
PDS23-2SR75
PDS23-2S1R5
PDS23-2S2R2
Input Data
Max Input Voltage(Voc)
DC 450V
Recommended Voltage, at MPP
DC 280-360V
Recommended PV Array Power[kW]
0.9 ～1.2
1.8 ～2.4
2.7 ～3.5
Alternate AC Generator
Input Voltage
Single Phase AC 200-240V(±10%)
Max Amps(RMS)[A]
8.2
14
23
Power and VA Capability[kVA]
1.5 3 4
Output Data
Output Voltage, Rated
Three Phase AC 200-240V
Max Amps(RMS)[A]
4 7 9.6
Output Power, Rated[kW]
0.75
1.5
2.2
Output Frequency
0～50Hz/60Hz
PDS23-4TXX Input and Output Data
Controller Model
PDS23-4T2R2
PDS23-4T004
PDS23-4T5R5
PDS23-4T7R5
Input Data
Max Input Voltage(Voc)
DC 800V
Recommended Voltage, at MPP
DC 500-700V
Recommended PV Array Power [kW]
2.7 ～3.5
4.8 ～6.4
6.6 ～8.8
9 ～12
Alternate AC Generator
Input Voltage
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
5.8
10.5
14.6
20.5
Power and VA Capability[kVA]
4
5.9
8.9
11
Output Data
Output Voltage, Rated
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
5.1 9 13
17
Output Power, Rated[kW]
2.2 4 5.5
7.5
Output Frequency
0～50Hz/60Hz
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Controller Model
PDS23-4T011
PDS23-4T015
PDS23-4T18R5
PDS23-4T022
Input Data
Max Input Voltage(Voc)
DC 800V
Recommended Voltage, at MPP
DC 500-700V
Recommended PV Array Power[kW]
13.2～17.6
18～24
22.2～29.6
26.4～35.2
Alternate AC Generator
Input Voltage
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
26
35
38.5
46.5
Power and VA Capability[kVA]
17
21
24
30
Output Data
Output Voltage, Rated
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
25
32
37
45
Output Power, Rated[kW]
11
15
18.5
22
Output Frequency
0～50Hz/60Hz
Controller Model
PDS23-4T030
PDS23-4T037
PDS23-4T045
PDS23-4T055
Input Data
Max Input Voltage(Voc)
DC 800V
Recommended Voltage, at MPP
DC 500-700V
Recommended PV Array Power[kW]
36～48
44～59.2
54～72
66～88
Alternate AC Generator
Input Voltage
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
62
76
92
113
Power and VA Capability[kVA]
40
57
69
85
Output Data
Output Voltage, Rated
Three Phase AC 380/400/415/440V(±15%)
Max Amps(RMS)[A]
60
75
91
112
Output Power, Rated[kW]
30
37
45
55
Output Frequency
0～50Hz/60Hz
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