PDS23 Plus Solar Pump
ControllerUser Manual
Version code：PDS23 Plus-EN-60200183-1707
PDS23 Plus Series
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Preface
Thank you for using PDS23Plus solar pump controller. 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 1How It Works ................................................................................... - 6 -
1.1 Features.................................................................................................................... - 7 -
Chapter 2 General Information .................................................................... - 9 -
2.1 Inspection ................................................................................................................ - 9 -
2.2 Descriptions and Features ........................................................................................ - 9 -
2.3 Protection Features ................................................................................................ - 10 -
2.4 PDS23Plus Solar Pump Controller Model Description .......................................... - 11 -
2.5 Outline &Installation Dimensions .......................................................................... - 13 -
Chapter 3 Mechanical and Electrical Installation ....................................... - 14 -
3.1 Mechanical Installation .......................................................................................... - 14 -
3.2 Electrical Installation ............................................................................................. - 15 -
Chapter 4 Start-up and Operation ............................................................. - 20 -
4.1 Keypad Description ............................................................................................... - 20 -
4.2 Keypad Operation Process ..................................................................................... - 21 -
4.3 Trial operation ........................................................................................................ - 22 -
4.4 Running status panel display parameters ............................................................... - 23 -
4.5User Definable Parameters...................................................................................... - 23 -
Chapter 5 Diagnostics and Troubleshooting .............................................. - 28 -
5.1 Fault Codes ............................................................................................................ - 28 -
PDS23 Plus Series
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5.2 Common Faults and Remedies ............................................................................... - 31 -
Chapter 6 Regular maintenance ................................................................. - 33 -
6.1 Controller and Pump .............................................................................................. - 33 -
6.2 Solar panels............................................................................................................ - 33 -
6.3 Cable ...................................................................................................................... - 33 -
Chapter 7 Backup AC power ...................................................................... - 34 -
PDS23 Plus Series
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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 ofthe controllerwhen installingormovingthe controller, can not
justhold theshellto prevent theinjuredorbrokencontroller.
◎ Install the controller on nonflammable material like metal. Otherwise it may cause a
fire.
◎ When thecontroller is mountedin a protectivecabinet, the cabinet need to
setventstoensureambient temperature is below40℃,otherwise itmay 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 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 1How It Works
PDS23 Plus solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable.PDS23 Plus solar
pump controller can convert DC from the PV array to AC, and drive kinds of pumps.
In sunny days, the 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 thatwhen thewater shortagepump is stopped. Figure 1 shows a
typical diagram of the pumping system. The major parts and components in the
system are listed after the diagram
Figure 1 PDS23 Plus solar pumping system
PDS23 Plus solar pumping system is designed which consists of:
A. Solar Array
B. DC Breaker or Disconnect Switch
C. PDS23 Plus series Solar Pump Controller
F. Water Tower
Float Switch
E. Well
Level Switch
D. Pump
A. PV Array
C. PDS23 Plus Solar Pump Controller
B. DC Breaker
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D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)
PDS23Plus 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.
1.1 Features
System Diagnostics
PDS23Plus 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, PDS23Plus
solar pump controller will be operating. Whenever the controller detects a need for
water, the controller always “ramps up” the motor speed while gradually
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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
PDS23Plus solar pump controller is designed for full power operation from a solar
array in ambient temperatures up to 45 °C.In excess of45 ℃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
PDS23Plussolarpumpcontroller canaccesstwowater level switch
detectsremotelycontrol the pumpautomatically.Level switchforthe controlleris
optional,not mandatory.
Switching to Backup AC Power
The input power of the PDS23 Plus solar pump controller can be switched to
standby AC power through a power switch box.
Note: the controllers support power input 380VAC three-phase.
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 switch and aAC switch must be installed in the power switch box,
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 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
PDS23Plus solar pump controller is a variable speed motor drive designed to run
any IEC three-phase asynchronous motor. PDS23Plus 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 to an alternate
three-phase AC input such as a generator, if available. The controller provides fault
detection, motor soft start, and speed control. The controller is designed to provide
these features with the plug and play ease of installation.
The PDS23Plus 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 controller unit. Verify that the part number
is correct and that no damage has occurred during transit.
NOTE: PDS23Plus solar pump controller is one component of the PDS23Plus solar
pumping system which has other two components, solar array and AC pump with
motor.
2.2 Descriptions and Features
The PDS23Plus solar pump controller is based on a standard PDS23Plus 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 controller continuously monitors system performance and incorporates a
number of features for pumping system protection. In the event of a fault, the
PDS23Plus solar pump controller will indicate the type of fault through the LED
display mounted on the front cover of controller.
Thepumping 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 PDS23Plus Solar Pump Controller Model Description
2.4.1 Model Description
PDS23Plus2.2K
①②③④
Segment
Description
Options
①
PDS series
②
Series ID
2: Series of 2nd generation.
3: Apply to three-phase induction motor
③
Plus
Enhancement type
④
Motor Power Rating
2.2K: 2.2kW; K: kW
Note 1:Rated input voltage 540VDC , recommended Voltage(MPP) 500VDC-700VDC ;
2:Supporting alternating current input, with voltage rating of 380VAC three phase
connected to terminal R, S and T.
2.4.2General parameters of PDS23 Solar Pump Controller
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
RS-485 Isolated
Others
Ambient Temperature Range
-20°C～60°C;>45°C, Derating as Required
Cooling Method
Fan Cooling
Ambient Humidity
≤ 95%RH
Level of Protection
IP65
Certificates
IEC/EN 61800-5-1,IEC/EN 61800-2:2004,IEC/EN61800-3:2004,CE
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2.4.3 Input and Output Parametersof PDS23 Plus Solar Pump Controller
Controller Model
PDS23
Plus 2.2K
PDS2Plus
4K
PDS23Pl
us 5.5K
PDS23Pl
us 7.5K
PDS23Pl
us 11K
Input Data
PV Source
Max Input Voltage(Voc)
DC800V
Recommended Voltage, at MPP
DC500～700V
Recommended PV Array Power
[kW]
2.7～3.5
4.8～6.4
6.6～8.8
9～12
13.2～
17.6
Alternate AC Generator
Input Voltage
380/400/415/440VAC(±15%), Three Phase
Power and VA Capability[kVA]
4.0
5.9
8.9
11.0
17
Output Data
Output Power, Rated[kW]
2.2
4.0
5.5
7.5
11
Output Voltage, Rated
380/400/415/440VAC(±15%), Three Phase
Rated Output Amps(RMS)[A]
5.1
9.0
13.0
17.0
25.0
Max Amps(RMS)[A]
9.0
13.0
17.0
25.0
32.0
Output Frequency
0～50Hz/60Hz
Note: according to different regions, the recommended PV array power is 1.2 ~ 1.6 times the
power of the controller.
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2.5 Outline &Installation Dimensions
2.5.1 Outline &installation dimensions diagram
(Unit: mm)
155.6
179
240
191.3
168
150
50
50
144.3
22
Figure 2 PDS23 Plus 2.2K，PDS23 Plus 4K
Outline &installation dimensions diagram
Figure 3PDS23 Plus 5.5K，PDS23 Plus 7.5K，PDS23 Plus 11K
Outline &installation dimensions diagram
214
202
300
235
117.5
195
65
65
154
20
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Chapter 3Mechanical and Electrical Installation
3.1 Mechanical Installation
3.1.1Overheat protection
Theprotection level of PDS23 Plussolar pump controller reached IP65; if installed
in the outdoor, the controllers should be installed in a well ventilated place, and
avoid direct sunlight and rain.The best installation location is below the solar array,
which can prevent the equipment from overheating and performance degradation.
In extremely high temperature, high temperature may cause the controller stop to
protect itself.
3.1.2 Location Selection
The PDS23Plus solar pump controller is
intended for operation in ambient
temperatures up to 60℃, but in order to avoid
failure caused by overheating, it is
recommended to install the controller in
shadow position.
PDS23 Plus solar pump controller can be
installed outdoors, but to avoid direct sunlight;
it can be installed in the bracket under the
solar module.
Figure 4Installation Location
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3.2 Electrical Installation
3.2.1 Terminals
The following are typical figures of terminal blocks.
Figure 5 Main terminals (The sequence may be different from actual product)
Figure6 Control terminals (The sequence may be different from actual product)
Note：The terminals not referred in the user manual are invalid.
3.2.2 Power in DC Wiring
For a solar pumping system, a two-pole DC disconnect switch must be installed
between the solar array and the PDS23Plus solar pump controller. Connect the
cables which comes from the two-pole DC disconnect Switch downstream
terminals marked with “+” and “-” (positive and negative poles of Solar panel
output), to PDS23Plus solar pump controller’s terminals block labeled as “R/+”,
“T/-”.
M1 M2 M3 COM M4 M5 M6 COM
NC
N0
Remote Float Switch
Low-water
sensor probe
No Function
S+
S-
RS485
Interface
R/+
S
T/-
U V W
DC/AC INPUT
GROUND
PUMP
To reverse direction,
reverse any two
wires.
The DC and AC can't
input at the same
time.
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WARNING
Before connect DC wiring, following the steps below to prevent hazardous electric shock
resulting in serious injury or device burning.
• Make sure that the external DC disconnect switch is off.
•Make sure that AC power is disconnected (If AC power supply is wired as backup
power,AC and DC power supply can not simultaneously put into the controller, otherwise it
will damage the controller.)
3.2.3 Junction box connection
If there are a large number of solar modules, it is needed to use a junction box to
converge the bus to the solar array.Thejunction box need to install fuses, lightning
protection device and DC switch.The fuse and the DC switch can prevent the short
circuit protection; the lightning protection device can play the direct current side the
lightning protection function. The junction box must be sealed, and water can not
enter.
3.2.4 Ground Wiring
Ground terminal (GND) is labeled as this icon . Please connect it to the ground
Correct grounding helps to prevent shock hazard if there is a fault in the motor.
3.2.5 Motor Wiring
Connect the cable with four wires from the Motor to the controller terminal block to
terminals U, V, W, and GND (See Figure 9). Check motor lead color to ensure
correct installation.。
Note: To reverse direction of motor rotation, reverse any two wires
US
Black（BLK）
Red（RED）
Yellow（YEL）
Ground（GND）
International
Gray（GRY）
Black（BLK）
Brown（BRN）
Ground（GND）
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It is recommended that use a wire tube to protect the electric wire from the
destruction of wildlife and natural weathering, and bury the wire tube into the
ground to strengthen protection. If you do not use a wire tube, you can use a higher
quality outdoor cable.
3.2.6Low water level probe wiring (optional)
In order to avoid dry pumping lead to pump damage, a wells probe can be
connected to the terminals of the PDS23Plus solar pump controller, so as to detect
the water level in wells; and the wire maximum length can not more than 50m. If
there is no water level probe for the detection of the water level, please keep the
two terminals of the controller short. The controller can also detect water through
the built-in software water detection function;look upFD function group in section
4.5.
3.2.7 Water tank level float wiring (optional)
Use a floating ball switch to prevent reservoir overflow is recommended. When the
reservoir is full, the pump will stop; when the water level is lower than the low level,
the pump will be restarted. It can prevent the overflow, limit the unnecessary pump
wear. The PDS23Plus controller allows the use of small signal line to connect to
remote float switch, even if the position of the reservoir is far away.
Figure 7FloatingBallDiagram
position
pump off
position
pump on
pumping
range
cable
weight
sealed cable
clamp
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Floating ball switch request:
1. Three signal line
2. The minimum requirements for 1 mm² line diameter, the distance up to 600m
3. I f the application is in a long distance transmission, the need to use the shielded
wire.The end of the shielding layer close to the controller needs to be grounded, the
end close to the floating ball switch;the end close to the float switch is not required
to be grounded.
If the float switch is not used, the M6 and COM are kept short.
Figure 8 Float ball wiring diagram
3.2.8Electrical conduit
When the system installed in the outdoor, electricalconduit can be used to protect the
outdoor electric wires, so as to avoid the impact from the weather, human activities,
chewing animals. If you do not use the electrical conduit, use the higher quality
outdoor wire.
M5
M6 COM
NC
N0
Remote
Float
Switch
COM
Float Switch
N0
NC
COM
if cable is shielded,
ground this end only
UP: closed
DOWN: open
normal: open
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3.2.9 System Wiring Diagram
Figure 9 System Wiring Diagram
NOTE:
1. The float switch is optional; if not use, please keep the terminal M6 and COM
short.
2. Low water level probe is optional; if not use, please keep the terminal M4 and
COM short.
In the case of conventional 250W polycrystalline components, the peak voltage is
30.6V and the open circuit voltage is 37V. Description of the number of input
components in series:
The PDS23Plus series controller is connected in series with the serial number of the
input components of the 18～20 block, and the 250W 500～700VDC (MPPT) is
satisfied.
DC/AC INPUT
Pump
To reverse direction,
reverse any two
wires
The DC and AC
can't input at the
same tim e
.
Remote Float
Switch
Low-water
sensor probe
Submersible
Cable Splice
Pump M otor
Low Water
Level Probe
(optional)
Float Switch
(optional)
Earth Ground
PV Array
R/+
S
T/-
U V W
COM M4 M5 M6 COM
NC
N0
GROUND
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Chapter 4 Start-up and Operation
4.1 Keypad Description
RUN
STOP
5 0 .0 0
PRGM
ENT
SHIFT
RUN
STOP
▼
▼
Program/exit
key
Digital
Display
Data enter
key
Shift key
Run/stop
key
Up increase
key
Down decrease
key
ALM1
ALM2
Figure 10 Keypad Schematic Diagram
4.1.1 Key Functions
Symbol
Button Name
Function Description
PRGM
Program/ Exit Key
Enter or exit of menu, parameter modification
ENT
Data Enter Key
Progressively enter menu and confirm parameter
▲
Up Increase Key
Progressively increase data or function codes.
▼
DownDecrease Key
Progressively decrease data or function codes.
SHIFT
Shift Key
Use it to select displayed parameters cyclically
during running or stop status. In parameter setting
mode, press this key to select the bit to be modified.
RUN/STOP
Run/stop key
Start to run the controller in keypad control mode.
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4.1.2Indicator Light Instruction
RUN: (Always on)running instruction;(Flicker)sleep instruction
STOP: stop or standby instruction
ALM1: controller fault alarm
ALM2: water shortage or full of water alarm
4.2 Keypad Operation Process
4.2.1 Parameter Setting
Three levels of menu are as following：
• Function code group (first-class)
• Function code (second-class)
• Setting parameter of function code (third-class)
In order to set up the electric automatic start function FD.07=11 as an example, the
modified parameter flow chart is as follows:
Figure11Schematic Diagram of Function Parameters
Display
Reading:
Button:
Stand By Status
0.00
f0
First Class
fd
fd.07
0.00
fd
fd.10
11
10
Run Status
Third Class
Value N ow
N ew Value
(Frequency/H z)
(Frequency/H z)
Display
Reading:
Button:
PRG M
▲
▲
EN T
EN T
EN T
First Class
First Class
Second Class
PRG M
PRG M
Second Class
Third Class
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4.2.2 Fault Reset
After the controller has failed, the controller will display the relevant fault code
information. The conventional fault code (E002/3/4/5/6/7/8/9/10/11/12/18) can
automatically reset after 10s operation, and can also choose to reset the RUN/STOP
on the keyboard. If the conventional failure persists, the controller will reset once
every 10s. Special fault code (E001/13/14) requires the user through theRUN/STOP
key on the keyboard to reset the fault; the controller can continue to run after the
reset.
4.3 Trial operation
●Check and make sure wiring are correct. If needed, take a megger to test the
insulation of motor, cable, etc.；
●Use a multimeter to test the PV output voltage at the DC switch.；
●Power on the controller by switch the DC switch.
●If necessary, modify and set the parameters of motor to the controller
For Example, if the motor which rated frequency is 60Hz, these parameters need
modification:
High limit of running frequency F0.12=60;
Other related parameters are: motor rated power F2.01, motor rated frequency
F2.02=60, motor rated speed F2.03, motor rated voltage F2.04, motor rated current
F2.05.
Note: default motor rated frequency setting is 50Hz.
Slowly start to check the direction
Pressing the RUN/STOP key to start the motor shortly and slowly, and check the
direction of the pump.
If the pump is in dry-run state, the maximum operating time can not exceed 15s,
otherwise it may cause damage to the pump.
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If the pump is in dry-run, the maximum operating time can not exceed 15seconds;
otherwise it may cause damage to the pump. If the pump steering error, close the DC
switch, according to the pump / motor wiring to change the wiring of the motor
section of the two leads.
After the above parts are complete, you can try to run the system.
Let the system work for an hour, check the water supply capacity.
Commissioning finish
When the light is insufficient, the solar power module output power will be
reduced, and the pump operation speed will be very slow until stop. The controller
will attempt to start every120s, and during the trial run, the running indicator is
always on.
When a shadow suddenly passes through the battery array, the controller will lose
track of the input voltage, and the pump will stop working. But the controller does
not show the fault, the controller will try to restart the pump.
4.4 Running status panel display parameters
Description: press "shift" key to switch
Display code
Name
Description
Unit
Remarks
H
OutputFrequency
The Operating Frequency
Hz
◎
P
Input Power
Input Power of the Controller
V
◎
A
OutputCurrent
Controller Actual Output Current
A ◎ d
DC BusVoltage
DC BusVoltage
V
◎
4.5User Definable Parameters
○：The parameters can be modified at stop or running status.
●：The parameters cannot be modified at running status.
◎ The parameters which are actual-detecting record value and cannot be modified.
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Function
Code
Function
Descriptions
Unit
Factory Setting
Modifica
tion Type
F0 Group: Basic Parameters
F0.12
High limit of
running frequency
30.00～60.00
Hz
50.00
〇
F0.14
Low limit of
running frequency
0.00～F0.12
Hz
20.00
F0.18
Acceleration time
0.1 ～3600
s
10.0
〇
F0.19
Deceleration time
0.1 ～3600
s
10.0
〇
F0.20
Default setting
0:Not restore to default setting
1: Restore to factory setting
2:Fault record clearing
0 ●
F2 Group: Motor Parameters
F2.01
Motor rated power
0.4 ～400.0
kW
Different
according to
inverter model
●
F2.02
Motor rated
frequency
10.00 ～F0.10
Hz
50.00
●
F2.03
Motor rated speed
0 ～36000
rpm
1500
(Different
according to
inverter model)
〇
F2.04
Motor rated
voltage
0 ～480
V
Different
according to
inverter model
●
F2.05
Motor rated
current
0.8 ～2000
A
Different
according to
inverter model
●
F7 Group: Display Interface Parameters
F7.00
User password
0 ～9999
0
〇
F7.02
Manufacturer
debug
Reserved
0 〇
F7.09
Module
temperature
0 ～100.0
℃ ●
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Function
Code
Function
Descriptions
Unit
Factory Setting
Modifica
tion Type
F7.10
Inverter firmware
version
◎
F7.11
Accumulative
running time
0 ～9999
hour ◎
FA Group: Protection and Malfunction Parameters
FA.14
Fault record of the
one before last
0: No fault
1: Inverter module protection
(E001)
2. Over-current when accelerate
(E002)
3: Over-current when decelerate
(E003)
4: Over-current at constant
speed (E004)
5: Over-voltage when accelerate
(E005 )
6: Over-voltage when decelerate
(E006)
7: Over-voltage at constant
speed (E007)
8:Hardware overvoltage (E008)
9:Under voltage (E009)
10:Inverter overload (E010)
11:Motor overload (E011)
12:Phase-lack of input (E012)
13:Phase-lack of output (E013)
14:Heatsink overheating (E014)
15:External fault (E015)
16:Communication fault (E016)
17:Reserved
18:Current detection fault
(E018)
20:Well level fault(E020)
21:Tank level fault(E021)
22:EEPROM fault (E022)
26:Water shortage fault (E026)
◎
FA.15
Last fault record
〇
FA.16
Current fault
record
〇
FA.17
Running
frequency when
fault occurs
Hz ◎
PDS23 Plus Series
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Function
Code
Function
Descriptions
Unit
Factory Setting
Modifica
tion Type
FA.18
Output current
when fault occurs
A ◎
FA.19
DC bus voltage
when fault occurs
V ◎
FD Group: Solar pumping special parameters
FD.07
Auto start when
power on
10：Disable
11：Enable
10
〇
FD.10
Water shortage
detection time
0～250 (0: disabled)
s
10
〇
FD.11
Lowest running
frequency when
yielding water
0.00 ～F0.10
Hz
20.00
〇
FD.12
Water shortage
detection current
ratio
corresponding to
no-load current
80.0 ～300.0
%
150.00
〇
FD.13
Interval of water
shortage detection
1 ～9000
min
20
〇
Parameter interpretation:
F0.14, Low limit of running frequency: this parameter defaults to 20Hz, when the
light becomes weak, and the controller output frequency is lower than F0.14, the
controller will be in standby mode. After the light becomes strong, the controller
will rerun. Can set this parameter artificially, in order to avoidpump at low speed
without water, reduce the pump abrasion at low speed.
F2.01～F2.05,Motor parameter: the user can be set according to the actual pump
motor nameplate parameters
F7.00 user password: the user can set a 5 digits password;after the password is set up
and confirmed, the password will be valid for a minute.
PDS23 Plus Series
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FD.07, Automatic start when power on: the factory defaults to 10 (disabled).Itcan be
set to 11 (enabled), then as long as the solar module power supply, the controller will
automatically start and achieve automatic operation of the whole day.
FD.10 water shortage detection time: when applied to a deep well pump, not using
the water level probe to detect the water shortage, the controller can use the built-in
water shortage detection function to complete the water shortage detection. When
this parameter is not 0, the software will start the function of water shortage.
Software shortage detection principle: If the water shortage happens, the controller
will still run FD.10 time, after that it will appear the water shortage fault E026.The
fault will be reset and the controller will restart automaticallyafter 20 minutes. If
there is no water shortage but fails E026, it may appear false; then you can simply
reduce FD.12 value.
WARNING ：DO NOT touch any other piece inside the PDS23Plus Solar pump
controller while power is applied. To service any other areas of the controller,
disconnect ALL power sources and wait 5 minutes before continuing.
For the selection of PDS23Plus solar pump controller, it can be matched with the
power of the pump. If the length of cable is more than 100m, add an output reactor.
PD20Series
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Chapter 5 Diagnostics and Troubleshooting
The PDS23Plus solar pump controller will attempt to drive the pump to deliver
water even under adverse conditions. To ensure years of reliable service, it must also
protect the system components from conditions that might result in equipment
damage. When adverse conditions arise, the controller will continue to deliver as
much water as possible at reduced output if necessary, and will shut down only in
extreme cases. Full operation will resume automatically whenever abnormal
conditions subside.
If the controller has stopped to indicate a fault code on the display, the associated
time-out delay will vary depending on the nature of the fault. The number following
the “E” symbol corresponds to the error code for the offending condition.
5.1 Fault Codes
Fault code
Fault description
Possible causes
Remedy
E001
IGBT module
fault
Too short acceleration time
Increase acceleration time
Damaged IGBT module
Ask for support
Malfunction caused by
interference
Inspect external
equipment and eliminate
interference
Improperly grounding
Check grounding wire
E002
Over-current
during
acceleration
Too fast acceleration
Increase acceleration time
Too low input voltage
Check the input power
supply or wiring
Lower-rating controller
Replace with higher-rating
controller
PD20Series
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Fault code
Fault description
Possible causes
Remedy
E003
Over-current
during
deceleration
Too-fast deceleration
Increase deceleration time
Too-heavy and large-inertia
load
Add proper braking units
lower-rating controller
Replace with higher-rating
controller
E004
Over-current at
constant running
speed
Sudden change of load
Check the load
Too low input voltage
Check the input power
supply or wiring
Lower-rating controller
Replace with higher-rating
controller
E005
Over-voltage
during
acceleration
Abnormal input voltage
Check input power
Restart the motor when
instantaneous trip-off occurs
Avoid prompt restart
when trip-off
E006
Over-voltage
during
deceleration
Too-fast deceleration
Add proper braking units
Abnormal input voltage
Check input power supply
or wiring
E007
Over-voltage at
constant running
speed
Abnormal input voltage
Install proper input AC
reactor
E008
Hardware
over-voltage
Abnormal input voltage
Check input power supply
or wiring
Too-fast deceleration
Increase deceleration time
E009
Under voltage of
DC bus
Too-low input voltage
Check input power supply
or wiring
E010
Controller
overload
Too fast acceleration
Increase acceleration time
Restart the motor when
instantaneous trip-off occurs
Avoid prompt restart
when trip-off
Too-low input voltage
Check input power supply
or wiring
Too-heavy load
Replace with higher-rating
controller
PD20Series
- 30 -
Fault code
Fault description
Possible causes
Remedy
E011
Motor overload
Too-low input voltage
Check input power supply
or wiring
Lower-rating controller
Replace with higher-rating
controller
E013
Output phase loss
Broken wires in the output
cable
Check the wiring and
installation
Broken wires in the motor
winding
Loose output terminals
E014
Controller
overheat
Instantaneous over-current of
controller
Refer to over-current
remedy
Output short circuit
Re-wiring of output
Cooling fans of controller
stopped or damaged.
Obstruction of ventilation
channel
Replace cooling fan and
clear the ventilation
channel
Too-high ambient temperature
Decrease the ambient
temperature if possible
Loose cables or terminals
Inspect and tighten the
wire and terminals
Abnormal power circuit
Ask for support
Abnormal control PCB board
E016
Communication
fault
Improper baud rate setting
Set proper baud rate
Receive wrong data
Push STOP/RESET to
reset and ask for support
Long-time communication
interruption
Check communication
devices and cables
E018
Current detection
fault
Loose wires or connectors of
control board
Check the wiring and
connectors
Amplifying circuit abnormal
Ask for support
Hall sensor is damaged
Power circuit abnormal
PD20Series
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Fault code
Fault description
Possible causes
Remedy
E020
Well Level Fault
Dry well or slow water
recovery
Wait for water to recover
or reinstall the pump
E021
Tank Level Fault
before auto start
High level limit is reached.
Wait until water level
comes below the low level
limit, and then the PDS23
Solar controller will start
the pump again
E022
EEPROM fault
Read/ Write fault of control
parameters
Push STOP/RESET to
reset
EEPROM damaged
Ask for support
E026
Water shortage
fault
Water shortage of water source
Stop the controller Repair
broken wiring or replace
water level switch
Verify if the setting of FD.12
"Water shortage detection
current ratio" is too high, while
FD.10 "Water shortage
detection time" is non-zero and
the current sensing is enabled.
Reduce setting value of
FD.12
5.2 Common Faults and Remedies
The PDS23Plus solar pump controller may have following faults or malfunctions
during operation, please refer to the following remedies.
5.2.1 Pump can not run
The main problem of the new system is that the wiring is not standardized and the
controller terminal line falls，so that the pump cannot run. Sometimes the RUN
indicator light on the keyboard is bright, and the controller also has voltage
output,but may be the solar array does not have enough power to start the pump;
then the controller will attempt to start the pump every 120s. There are the following
reasons for the pump can not run:
PD20Series
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① If there is no enough sun light, and the controller's input power is not enough.
② Motor wiring errors cause the pump to reverse, change the wiring.
③ The motor shaft vibratesand can not rotate, it may be caused by the wiring
errors;Need to re check the motor wiring.
④ Pumps and pipes are clogged with mud and debris, and the pump can't run
5.2.2 Controller over current, overload fault（E002/3/4/10/11）
The controller appears over current and overload failure may be due to the following
reasons:
①The pump or pipe plug causes the pump current increase and the controller
protection; Need to pull out the pump and check
②Because of the increase in operating current of the pump, which is caused by the
pump wire is too long, the controller will be protected, and the controller will be
enlarged to use.
5.2.3 DC switch trip when power on
① A multimeter can be used to check the internal circuit of the controller, if there is
a short circuit, the machine has been damaged
②Check if the machine has a burning smell; if there is a burning smell, please
contact the agent to replace the controller
5.2.4 The keyboard without display after power on
① Use a multimeter to measure the input voltage of the controller; check the
voltage is normal.
②Check if the machine has a burning smell; if there is a burning smell, please
contact the agent to replace the controller
PD20Series
- 33 -
Chapter 6 Regular maintenance
6.1 Controller and Pump
• Controller
Periodically checking of Status display, error code display and fault record, long
term verification of cooling fan and cleaning of heat sink are needed.
• pump
The pump’s motor is permanently sealed, no need to maintain. Pump head is a
mechanical device, may be used for a period of time, due to the sand in the water,
and other impurities cause a certain wear, the performance of the pump needs to be
regularly detected. If the flow of the pump is less than the normal value, may need to
be replaced.
6.2 Solar panels
Periodically cleaning of the surface of panels and checking wiring are required.
6.3 Cable
Need to regularly check the power cable and ground wire to make sure all the wires
are reliably connected and without being corroded.
PD20Series
- 34 -
Chapter 7 Backup AC power
In order to ensure continuous water supply, solar water pump system can be
manually switched to standby AC power supply when the light is insufficient or wet
days. When switching, the need to ensure that the DC and AC power supply reliable
mutual lock. Backup AC power source can be a local power grid, or a diesel
generator (please refer to the 2.4.3 technical form).
Warning: at any time, only one power supply can be entered, otherwise it may cause
the controller to damage.
Take three phase 380VAC backup AC power supply for example, the wiring is
shown in the following diagram:
Figure 12 schematic diagram of alternate AC power supply
DC/AC INPUT
Pump
GROUND
To reverse
direction ,reverse
any two wires
The DC a nd AC
can't input at
the same time
.
Remote Float
Switch
Low-water
sensor prob
e
Pump Motor
Low Wat er
Level Pro be
(optiona l)
Float Switch
(optiona l)
Earth Gro und
PV Array
Backup
AC Power
DC Switc h
AC
Switch
R S T U V W
COM M4 M5 M6 COM
NC
N0
Power Switch Box
PD20Series
- 35 -
System Report
System and Components
Date ofPurchase
Distributor
(Contact details)
System
Controller
Serial Number
Motor Serial
Numberor
Power
Pump Type
Submersible
Surface
Solar Power
Solar Module
Manufacturers
Type
PeakVoltage(V
mp）
Open Circuit
Voltage(Voc)
Quantity
Connection
Series
Parallel
PD20Series
- 36 -
Installation
Installation Date
Installer
(contact details)
Submersible Pump
Surface Pump
Well Depth
m/ft
Head
(self suction)
m/ft
Pump Depth
m/ft
Vertical Height (well
mouth to the tower
top)
m/ft
Suction lift
m/ft
MAX. Suction
lift
m/ft
Static Water Level
m/ft
Dynamic Water Level
m/ft
Vertical Pipe in Well(pump)
Suction Pipe
Diameter
mm/inch
Diameter
mm/inch
Type
Type Length
m/ft
Length
m/ft
Additional Pipe (to water tower)
Vertical Pipe
Diameter
mm/inch
Diameter
mm/inch
Type
Type Length
m/ft
Length
m/ft
Cable of Submersible Pump
Cable of Surface Pump
Wire Diameter
mm²/
AWG
Wire Diameter
mm²/
AWG
Length (from the
controller to pump）
m/ft
Length（from
the controller to
pump）
m/ft
PD20Series
- 37 -
V1.1
Inverter
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