Lorentz Ps150 c Manual En

7/30/2019 Lorentz Ps150 c Manual En

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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.

PS150CInstructions for Installation, Operation and Servicefor Controllers from serial # 10070901

1 Introduction

Thank you or purchasing a LORENTZ PUMP. LORENTZ hasset a new standard or quality and economy in solar pum-ping. It incorporates the best solar pump technologies thatwere very expensive until its introduction in 2002.

PS150 is a highly ecient pump system which is economic-al or (drip-) irrigation, livestock, dugout foating pump, wa-ter transer to remote places and many other applications.

PS150C is a submersible pump with a centriugal pumpend. The PS150 brushless DC motors are specially madeor this system. The motor is using very advanced raw earthmagnet technology, hand made wiring or highest copperdensity and does not need wearing brushes. This results inan exceptional high eciency with low temperature dissi-pation.

PS150 can either be used in a battery system with voltageso 12 V or 24 V or alternatively it can be operated as a so-lar-direct system using the same Controller PS150.

The solar battery is charged up during daylight hours usinga separate charger. The charger works eectively during re-duced sunlight conditions when direct pump operation is

not possible. The energy stored in the battery is availableto operate the pump at any time, day or night and duringperiods o bad weather. Extended bad weather periodswith water demands o up to 10m3 per day will be reliab-ly bridged due to the high system eciency even with lowcapacity batteries.

The pump is manuactured rom non-corrosive material(stainless steel).

Beore you begin, check the model numbers o all the com-ponents o your system, and veriy that they are the i temsthat you ordered. Also check against the pump specica-tions and perormance charts to be sure the system is ap-propriate or your application. I you think you may havethe wrong pump or your application, call your supplierimmediately.

Please ll in the System Report. This will be essential inor-

mation i any problems occur.

3 System Dimensions

Dimensions Packing

L A B D E S packaging shippingvolume

netweight

grossweight

[mm] [mm] [mm] [mm] [mm] [mm mm mm] [m3] [kg] [kg]

Pump UnitC-SJ5-8

593 408 185 100 98 G 1 1/2 in 650 160 150 0.0160 12.0 12.5

ControllerPS150

see drawing 320 240 160 0.0123 1.2 1.8

Symbols

WarningDisregard might lead to injury or damage theinstallation

CautionRecommended to avoid disunction or prema-ture ageing o the pump etc.


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Saety Directions or Maintenance, Inspection

and Assembly Work It is the users responsibilityto make sure that all maintenance, inspection and as-sembly work is perormed exclusively by authorized andqualied experts suciently inormed through careulperusal o the Operating Instructions.The accident pre-vention regulations must be observed. Basically, all workon the machine is to be perormed while the machine isnot in operation. The sequence or shutting the machinedown described in the manual must be strictly observed.Pumps or pump units handling hazardous liquids mustbe decontaminated. Immediately upon completion othe work, all saety and protective equipment must berestored and activated.

Unauthorized Changes and Manuacturing o

Spare Parts Any conversion or changes o the machi-ne may only be undertaken ater consulting the manu-acturer. Original spare parts and accessories authorized

by the manuacturer guarantee operational saety. Usingnon-authorized parts may void any liability on the parto the manuacturer in case o consequential damage.

Unauthorized Operation The operational saety othe machine delivered is only guaranteed i the machineis used in accordance with the directions contained inmanual. Limits stated in the data sheets may not be ex-ceeded under any circumstances.

Cited Standards and other Documentations DIN4844 Part 1 Saety marking; Saety symbols W 8, Sup-plement 13; DIN 4844 Part 1 Saety marking; Saetysymbols W 9, Supplement 14

Transportation and Intermediate Storage

Pro-longed intermediate storage in an environment o highhumidity and fuctuating temperatures must be avoided.Moisture condensation may damage windings and me-tal parts. Non-compliance will void any warranty.

Failure to ollow these instructions will

void the warranty.

Beore beginning installation procedu-

res, these installation and operating ins-

tructions should be studied careully.

The installation and operation should

also be in accordance with local regula-

tions and accepted codes o good

practice.

This Instruction Manual contains main-

tenance inormation, and is the property

o the pump owner. Please give this ma-

nual to the pump owner or maintenance

personnel when the installation is fni-

shed.

2 Warnings

The manual contains basic instructions which must beobserved during mounting, operation and maintenance.Thereore the manual should be careully read beoreinstallation and start-up by the person in charge o theinstallation as well as by all other technical personnel/operators and should be available at the installation siteat all times.

Personnel Qualifcation and Training All person-nel or the operation, maintenance, inspection and ins-tallation must be ully qualied to perorm that type o

job. Responsibility, competence and the supervision osuch personnel must be strictly regulated by the user.Should the available personnel be lacking the necessaryqualication, they must be trained and instructed accor-dingly. I necessary, the operator may require the manu-acturer/supplier to provide such training. Furthermorethe operator/user must make sure that the personnelully understands the contents o the manual.

Dangers o Ignoring the Saety Symbols Igno-ring the saety directions and symbols may pose a dan-ger to humans as well as to the environment and themachine itsel. Non-observance may void any warranties.Non-observance o saety directions and symbols mayor example entail the ollowing: Failure o importantunctions o the machine/plant; ailure o prescribedmethods or maintenance and repair; endangermento persons through electrical, mechanical and chemicaleects; danger to the environment because o leakageo hazardous material; danger o damage to equipmentand buildings.

Saety-oriented Operation The saety directions

contained in the manual, existing national regulationsor the prevention o accidents as well as internal wor-king-, operational- and saety-regulations o the opera-tor/user must be observed at all times.

General Saety Directions or the Operator/User I hot or cold machine parts pose a danger, such partsmust be protected by the operator/user against contactwith personnel. Protective covers or moving parts (e.g.coupling) must not be removed when the machine isrunning. Leakages (e.g. at the shat seal) o hazardouspumping media (e.g. explosive, toxic, hot liquids) mustbe disposed o in such a way that any danger or per-sonnel and the environment is removed. All governmentregulations must be observed at all times. Any danger

to persons etc. by electrical energy must be excluded.(For details see e.g. regulations o VDE and the localutilities).


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3 Installation o the Controllers

3.1 Controllers Functions

Controlling and monitoring o the motorIntegrated MPP-tracking and LVD battery protectionLVD protection (low voltage disconnect) or 12 V and24 V batteriesHigh-run battery unction to avod cycling o batteryLED display o the the operating statusTwo control inputs or foat- or pressure switches,remote control, etc.92% max. eciency (motor + controller)Adjustable maximum RPM setting

3.2 Warnings to the Installer

Motor cable strain relie: Submersible

motors must use a saety rope or cable

to act as a strain relie or the motor

cable and to avoid losing the pump in

the well i the pipe breaks.

Open circuit (no-load) voltage above

50 V DC will destroy the controller. This

may occur i the wrong PV modules (so-

lar panels) are used, or i the solar array

is incorrectly wired. Measure the array voltage be-

ore connecting to the controller. A 12 V DC (nomi-

nal) array should produce an open circuit voltage

around 22 25 V under any daylight conditions.

Some thin-flm PV modules might produce a higher

open-circuit voltage when they are new. I 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 qualifed 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 or saety and

lightning protection.

Do not touch the controller input or mo-

tor wires together to test or a spark.

3.3 Mechanical Installation

Location Place the controller close to the solar array, notthe pump. This will reduce the risk o lightning damage. Iit is outdoors, mount the controller in a vertical position toassure that rain will not enter the box.

Protection rom heat Electronic devices are most reliablewhen they are protected rom heat. Mount the controller inthe shade o the mid-day sun. An ideal location is directlyunder the solar array or in a nearby shaded location. An al-ternative is to old a piece o sheet metal so that it mountsbehind the controller and curves over it to provide shade.This provides protection in extremely hot climates.

Battery system Place the controller near the batteries butsaely isolated rom the battery terminals and rom corrosi-ve gases. Batteries must be in a cool location or best lon-gevity and enclosed or cleanliness and saety.

Connect the battery (12 V or 24 V) directly with the + and terminal o the controller. Do not use the load terminalso the charge controller as they maybe not strong enoughto allow the start current to fow. The PS150 controller hasa low voltage unction to protect the batteries rom deepdischarge. An additional charger is needed or charging thebatteries.

3.4 Electrical Installation

Power IN For PV-direct systems, a two-pole disconnectswitch may be installed between the solar array and thecontroller. Switch it o to prevent shock and arc burn ha-zard during installation and maintenance, or i the systemwill be shut down or the season. For battery systems a30 A slow blow use must be installed between the control-ler and the battery.

Ground Connect the ground wire to the ground connec-tion in the controller. Grounding helps to prevent shock ha-zard i there is a ault in the motor.

L1-L2-L3 The motor requires our-conductor (ourwire)cable between the controller and the motor. The three wiresL1, L2 and L3 carry power. The ourth wire carries ground.To reverse direction o rotation reverse any two wires.

No disconnect switches must be installedin power wires between motor pump

controller. Connecting the motor wire to

the switched-on controller might

irreparably damage it. Such damages are

excluded rom the warranty.

No. 1 and 2 In order to protect a pump rom being dama-ged by dry running connect one well probe cable to eachterminal. I dry run protection is not needed, short cut thesetwo terminals.

No. 3, 4 and 5 Connect any kind o external switch (NOor NC type) or remote control o the controller. In case noswitch is used the terminals No. 4 and 5 have to be con-

nected with a short cable (actory setting). In case a NO-switch is used (connected to the terminals No. 3 and 4) theshort cable (connecting the terminals No. 4 and 5) mustremain installed.

No. 6 and 7 Connect these two terminals to switch thecontroller to battery mode. The motor will be switched OFFby the controller i the input voltage is below 11 V or a12 V battery system and 22 V or a 24 V battery system inorder to protect the battery. I the battery voltage increasesto 12 V or 24 V the motor will be switched ON automati-cally. (For High-run mode at 13.3 V and 26.6 V.)

Table 1: Technical Data o Controller

system PS150Cmotor power [W] 250

max. power input o 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 typecontroller IP54 weatherproo (NEMA type 3R)

motor IPX4 weatherproo (NEMA type 3)

ambienttemperature

storage [C] 30 to +55

operation o controller [C] 20 to +50

operation o pump [C] 0 to +50

*) PV modules at standard test condition: AM = 1.5, E = 1,000 W/m2, cell temperature: 25 C


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3.5 Monitoring the System

System switched on (SYSTEM)Green light indicates SYSTEM ON

Pump running (PUMP ON)Green: MOTOR / PUMP ONRed: Motor OFF caused by overload protection

PUMP SPEEDPump speed is indicated by the blinking sequence o thePUMP ON LED:

LED is on > 700 min -1

1 fash > 1,200 min -1

2 fashes > 1,600 min -1

3 fashes > 2,000 min -1

4 fashes > 2,400 min -1

5 fashes > 2,800 min-1

Dry-running protection (SOURCE LOW)

Red light: Water level is low. Ater recovering the motor willstart within 20 minutes. Red light will remain ON to indica-te low water level has occurred. For Reset press the ON/OFF switch.

TANK FULLRed light: The motor has been switched OFF by remoteswitch.

BATTERY LOWRed light fashing: LOW VOLTAGE DISCONNECT whenbattery is empty (in battery mode only)

LEDs or Monitoring

The power wires on the pump are black with white lette-ring to indicate L1, L2 and L3. WRITE DOWN the coloursthat you splice to L1/L2/L3 so you can match them with theL1/L2/L3 terminals in the pump controller.

I your pump cable has the standard GREY, BROWN, BLACKand GREEN-YELLOW colours, use this sequence:

GREY BROWN BLACKYELLOW-GREEN

L1 L2 L3 Ground

The power wires on the pump may also be brown-black-grey or motors delivered rom Q2 2005 on. Then usebrown as L1, black as L2 and grey as L3.

Testing the pump or direction Centriugal pumps will pro-duce water fow even when the turn backwards. However,the backwards pumping fow will be considerably less and

the lit ability lower. Make sure that the pump turns counterclockwise as indicated on the pump and motor body. I youplace it in a water tank or a bucket, submerge at least 75%to observe fow.

Alternative dry test I you do not have a water vessel totest the pump in, you can test it dry by watching the pumpshat and running it or only a ew seconds. The metal labelon the pump has an arrow to indicate the proper directiono rotation. I the pump is new rom the actory, it is lubri-cated so it can run dry or about 90 seconds without risk. Ithe pump is not new, it can be run dry saely or about 15seconds. Either way, this is more than enough time to ob-serve the direction o the shat.

I you did not write down the color match (or the windblew your note away) connect the three power wires to thecontroller in ANY random order. Apply power. Observe thepump shat rotation, then turn the power o. I the direc-tion is wrong, exchange ANY TWO o the power wires atthe controller. In any case, when you are nished connec-ting the pump to the controller, test it to assure the properdirection.

Question The motor shat is hard to turn by hand, andmoves in a bumpy manner. Is this normal?

Answer YES. This is caused by permanent magnets in themotor. It is especially hard to turn when it is connected tothe controller, or i the pump wires are connected together.

WARNING I the pump wires are in the

wrong order, the motor will run in rever-

se and the pump will not unction. Da-

mage may result. Check the direction

BEFORE installing the pump. The proper direction is

COUNTERCLOCKWISE when viewed rom above.

WARNING When testing or direction, do

not run the pump dry or more than 15

seconds.

3.6 Wiring the Motor


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4 System Wiring

4.1 12 V Battery System

12V system Voltage rom panels will read 22-25 V whendisconnected (open circuit). Connect the pump controllerdirectly to battery bank.

Remote Tank Float Switch Connect foat switch to ter-minals 4-5 o the pump controller when it breaks contacton rise, to turn the pump OFF. Otherwise use terminals 3-4or opposite unction.

Grounding Connect either battery minus or solar minus toground, never connect both to ground!

Solar Tracking Use stranded wire or fexibility. Securethe wires to tracker with plenty o tape. Leave a good slackloop to allow ree motion o tracker.

4.2 24 V Battery System

24 V system Wiring scheme shows serial wiring or a sys-tem o 24 V nominal. Voltage rom panels should read 45 Vwhen disconnected (open-circuit).


Grounding Connect either battery minus or solar minus toground, never connect both to ground!


2 batteries 12 Vin series

externalcharge controller

externalcharge controller

1 battery 12 V 1 PV module 12 V

2 PV modules 12 Vin series

low water sensor

low water sensor

fuse30 A

fuse

30 A


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6

Jmp2 Jmp3

Jmp1

SYSTEM

PUMP ON

OVERLOAD

WELL DRY

TANK FULL

BATTERY LOW IF FLASHES

1 2 3 4 5 6 7

low-water

sensor

probes

connect

forbattery

mode

remote

float switch

NO

Com

NC

Max. 50V

Do not connect

this terminal

www.LORENTZ.de

T1 T2 T3 T4 T5

T7

V8



Solar direct system Voltage rom panels will read 22 45 Vwhen disconnected (open circuit). Use the let power termi-nals to connect the solar array with the controller.

The jumper wire on terminal 6 and 7 must be taken out orsolar direct mode.



4.3 System Wiring or 12 V 24 V Systems in PV-direct Operation

4.4 Jumper Setting or PS150C Mode

Beore start-up check that jumper Jmp2

is set to PS150C mode, c. sketch on the

right.

4.5 High-run Mode

In order to set the battery high-run mode set the jumperJmp1 as shown in above picture. This will increase the Low

Voltage Disconnect (LVD) settings to 12.3/24.6 V and there-start voltages to 13.3/26.6 V to allow pumping onlywhen the batteries receives charging current rom the solararray. The lietime o the battery will be increased consi-derably as cycling is avoided.

4.6 Power Control or PV-direct Operation

PS150 pumps require dierent current depending on speedand lit. When low light conditions are present, the PVarray cannot supply the required current. I you dont usea controller the voltage will drop to nearly zero, and thepump 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 powersource to the load by transorming the voltage down whileincreasing the current delivered to the motor (like an auto-matic transmission).

1 PV module 12 V or2 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


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5 Trouble Shooting

Please read this section beore calling or help. I you callor help, please reer to the model and serial numbers.

I The Pump Does Not Run

Most problems are caused by wrong connections (in a newinstallation) or ailed connections, especially where a wireis not secure and alls out o a terminal. The System ONlight will indicate that system is switched on and connectedto the controller. It indicates that VOLTAGE is present but(in a solar-direct system) there may not be sucient powerto start the pump. It should attempt to start at intervals o120 seconds.

Pump attempts to start every 120 seconds but

doesnt run.

The controller makes a slight noise as it tries to start thepump. The pump will start to turn or just vibrate a little.

There may be insucient power reaching the control-(1)ler. A solar-direct (non-battery) system should start ithere is enough sun to cast a slight shadow. A batterysystem should start i the supply voltage is greaterthan 12V (12V system) or 24V (24V system).

I the pump was recently connected (or reconnected)(2)to the controller, it may be running in reverse directiondue to wiring error. See section 4.7

I the motor shat only vibrates and will not turn, it(3)may be getting power on only two o the three mo-tor wires. This will happen i there is a broken connec-tion or i you accidentally exchanged one o 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 aulty or stuck,(5)allowing downward leakage when the pump is o.This can prevent the pump rom starting.

Pump Overload

PUMP ON light shows red instead o green. The sys-tem has shut o due to an overload. This can happen ithe motor or pump is blocked or very dicult to turn andis drawing excessive current (hard to turn). Overload de-tection requires at least 250 W output o the solar array.This can be caused by a high concentration o solids in thepump, high water temperature, excessive pressure due tohigh lit or a restriction in the pipe, or a combination othese actors. The controller will make three start attemptsbeore shutting down the system. The System ON LED willbe OFF and the red OVERLOAD LED ON. The system willnot reset until the ON / OFF switch is turned OFF and ONagain.

6 Warranty

2 years warranty in material and workmanship.Details in separate warranty document.


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Date o installation

Installer(ull contact details)

Well depth m | t

Pump depth m | t

Additional vertical lit (to top o tank) m | t

Static water level m | t

Drawdown level m | t

Drop pipe (vertical rom the pump)

Size mm2 | in

Type

Length m | t

Additional pipe length (to tank)

Size mm2 | in

Type

Length m | t

Submersible pump cable

Wire size mm2 | AWG

Length (controller to pump) m | t

Max. RPM control

Factory setting is maximum. yes no

I this setting was reduced,

enter setting here:

Date o purchase

Dealer(ull contact details)

System voltage V

Battery system yes no

Quantity o 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

Lorentz Ps150 c Manual En

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