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1. Dimension mm Controller Modell w1 w2 w3 H1 H2 H3 D1 D2 Weight Kg PS150 to PS200 non UL 190 174 272 250 234 100 70 5 1 2 PS150 to PS200 UL 178 156 116 396 364 150 165 4 5 PS600 to PS1800 PS4000 178 156 116 595 563 150 165 9 0 22 Controller Installation 7 7 Wiring the Controller 7 7 1 Controllers without pre wired Plugs 7 7 1 1 Terminal Descriptions WARNING All electrical connections must If you use the controller version without pre wired plugs A be performed by qualified experts only open the housing by unscrewing the four screws at the Unqualified handling might lead to shock bottom cover After removing the cover the terminal rail will burns or death slide out for easier access If the controller with prewired plugs is used pay attention to chapter 7 7 2 Controllers WARNING Beware of high voltage with pre wired Plugs on page 32 All warnings and Never work on a system connected to instructions concerning the wiring must be followed for both power to avoid electric shock hazard controller versions Before starting to work on the electrical system make sure that all components are disconnected from the power source Do not work on any components when power is connected or within five minutes after disconnection The controller needs time to discharge Switch the system on only when all work is completed CAUTION The controller should only be connected to po
2. When the water level is high the float switch will stop the pump The TANK FULL indicator on the controller will light up When the water level drops the float switch will signal this to the controller The indicator light will turn off and the pump will restart if sufficient power is available Wiring to the controller The float switch must be wired to the controller at terminal 3 and 5 cf 7 7 1 3 Pump Accessories Wiring on page 28 Plug controller The dry run protection must be connect ed to the controller at socket B1 cf 7 7 2 Controllers with pre wired Plugs on page 32 Manual remote control switch The float switch circuit can be used with a manual switch to turn the pump on and off from a distance Use any simple on off switch available from an electronic supply electrical supply or hardware store it only carries low voltage very low current Wire it according to the illustration above for a normally closed float switch 9 3 SunSwitch CAUTION Installing a SunSwitch is mandatory for PS1800 CS F and all PS4000 pump systems Operating without a SunSwitch can lead to increased wear or damage the pump Such damage is excluded from the warranty In the early morning and the late evening hours there will be a timespan where the irradiation is sufficient to start a slow rotation of the pump but insufficient to deliver any wa er Without water flow the input power will be converted to heat an
3. Check all wires and connections Carefully check for improper wiring especially in a new installation and wiring condition Wires are often damaged by animals if they are not enclosed in conduit pipe Pull on wires slightly to check for failed connections Check the dry running protection If the controller indicates SOURCE LOW when the pump is submerged in water or draws from a sufficient water source check the dry running protection system The probe is mounted on or near the pump If inspection is not feasible you can bypass the probe or test it electrically Check the float switch If the controller indicates TANK FULL when the storage tank is not full inspect the float switch system If your system has a float switch it will be mounted in the tank If inspection is not feasible you can bypass the switch or test it electrically Force a quick start If you restore a connection or bypass the probe or float switch there is no need to wait for the normal time delay Manually switch the on off switch or the power source off and on to reset the system The pump should start immedi ately if sufficient power is present If the pump responds to the bypass tests but not to the float switch the wires may be shorted touching each other or open broken or the switch may be stuck with debris or out of its correct position Troubleshooting Quick checklist Make sure the pump is suited for the total lift tha
4. 1 1 Terminal Descriptions on page 22 for terminal descriptions and to 7 7 1 6 Grounding on page 31 for grounding instructions 30 Controller Installation 7 7 1 5 Input Wiring for Battery based Systems CAUTION The PS4000 pump system can Short circuit protection Install a fuse or circuit breaker not be operated from batteries near the power source Use a 30 A circuit breaker or a time delay slow blow fuse Install a jumper wire between terminals 6 and 7 to set he controller to battery mode when operating a PS150 to Low voltage disconnect function Lead acid batteries PS1800 controller This will deactivate the MPP Tracking can be permanently damaged by over discharge when unction and activate the Low Voltage Disconnect LVD the voltage falls below a critical point To prevent this the PS battery system controller will turn off at low voltage Connect the PS controller directly to the battery and NOT to and turn back on only after the battery has recovered he load terminals of the charger as the terminals may not significantly be rated for the starting load current of the pump The PS controller has a low voltage disconnect function to protect Table 7 Set points for low voltage disconnect he battery from being deeply discharged Controller Voltage OFF ON Some charge controllers monitor the capacity of the battery and regulate the charging accordingly This method does not PS 150 12 VDC 11 VDC 12 VDC work when t
5. 5 1 Safety Rope 8 3 5 3 Stilling Tube We recommend the use of a safety rope as a loss insurance For the maximum recommended sand content before any If the pipe breaks because of start up torques of the motor significant detrimental effects occur check chapter 4 too much weight pipe corrosion or wrong installation a Operating Conditions on page 9 safety rope can prevent the total loss of the pump system and damage to the well A higher content will cause excessive wear within the pump and reduce the pump s life span considerably Any pump Choose a safety rope that can handle the weight of the that is blocked by sand will not be covered by warranty whole installation and the water inside the pipes The rope material must be water resistant Near the well head the To reduce the amount of particles entering the pump a rope needs to be UV resistant or protected from sunlight stilling tube can be installed CAUTION Do not use a nylon rope Nylon is known to absorb water over time which will weaken the rope 8 3 5 2 Plastic Pipes When the pipes are strong enough the use of plastic pipes is possible If you are not sure about the strength of your pipes contact the pipe manufacturer CAUTION The pipes must be strong enough to hold the whole weight of the a pump the motor the pipe system and the water in the pipes It must also withstand the water pressure generated by the total dynamic head CAUTION W
6. O DataModule Motor OO __ o _ Y X J GC J Communicator SIM ID 19 digits chiffres cifras Communicator LORENTZ www lorentz de
7. Pump ON LED RPM LED On gt 900 1 flash gt 1200 2 flashes gt 1600 3 flashes gt 2000 4 flashes gt 2400 5 flashes gt 2800 If the PUMP is OVERLOADED green changes to red PUMP ON red pump overload System shutoff due to overload e g a blocked motor or pump Overload detection requires at least 250 W output of the PV generator The controller will attempt three starts before shutting down the system To restart a reset with the POWER switch is necessary Flashing indicates that the controller s thermal protection was triggered due to a too high temperature The controller will automatically restart after cooling down SOURCE LOW red The water source has dropped below the level of the low water probe or the water sensor has detected air in the suction pipe After the water level recovers or the suction pipe has been re filled with water the pump will restart after a delay of 20 minutes Flashing indicates that the controller has stopped due to a SOURCE LOW incident detected earlier The number of flashes indicates the number of incidents Toggle the ON OFF switch to reset this indicator TANK FULL red The 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 PS150 to PS1800 only BATTERY LOW tank light flashes The measured battery voltage fell to a specific threshol
8. Read and follow the manual carefully to ensure reliable operation and long life of the WARNING This installation overview does not substitute the detailed instructions given in this product and to avoid danger to health and life 1 PV and Controller Installation Please follow manufacturer instructions for PV installation Every PV installation must be equipped with a PV discon nect switch Suitable switches are available from LORENTZ Install the controller close to the PV array in a shaded location to minimize cable length on the input side 2 Electrical Installation Please refer to DC Disconnect Switch on page 17 for more information on the requirements the PV disconnect must meet For detailed information refer to 7 6 Mounting Space and Ventilation Requirements on page 20 1 Pump wiring The ECDrive must be connected to the terminals L1 L2 L3 and GROUND Observe rotation direction 2 Accessories wiring Connect a well probe to terminals 1 and 2 required remote control switches to terminals 3 4 and 5 depending on type flow meters to terminals 8 and 9 with DataModule only pressure sensors to termi nals 10 and 11 with DataModule only 3 DC input wiring Connect the positive terminal of the PV array to the negative terminal to Observe max input voltage For battery systems install a jumper between terminals 6 and 7 4 Grounding A protective earth connection must be wired to e
9. connect to the L1 phase of the motor Output to motor L2 connect to the L2 phase of the motor L3 connect to the L3 phase of the motor 24 Controller Installation Terminal Wiring Example PS150 to PS200 non UL Figure 5 Terminal wiring example PS150 to PS200 non UL D elo 1 2 3 4 5 6 7 L1 L2 L3 LJ li surge protector 1 PV disconnect PV generator well probe float switch pump grounding rod Controller Installation 25 Terminal Description PS150 UL to PS200 UL PS600 to PS4000 Figure 6 Terminal PS150 UL to PS200 UL PS600 to PS4000 HH 12 Lo jofejolojolo ojelefeje o o o E eeeeeeeeeee o 9 9 2 2 3 4 7 8 9 L1 L2 L3 GND 1 5 6 GND 10 11 Socket Terminal Connection Table 5 Terminal explanation Ground GND connected to protective ground wire PE connect to positive terminal of PV module POWER IN connect to negative terminal of PV module connection to NC Well probe 2 connection to COM 3 connect N O Float switch 4 connect ground 5 connect N C Jumper 6 connect cable jumper for battery mode Battery Mode 7 connect cable jumper for battery mode 8 connect to signal Flow meter 5 9 connect to COM 10 connect positive Operative only Pressure s
10. de iio ls Aa ed 54 9 2 Float Switch Full Tank Shut off ee 56 9 3 SUNSWIECN 2s se rs E O A ee A A e A A A GO 57 9 4 Water Meter Installation o o o o o o o o ooooooore a a a e a a a e a a e a a 58 9 5 Pressure Sensor Installation i ee 0555 2659 3964 669445594 5555 4554 4454 4444 4 58 9 6 Level Sensor Installation o 58 9 7 Sacrificial Anode s s baada s a sasdwd 58 9 8 Surge Protector s sied resad DAA AAA 59 9 9 PV Disconnect with Lightning Surge Protection oa aa a 59 10 Operating the PUMP ooo a A a 60 10 1 VED Status s io a altae a e a AAA 61 10 2 Starting the Pump eos Du Aa u DS S bebe babe be suis 63 10 3 TimeDelaYS si s sei vas a cr 63 10 4 Parameter Setting with DataModule only 1 a 64 11 LORENTZ CONNECTED 050 co a ad a a ed 65 11 1 DataModul s s s Pe d d dlia e e e A a e A a e bad beee eased E 65 11 2 PUMPSCAMEN ocaso o o e o so o o is ae 65 11 3 PS Communicator amp pumpMANAGER aaa 66 12 Troubleshooting lt i 2020 6a en eee ir a a a a A A 67 12 1 PUMP does NOLTE s ee e eh ai s a aaa e 67 12 2 Pump attempts a Restart every 120 Seconds o 67 12 3 Pump Overload Pump ON LEDisred 2 ee 68 6 Declaration of Conformity 1 Declaration of Conformity We BERNT LORENTZ GmbH amp Co KG Germany declare under our sole responsibility that the products PS150 Boost PS150 C PS150 HR PS200 HR PS600 HR PS600 C PS600 CS F PS1200 HR PS1200 C PS1800 HR PS1800 C PS 1800
11. expected to clog often maintenance may be minimized by plumbing two or more filters in parallel The inline filter has a clear bowl so its condition may be observed CAUTION Have replacement cartridges ready Filter cartridges are available at retailers and local wa ter system suppliers LORENTZ recommends the use of 10 20 micron spun polypropylene type filters Carbon taste and odor cartridges have less capacity for dirt more resistance to flow and are more expensive to use Use them only if you have taste and odor problems A filter cartridge may look clean and still be clogged due to fine silt embedded in the fibres If the pump becomes in creasingly noisy over time it is usually due to a clogging fil ter cartridge On the other hand a cartridge that looks dis coloured may not be clogged As long as the pump runs qui etly the filter is okay to use The pump noise is an indicator for the need to change cartridges Pump Installation Iron pipes or fittings will introduce abrasive rust particles if installed on the intake side of the pump Dirt is also intro duced as pipe joints are assembled especially in a trench CAUTION Make sure inlet lines and fittings are flushed clean before attaching them to the pump The inline filter may have a red push button valve to release pressure for maintenance If the filter is placed more than a few feet above the water source at lowest level the suction may open the
12. in the ground 2 5 m 8 ft below ground level You must refer to local standards and requirements The grounding cable should be a copper cable with a cross section of not less than 16mm AWG6 Controller Installation PS150 to PS200 non UL A protective earth connection must be linked to the controllers earth connector marked with the protective earthing symbol The protective earth wire of the motor must also be connected to the controllers earth connector PS150 UL PS200 UL and PS600 to PS4000 A protec tive earth connection for the controller must be connected to the left GND terminal The right GND terminal next to the motor phases L1 L2 L3 is for the protective earth wire of the motor All metallic support structures and electrical enclosures must be grounded For grounding of the PV generator follow manufacturer instructions 31 32 Controller Installation 7 7 2 Controllers with pre wired Plugs A NOTE This section is for controllers with prewired plugs only CAUTION All warnings and instructions mentioned for the wiring of the standard controller version must be considered and strictly observed CAUTION For splicing accessories to the plugs and the grounding rod to the grounding connection use a proper crimping tool and sleeves matching the cable size WARNING All electrical connections must be performed by qualified experts only Unqualified handling might lead to shock
13. protection for every pump system Terminals 3 4 and 5 Connect any kind of external switch NO or NC type for remote control of the controller If no switch is used the terminals No 4 and 5 have to be connected with a jumper cable factory setting If a normally open switch is used connected to the terminals No 3 and 4 the jumper cable connecting the terminals No 4 and 5 must remain installed Terminals 6 and 7 not for PS4000 Connect a jumper cable between these two terminals to switch the controller to battery mode Refer to 7 7 1 5 Input Wiring for Battery based Systems on page 30 CAUTION Only PS150 PS200 PS600 PS1200 and PS1800 pump systems can be operated from batteries Controllers with DataModule Terminals 8 to 11 can only be used if a DataModule is installed If you are not sure whether a DataModule is preinstalled check the label on the controller housing Terminals 8 and 9 Install a flow meter in the pipeline and connect it to termi nal 8 and 9 An impulse input of the flow meter between 11 Impulse to 10l impulse is recommended The DataModule can handle up to 1000 impulse per second The flow can be viewed with the LORENTZ PumpScanner software Terminals 10 and 11 Connect the pressure sensor to the terminals 10 and 11 The output voltage is 15VDC the current signal range 4mA to 20mA and the load impedance 1000 Choose a pressure sensor which works with these characteristic values Con
14. settings for the PS controller Do not forget to scroll to the bottom and SAVE the changes before leaving the pump profile menu Controller and pump unit Use the pull down menu to select the correct controller and the correct pump unit Cable length and cable size Enter the length and size of the installed motor cable to allow PumpScanner to calculate the correct cable losses for the pump system Flow meter and pressure sensor If any Water Meter or Pressure Sensor is connected to the PS controller enter the characteristics of the sensors as described The remaining options are explained in the PumpScanner manual Always click the SAVE Button on the bottom of the pump profile menu to keep the changes The pump profile configuration is done and the pump can be switched ON 11 LORENTZ CONNECTED The LORENTZ CONNECTED portfolio takes water pumping to the next level If offers a range of features for monitoring and managing pumps even remotely over the internet CONNECTED a new water pumping experience 11 1 DataModule The LORENTZ PS DataModule is an integral data logger and remote control device for the whole PS range of helical cen trifugal and surface pumps Together with the PumpScanner App for Android the LORENTZ Communicator and pump MANAGER the PS DataModule opens new opportunities in drinking water supply for people and livestock irrigation and swimming pool applications The PS DataModule col
15. splicing Controller Installation 33 B1 Low water sensor B2 Remote float switch For the connection of the low water sensor and remote float switch 2 pin plugs are used see Figure 12 2 pin plug on page 34 Cut the wire of the plug and splice the cables of the corresponding pump accessory to it The polarity does not matter If a plug socket is not used plug it into the socket of the controller housing without cutting the wire 2 pin plugs are connected as normally closed to the controller terminals CAUTION If a Surge Protector is installed see 9 8 Surge Protector on page 59 correct polarity must be ensured Therefore the cables of the plugs are marked accordingly B3 to B5 Accessories UL controllers only For any additional accessories the cable glands can be used They have to be connected in the same way as in PS control lers without prewired plugs cf 7 7 1 3 Pump Accessories Wiring on page 28 The controller case has to be opened and the wires must be connected to the terminal clamps Figure 9 PS UL plug controller label For Non UL controllers check the plug naming on the device 34 Controller Installation Battery Mode not PS4000 The battery mode is activated in the same way as for PS controllers without pre wired plugs The controller case has to be opened and a jumper must be connected between terminals 6 and 7 refer to 7 7 1 5 Input Wiring for Bat tery based Sy
16. that it is located higher than the pump and in a vertical position Pump Accessories Installation 55 Pump Accessories Installation 9 2 Float Switch Full Tank Shut off We recommend the use of a float switch or other means to prevent overflow of your tank This will stop the pump when the tank is full then reset when the level drops This conserves ground water prevents overflow and eliminates unnecessary pump wear PS controllers allow the use of a small signal cable to a remote float switch even if the tank is along distance away Float switch requirements 1 A switch must be used not wet electrodes 2 The preferred system requires a float switch to OPEN contact on rise to turn the pump OFF This is called normally closed N C Float switch cable requirements 3 Two wires are needed 4 Minimum wire size 1mm2 AWG 18 This is good for a distance as far as 600 m 2 000 ft 5 The cable must be suitable for its environment 6 If it must run a long distance use twisted pair shielded cable to reduce the chance of damage from light ning induced surge Figure 23 Float switch scheme sealed cable clamp cable weight Grounding shielded float switch cable If you use shielded cable connect the shield to ground at the control ler only Do not ground the shield at the float switch This will reduce surges induced by nearby lightning Operation of the float switch system
17. the power supply Before any installation maintenance or inspection activities wait at least five minutes after the power supply has been disconnected from the controller CAUTION Installing a SunSwitch is mandatory for all PS1800 CS F and all PS4000 pump systems Operating without a SunSwitch can lead to increased wear or damage to the pump Such damage is excluded from the warranty CAUTION Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires a dry run protection for every pump system For more information on mandatory accessories and their installation please refer to 7 7 1 3 Pump Accessories Wir ing on page 28 and 9 Pump Accessories Installation on page 54 Treat the controller as industrial waste when processing the discarded controller It is possible that some components could produce toxic and harmful gas DC Disconnect Switch Every solar pump system must be equipped with a properly sized DC disconnect switch The switch must be installed between the PV generator and controller It must meet the following requirements minimum rating according to Table 1 Minimum DC disconnect rating on page 17 continuous current rating according to maximum current of the connected PV generator or higher the switch must be rated for DC current not AC A PV disconnect switch matching all requirements above can be purchased from LORENTZ CAUTION
18. the same way and are to be wired according to the instructions in this manual NOTE The on off switch only affects the A pump operation it does not work as a power disconnect switch Figure 2 Controller Types PS150 to PS200 not UL PS150 UL to PS200 UL PS600 to PS1800 Prewired plugs If ordered the controller will have prewired plugs In this case no wiring is needed inside the controller Refer to 7 7 2 Controllers with pre wired Plugs on page 32 Datamodule The datamodule is an optional internal component It allows easy configuration of the pump system using the LORENTZ PumpScanner smartphone appli cation If combined with a PS Communicator it also allows remote pump monitoring and management with LORENTZ pumpMANAGER For more information on the DataModule refer to chapter 11 LORENTZ CONNECTED on page 65 For setup of the controller using PumpScanner please refer to the PumpScanner documentation available on partner NET For more information on pumpMANAGER please go to www lorentz de connected PS4000 7 3 Controller Elements Power on off switch The power switch is used to start or stop the system and as a reset switch It does not work as power disconnect switch Indicator Lights The five LED lights on the front indicate different operational situations For a detailed explanation refer to chapter 10 Operating the Pump on page 60 Table 2 Technical data
19. 40 8 33 Installation Depths so borrosas aa e a AAA 41 834 Removal t sa ssu dusen e e ba E ds o wha d 41 8 3 5 Additional Feat s s sostare taantua ea e Sooo a e A 42 8 3 9 1 Salely RODES usd so ss ss 42 8 3 5 2 Plastic Pipes se sieu abaa AIDA 42 8 3 5 3 Stilling TUD onan a e ae a E S a DAY e S SHES 42 Contents 5 8 4 CSF Surface PUMPS as xsara a ae eee A 43 8 4 1 Placement and Foundation 2 ee 43 8 4 2 Pump Motor Wiring os o wae atan ace cae eee aR BRR RA a 44 8 43 Installation and Handling 522222242258 8e888s444440 0000868 444 45 O44 E E ECE E AE AOR ae a ee oe aa 46 8 4 5 Initial Stari Up e aces ee eee A A AA OREO RR A 47 8 4 5 1 Filling Pump with Water is scrasa acacaca acav aca aac ace RIDE POR EOE ee ee a S 47 8 4 5 2 Rotary Direction ssc tees eae ae eee ee eee ee ee 48 84 53 Final Check UH 4 4 lt a e a0a aace ce ET ECEE E a ace ac AORTE E aaa ee ae E HORSE 48 8 5 Boost Surface PUMPS 2 66 eee eee eee eS 49 8 5 1 Placement and Foundation oaa aa ee 49 8 5 2 Pump Motor Wiring s s s a ak as a la oa eo ae S R R we e 49 8 537 Installation POSION ci arats 4 ake a a e SAAR an RES oh RSE a IAE Sh SGAE A SS ah STE 50 8 54 FING ewrrrorrisrs eee an a AA 51 8 5 5 Plumbing Design seee ue ee a ee hw a e Kaa a ee a a ek ee Se e 52 85 6 Freez amp Protecion s ss esad ea ee Ao RR n A A 53 9 Pump Accessories Installation aaa aaa a 54 9 1 Well Probes sri usg w e sehen de eae
20. COMPASS can be used for NPSH calculation Pump Installation 4 8 4 5 Initial Start up CAUTION Never start the pump if it is not filled with water and has not been vented The pump and suction pipe must be fully filled with clean water 8 4 5 1 Filling Pump with Water The pump and the whole suction pipe must be fully filled with clean water If the water level is higher than the pump inlet 1 Close the gate valve in the outlet pipe and loosen the air vent screw 2 Open the gate valve in the suction pipe slowly 3 Tighten the air vent screw when water streams out continuously If the water level is below the pump inlet Suction pipeline and pump must be filled with water 1 Close the gate valve in the outlet pipe and open the gate valve in the suction pipeline 2 Loosen the air vent screw and fill the water into the pump 3 Fasten the air vent screw after the pump and the suction pipeline are completely filled with water In open systems where the liquid surface is below the level of the pump the water injection hole can be used CAUTION For larger diameter pipes the suction pipe should be primed separately from the pump Installing a filler pipe simplifies this The pump must be fully primed after the suction pipe is full CAUTION A nonreturn valve must be installed at the start of the inlet pipeline WARNING Do not start the pump until it has been filled completely with water WARNING
21. CS F PS4000 HR PS4000 C PS4000 CS F to which the declaration relates are in conformity with the Council Directives on the approximation of the laws of the EC Member States relating to Machinery 2006 42 EC Electromagnetic compatibility 2004 108 EC Electrical equipment designed for use with certain voltage limits 2006 95 EC Henstedt Ulzburg Germany 1 January 2014 BL Bernt Lorentz CEO 2 Receipt Storage and Handling Check upon receipt that the packaging is undamaged and complete If any abnormity is found contact your supplier LORENTZ pumps are supplied from the factory in proper packing in which they should remain until they are to be installed at the site Handle the pump with care and avoid unnecessary impacts and shocks Prolonged intermediate storage in an environment of high humidity and fluctuating temperatures must be avoided Moisture condensation may damage metal parts Non com pliance can void the warranty It is recommended storing the parts in a closed and dry room The motor the pump end and controller can be stored not used in the range of 20 C to 65 C 4 F to 149 F The components should not be exposed to direct sunlight Product Specification 7 3 Product Specification 3 1 General 3 2 Features LORENTZ solar submersible and surface pump systems LORENTZ pumps have the following features are designed to efficiently deliver high volumes of water running exclusivel
22. Make sure that the installed shutoff valves in the suction and pres sure lines are completely open during operation the pump must never run with shutoff valves closed Figure 20 Vent and drain holes Air vent hole Water drain hole 48 Pump Installation 8 4 5 2 Rotary Direction CAUTION Never let the pump run dry not even for the purpose of checking the direction of rotation Dry running will damage the pump and void the warranty Switch on the power supply and look at the rotary direction by looking at the motor fan An arrow on the pump unit indicates the correct direction of the rotation Viewed from the top the pump turns counterclockwise 8 4 5 3 Final Check up Check whether the foundation bolts are fastened the pump and suction pipes are completely filled with water the voltage of the power supply is correct and that the pump turns correctly Make sure all pipelines are connected tightly and can supply water normally Make sure there is no closed valve or other obstruction in the water line 8 5 Boost Surface Pumps 8 5 1 Placement and Foundation WARNING PS Boost pumps must not be submerged in or exposed to other sources of water e g rain Operating noises Make sure by applying appropriate measures that the environment will not be impaired by any sound produced by the pump Space During installation make sure that there is enough space available to permit subseque
23. NU Na PAS 8LE0S1 Introduction Thank you for purchasing a LORENTZ pump system LORENTZ has set a new standard for quality efficiency and durability in solar pumping Before you begin All pump systems are equipped with nameplates which contain all important data Check the model numbers of all the components of your system verify that they are the items that you ordered and ensure that the packaging is undamaged and complete To allow best system performance and to avoid damage read and follow the installation instructions carefully How to use this guide This manual is for system installation only follow it closely for a safe and durable installation The system layout must be planned beforehand We advise using the LORENTZ COMPASS software for correct pump system sizing SITES We highly recommend registering the installation at SITES in LORENTZ partnerNET SITES provides an easy overview of all installed pump systems including serial numbers and installation details This will be essential information should problems occur and will simplify trouble shooting and warranty topics to great extent Installation Overview This installation overview is provided to familiarize you with the typical steps that are taken when installing a solar water pumping system Your particular installation may require the steps to be done in a different order You should read the whole manual before making your first installation manual
24. The use of a properly sized disconnect switch is an important safety measure and obligatory for a professional installation of a solar pump system Table 1 Minimum DC disconnect rating Controller Min DC disconnect switch rating PS150 50V DC PS200 100V DC PS600 150V DC PS1200 200V DC PS1800 200V DC PS4000 375V DC Controller Installation 17 Electrical Conduit Electrical conduit is recommended We recommend the use of an electrical conduit pipe to protect outdoor wiring from the weather from human activities and from damage caused by animals If you do not use a conduit use a strong high quality outdoor cable Where cables enter the junction box install sealed strain relief cable glands Wire sizes For signal cables the min wire size should be 1 5 mm 16AWG For power cables the min wire size should be 2 5 mm 14AWG Compare your wire sizes to the LORENTZ COMPASS sizing reports Cables should be shielded to meet the EMC requirements Controller Installation 7 2 Controller Types Depending on the pump system the controller will either be in transparent plastic or aluminium housing Controllers in transparent housing have all indicator lights directly on board The power on off switch is located at the bottom of the housing next to the cable glands The controllers in aluminium housing have indicator lights and a power on off switch on the front Both controller types function in
25. and lo cal regulations must be observed at all times Any danger to persons from electrical energy must be eliminated by using good installation practices and working to local regulations e g VDE in Germany Safety directions for maintenance inspection and assembly work It is the user s responsibility to make sure that all maintenance inspection and assembly work is performed exclusively by authorized and qualified experts sufficiently informed through careful study of the operating instructions The accident prevention regula tions must be observed All work on the equipment must be done when it is not operational and ideally electrically isolated Ensure all power sources and accessories e g float switch are disconnected when working on the system Follow all appropriate electrical codes There are no user serviceable parts inside the motor or the con troller The sequence for shutting the equipment down is described in the manual and must be strictly observed Pumps or pump units handling hazardous liquids must be decontaminated Immediately upon completion of the work all safety and protective equipment must be restored and activated Before restarting the equipment all points contained in chapter Initial start up must be observed Safety Instructions Unauthorized changes and manufacturing of spare parts Any conversion of or changes to the equipment may only be undertaken after consulting the manufacture
26. asuring and noting down the system distances between the fixing will help to lower the pump to the right depth It is also helpful to lower a pump dummy into the borehole before you lower the pump to make sure that the hole is completely free and the pump can slide into the hole without obstructions WARNING Never stand under suspended loads WARNING Always take suitable security precautions e g a strong safety rope to Figure 15 Fixing of the motor cable at a joint and a strait safeguard the pump against slipping into pipe the well during installation CAUTION Be careful not to bend the pump take particular care with centrifu gal C pumps with a high number of tape stages Make sure that the pump never stands on the motor cable that the cable does not get jammed or damaged by sharp ledges or that the cable is not pulled or jerked where it enters the motor During the process of lowering the pump into the well the motor cable has to be fixed properly to the pipe see Figure 15 Fixing of the motor cable at a joint and a strait pipe on page 40 Where a plastic pipe is used the longitudinal stretch of the pipe under load has to be considered by leaving a sufficient gap between the pipe and the cable The cable should be fixed with water resistant tape It is a good installation practice to form a loop with the motor cable near the pump and repeat it about every 40 m 130ft along 3m the riser pipe Th
27. b serve the pump to ensure pipes are not overstressed or loos ened as it starts CAUTION Do not mount the pump direct ly to a wall or wood floor in your home This will increase the noise Changing the pump head position The pumps fit ings can be changed to face sideways or downwards The pump head may be rotated to a different position by loosen ing the clamp screws that secure the pump to the motor Be ore installing the pump inject water into the inlet and run he pump The pump may be installed either max 3 m below gravi ty feed or above suction mode the water level Thereby the geodetic head between liquid level and pump inlet must not exceed 3 m The suction lift may be significantly reduced by low resistance in the suction line if the pipes are very long and or insufficiently dimensioned 8 5 4 Filtering CAUTION Sand clay rust or other solids will cause rapid wear or immediate damage to the pump If your water is free of any contamination the LORENTZ fine intake strainer will provide sufficient protection The use of the LORENTZ intake strainer is recommended as third par ty solutions may not be sufficient Since water conditions can be subject to change the additional use of a filter is rec ommended A 30 inch intake filter foot valve is necessary for pumps low ered into wells For other installations an inline filter is best installed close to the pumps intake If filters are
28. bligatory for a professional installation of a solar pumping system The switch must be installed between the solar generator and the pump controller It must meet the electrical requirements of the connected devices The PV Disconnect has been designed to cover the range of PS pump systems PS150 to PS4000 Optionally a lightning surge protection device can be purchased from LORENTZ that fits into a pre built hole of the PV Disconnect It requires proper grounding to fulfil its protective function There are a number of different devices available to suit the voltage level of each controller type For more information on installing the PV Disconnect please refer to the PV Disconnect manual Figure 27 PV Disconnect with surge protection 59 60 Operating the Pump 10 Operating the Pump This graphic displays the LED and label layout for PS150 UL PS200 UL and PS600 to PS4000 PS150 and PS200 control lers have LED indicators directly on board a The LED status indication described in 10 1 LED Status applies to all types of controllers unless specified differently o POWER OFF SYSTEM ON LIGHT GREEN CONTROLLER ON POWER PRESENT PUMP ON LIGHT GREEN MOTOR ON LIGHT RED OVERLOAD SOURCE LOW LIGHT FLASHES AFTER WELL HAS RECOVERED SWITCH ON OFF TO RESET POWER SWITCH ON OFF Only switches pump operation ON OFF Does not work as power disconnect switch When
29. burns or death Figure 8 Plug Controller Types PS150 plug non UL Plug connections are easy to assemble without opening the controller housing The socket parts of the plug connections are prewired and preassembled inside the controller The counterparts must be connected to the wires All counter parts are included in the delivery except the standard PV power plugs CAUTION Even if a sensor plug is not used to connect a sensor it must be plugged into the controller to allow correct operation of the pump system If a plug is not connected it will cause the pump system to stop PS150 to PS1800 UL plug PS4000 UL plug A1 Power In Connect the solar generator to the male and female MC4 plugs of the PS Controller Type PV KBT4 6IIUR PV KST4 6IIUR see Figure 10 MC4 plug for power input on page 34 Observe correct polarity The counterparts to the MC4 plugs are not included in the delivery Only original multiConnect plugs or plugs approved by multiConnect are supported The PV side of the plug is not included in delivery A2 Motor out Figure 11 Plug W for motor cable on page 34 shows the arrangement of the pins The pins are numbered and the plug has small grooves to ensure correct assembly Pin1 Motor cable L1 Pin 2 Motor cable L2 Pin 3 Motor cable L3 Pin Motor grounding cable Grounding A grounding cable is led out of the controller that needs to be extended by
30. ciency throughout the entire system A main reason for loss of efficiency is pipe pressure losses Make sure that you have included the pipe pressure losses during the sizing process of your system Consider a smart pipeline design from the beginning CAUTION Consult COMPASS or a pipe pressure sizing chart to determine the correct size Oversize the pipe line to reduce the pressure drop CAUTION The length of the inlet and of the outlet pipeline must be considered for the calculation of the pressure losses CAUTION Only run the pump when it is completely prefilled with water surface pumps submersible pumps must be completely submerged This means there must be no air in the pipes CAUTION For surface pumps air locks must be avoided at the inlet pipe line Avoid sharp 90 elbows and sharp pipe size adaptors 8 1 2 Cable Splicing To connect the motor cable with a cable extension you should connect the cable ends with a splicing kit It is very important that the cable joints are fully sealed oth erwise moisture could cause a short circuit This will damage the pump system For more information about connecting cable ends with a splicing kit see the submersible cable splicing manual in the package of the splicing kit CAUTION Cable splice failures are a common source of errors Check the splice for proper connections CAUTION Bad cable splicing can damage the controller and or the pump Such
31. d and has not yet recovered to the nominal battery voltage Battery system voltage and nominal voltage are detected automatically The voltage thresholds for BATTERY LOW indication are given in the table below BATTERY LOW Nominal battery threshold in V voltage in V 11 12 22 24 44 48 88 96 Operating the Pump 63 10 2 Starting the Pump 10 3 Time Delays 1 Make sure that an unhindered water flow is possible Event Time delay and not blocked e g by closed valves Pump stops due to 120 seconds 2 Switch on the PV generator disconnect switch insufficient irradiation 3 Toggle the power switch on the controller to ON Full tank float switch 2 3 seconds A solar direct pump will now start when sufficient resets irradiation levels are reached and neither the well probe nor float switch respond to a low water source Low water well probe 15 Minutes or full tank regains contact with water Shutdown due to Automatic restart after overtemperature cooling down Shutdown due to overload Manual reset of POWER switch necessary To force a quick start the above listed delays can be by passed by switching the POWER switch OFF ON The pump should now start immediately if sufficient power is present 64 Operating the Pump 10 4 Parameter Setting with DataModule only NOTE Please always refer to the PumpScanner documentation available on partnerNET for the latest developments It is highly reco
32. d the water will heat up Depending on the ambient conditions it might even be possible that the water starts o boil The LORENTZ SunSwitch light sensor allows an irradiation level to be set at which the pump is switched on This means he SunSwitch will not allow the pump to start until there is sufficient irradiation to power the pump to the point of water delivery For information about the SunSwitch installation and the correct settings please refer to the SunSwitch manual Figure 24 SunSwitch Pump Accessories Installation 57 Correct SunSwitch settings are given in the COMPASS report subject to correct parameters These settings must be checked on site to make sure that the parameters entered in COMPASS match the conditions on site and that the SunSwitch is working as intended 58 Pump Accessories Installation Only for Controllers with DataModule For setup of DataModule related accessories the LORENTZ PumpScanner application for Android must be used cf 10 4 Parameter Setting with DataModule only on page 64 9 4 Water Meter Installation For information on the water meter installation please refer to the manufactures manual Pay attention to the installa tion position flow direction and the calming section Basic rule The water meter should have 10 nominal diameters straight pipe ahead of the meter and 5 nominal straight pipe diameters after to ensure proper flow through the me
33. damage is excluded from the warranty Pump Installation 37 8 2 Pump System Type Depending on your pump system please refer to the correct chapter for installation instructions Pump type Chapter Submersible 8 3 Surface CS F 8 4 Surface Boost 8 3 To determine the type of system you have please refer to chapter 3 3 Naming on page 8 38 Pump Installation 8 3 Submersible Pumps For submersible pumps only The pumps are water lubricated and therefore prefilled with water If the motor is stored for more than three months the water will have been pressed out the rotor must be turned by hand before use to ensure that the rotor is not stuck 8 3 1 Wiring the Pump CAUTION No disconnect switches must be installed between the motor and the pump controller Connecting the motor wire to the switched on controller might irreparably damage it Such damage is excluded from the warranty CAUTION If the pump wires are in the wrong order the motor will run in reverse and the pump will not function correctly Damage may result Check the direction before installing the pump The proper direction is counter clockwise when viewed from above CAUTION Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires dry run protection for every submersible pump system Figure 14 Exemplary LORENTZ submersible pumps The motor cables of the pump have a marki
34. ening the pump to the foundation should be done exclusively by means of properly sized bolts or threads dowels in order to avoid any movement of the pump unit CAUTION The pump must be mounted vertically Space During installation make sure that there is enough space available to permit subsequent disassembly of the motor unit It is recommended to have at least 1m of free space above the pump 44 Pump Installation 8 4 2 Pump Motor Wiring WARNING The wiring has to be done by qualified service personnel only WARNING Beware of high voltage Electric shock hazard The ECDRIVE must be connected to the terminals L1 L2 L3 and GROUND The ECDRIVE requires four conductor four wire cable between the controller and the motor The three wires L1 L2 and L3 carry power The fourth wire carries ground Connect the ground wire to the ground connection in the controller Grounding helps to prevent shock hazard if there is a fault in the motor The correct order of the three motor phases is marked on the motor cables itself Prior to splicing the order of the motor phases should be transferred to the cable This will simplify the wiring CAUTION No disconnect switches must be installed in power wires between motor and pump controller Connecting the motor wires to a switched on controller may cause irreparable damage which is excluded from the warranty CAUTION If the pump wires are in the
35. ensor surge protector Cree A safety rope submersible pump CA A grounding rod splicing kit stilling tube well probe 14 Pump System Sizing amp Layout Diagrams 6 3 System Layout Surface Pumps CAUTION This graphic is an exemplary pump system layout diagram and for ease of understanding only For system installation and wiring read and follow the detailed instructions given in this manual PV generator PV module PV disconnect PS controller float switch for SunSwitch surge protector well probe or float switch lt a SS water meter valve filler pressure sensor grounding rod P surface pump Strainer gate valve Pump System Sizing amp Layout Diagrams 15 6 4 System Layout Surface Boost Pumps CAUTION The displayed pump system layout diagrams are exemplary and for ease of understanding only For system installation and wiring read and follow the detailed instructions given in this manual water tap pressure tank surge protector PS controller PV disconnect PV generator PS Boost installation kit PS Boost pump float switch grounding rod PS Boost inline filter underground tank 16 7 Co Controller Installation ntroller Installation 7 1 General WARNING All electrical connections must be performed by qualified experts only A WARNING Do not dismantle the controller while still connected to
36. ensor in controllers 11 connect negative equipped with L1 connect to the L1 phase of the motor DataModule Output to L2 connect to the L2 phase of the motor motor L3 connect to the L3 phase of the motor GND connect to protective motor ground wire PE 26 Controller Installation Terminal Wiring Example PS150 UL PS PS600 to PS4000 Figure 7 Terminal wiring example PS600 to PS4000 surge protector PV disconnect A AA grounding rod water meter PV generator well probe float switch pressure sensor pump Controller Installation 27 7 7 1 2 Pump Wiring The motor cables of the pump have a marking to allow correct wiring Connect the wires using this sequence 1 Motor cable L1 2 Motor cable L2 3 Motor cable L3 GND If necessary interchange any two phases to reverse direc tion Refer to chapter 8 Pump Installation on page 36 for detailed pump installation instructions Controller Installation 7 7 1 3 Pump Accessories Wiring Terminals 1 and 2 To protect the pump from being damaged by dry running connect a well probe to terminal 1 and 2 If dry run protec tion is not needed add a jumper wire between these two terminals CAUTION Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires a dry run
37. f no shade is 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 function in the controller causing it to reduce the power consumption or turn it off The controller housing can reach high temperatures when operating at high ambient tem peratures This is normal and will not reduce the expected lifetime of the controller or its components 7 6 Mounting Space and Ventilation Requirements PS controllers can be mounted side by side All PS controllers have a fan less design they are cooled by air convection It is strictly advised not to install the control ler in an additional enclosure If an additional enclosure is necessary a sufficient vertical airflow from bottom to top has to be ensured to allow sufficient cooling For controller dimensions cf Table 3 Controller dimensions for installation on page 21 Figure 3 Controller dimensions for installation Left PS150 to PS200 non UL Right Controller Installation PS150 to PS200 UL e PS600 to PS1800 e PS4000 w1 W2 56 Table 3 Controller dimensions for installation
38. he COMPASS datasheet Figure 25 Sacrificial Anode for HR pumps 9 8 Surge Protector CAUTION Installing a surge protector at all sensor inputs is recommended damaged inputs due to electric surges are not covered by the warranty CAUTION Surge protectors provide an extended protection not a guaranteed safety Damages caused by electric surges are not covered by warranty CAUTION When installing surge protectors correct polarity must be ensured Surge protectors are designed to protect electrical devices from voltage spikes The surge protectors are to be connect ed in parallel to each sensor input ideally within the PS controller case For more information on the surge protector please refer to the datasheet in COMPASS Figure 26 Surge Protector Pump Accessories Installation 9 9 PV Disconnect with Lightning Surge Protection The LORENTZ PV Disconnect series is a PV connection box with an integrated disconnect switch and optional integrat ed lightning surge protector The box is designed to connect one PV module string 6 strings for the 440 40 6 with the pump controller by using the terminal clamps located inside the box The DC rated disconnect switch is used as a manual circuit breaker between the solar array and the load This switch is easily accessible by opening the hinged lid at the bottom spring lock The use of a properly sized DC disconnect switch is an important safety measure and o
39. he PS controller is connected to the battery In 24 VDC 22 VDC 24 VDC order to provide correct charging the charger should be set to voltage orientated regulation This may require a jumper PS600 48 VDC 44 VDC 48 VDC to be set in the charger Check the manuals of the charger PS1200 96 VDC 88 VDC 96 VDC manufacturer PS1800 96 VDC 88 VDC 96 VDC 7 7 1 6 Grounding Before starting to work on the electrical system make sure that all components are disconnected from the power source Only switch on the system when you have finished all work Grounding is mandatory to protect the users from potential ly fatal electric shocks It also protects against electric charg ing or a short circuit inside the device This is accomplished through clamping bolting or other mechanical means to provide an effective grounding path to the earth to ensure safe operation at all time The grounding is also important to the system for lightning protection In general it is meant for indirect lightning strikes and induced electrical potentials during operation of the pump system Before installation contact the local code authorities to determine the necessary grounding requirements Insufficient ground source Where there is an inadequate ground source you can use a grounding rod A grounding profile rod should be located about 4 5m 13 16 ft from the controller The cable must not carry any mechanical loads The rod must be completely buried
40. hen using plastic pipes you ICJ should always use a safety rope Figure 16 Stilling tube Pump Installation 4 8 4 CS F Surface Pumps 8 4 1 Placement and Foundation Rain and weather protection The pump is equipped with IPX4 type motor protection If it is installed outside the pump must be protected from rain and direct sunlight This will increase the durability of your pump CAUTION CS F pumps must not be submerged in water or subjected to rain or dripping water CAUTION If the pump is installed in a humid area effective ventilation and aeration must be provided in order to prevent condensation CAUTION When installing in very small installation spaces the natural cooling may be insufficient Carefully consider the ventilation in order not to exceed the maximum ambient temperature CAUTION The pump might heat up in operation The pump must not be installed on combustible surfaces Strong incombustible surfaces should be used e g concrete or stone surfaces Figure 17 Exemplary LORENTZ surface pumps Foundation An arrow on the pump base shows the direction of the flow of the fluid through the pump It is recommended to install the pump on a concrete foundation The foundation must be level and should have min approx 1 5 times the weight of the pump to absorb vibration shock and strain Connecting the pump to the foundation Fast
41. in five different temperature classes Temp class 0 0 10 C Temp class 1 10 20 C Temp class 2 20 30 C Temp class 3 30 40 C Temp class 4 40 50 C The pumps have a tolerance range of 2 C regarding the respective temperature ranges except for the lowest allowed temperature of 0 C The temperature class is part of the pump units name tag please refer to chapter 3 3 Naming on page 8 The pump system shall only be operated within the temperature range specified upon ordering CAUTION PS200 HR pump ends and pump units must always be ordered with the next higher temperature class to avoid starting problems in weak irradiation conditions CAUTION Operating the pump outside of the specified temperature range can lead to reduced efficiency and or damage the pump and can void the warranty Safety Instructions 5 Safety Instructions Safe operation of this product depends on its correct trans portation installation operation and maintenance Failure to follow these instructions can be dangerous to life or health and or void the warranty READ AND FOLLOW ALL INSTRUCTIONS Explanation of warning symbols WARNING Disregard can lead to injury death or damage the system CAUTION Recommended to avoid damage premature ageing of the pump or similar negative consequences When installing and using this electrical equipment basic safety precautions
42. is will keep any tensile forces away from the motor cable To extend the motor cable pay attention to chapter 8 1 2 Cable Splicing on page 37 8 3 3 Installation Depth Make sure that the pump unit is suspended properly and is not in contact with sand and mud from the well bottom It is recommended to install the pump above the filter zone water entry zone of the well to keep the sand content in the water low and ensure proper cooling of the motor CAUTION The pump must be submerged completely Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires a dry run protection for every pump system CAUTION If the pump does not hang above the filter zone a flow sleeve is necessary Pump Installation 8 3 4 Removal If you have to remove the pump system it is the same prin ciple as the installation in reverse order When removing the pump the pipes will be full of water and will be heavier CAUTION When you lift the pump system out of the well the pipes are full of water This causes additional weight In the table below you can see the additional weight of the water per meter pipe length Table 8 Additional weight per meter pipe length Pipe diameter Additional weight in kg m lb ft 2 2 0 14 5 25 3 2 23 1 3 4 6 33 3 4 8 2 59 3 5 127 91 9 6 18 4 133 1 41 42 Pump Installation 8 3 5 Additional Features 8 3
43. ither GND or depending on the type of controller For detailed information refer to 7 7 1 2 Pump Wiring on page 27 For detailed information refer to 7 7 1 3 Pump Accessories Wiring on page 28 For detailed information refer to 7 7 1 4 Input Wiring for Solar direct Systems on page 29 For detailed information refer to 7 7 1 6 Grounding on page 31 3 Pump Installation Submersible pumps Lower the pump into the water source with caution use a safety rope Surface pumps Install the surface pump on an adequate foundation with sufficient pipe sizing to ensure efficient op eration Fill the pump with clean water prior to starting it For detailed information refer to 8 3 Submersible Pumps on page 38 Depending on your pump system refer to 8 4 CS F Sur face Pumps on page 43 or 8 3 Submersible Pumps on page 38 for detailed information 4 Contents 1 Declaration of Conformity o ooo 6 2 Receipt Storage and Handling o oo e e e 6 3 Product Specification se see oa woe a a a a a E a 7 3 1 General s ssa ea a AR O ee a de 7 3 2 A e ata AAA 7 3 3 N MING cas ace ee a eR AR ee RR ae A A 8 4 Operating Conditions cs ee ooo ee a a a a o 9 5 Safety Instructions a 10 6 Pump System Sizing amp Layout Diagrams aaa a 12 6 1 Pump System Sizing se e a a aan dhe ba bd ls iR ew 12 6 2 System Layout Submersible Pumps 2 13 6 3 Sy
44. lects performance data from the pump system and stores it for periodic collection It uses Bluetooth to communi cate with the LORENTZ PumpScanner Android App and via Communicator with the browser based pumpMANAGER service allowing secure data collection without physical connections The PS DataModule opens up new opportunities to improve customer service knowledge and certainty LORENTZ CONNECTED 65 11 2 PumpScanner PumpScanner allows you and your customers to monitor and manage your PS and PSk2 solar pumps from a smart phone or tablet This exciting development for the LORENTZ pump systems is a clear differentiator from the competitor offerings To use PumpScanner you need to order your PS controllers with a DataModule pre installed there is small premium for this but it opens up a new world of information PumpScanner will give you detailed information about the pumps operational status and help you to fault find any problems more effectively so saving you money time and effort You can download PumpScanner and see the demo features today without any additional equipment PumpScanner runs on the Android operating system which is found in many smart phones and tablets More information is available on LORENTZ partnerNET at www lorentz de en partnernet support pumpscanner and at www lorentz de connected 66 LORENTZ CONNECTED 11 3 PS Communicator amp pumpMANAGER The LORENTZ PS Communicator and pu
45. mmended to make an initial configuration of the DataModule inside the PS controller using LORENTZ PumpScanner our Application for Android smartphones To gain access to the DataModule using PumpScanner the installation must be registered online in partnerNET at Sites first The License list within PumpScanner settings must be updated afterwards For detailed instructions on how to set up a Site and how to install and use PumpScanner read the PS Datamodule and PumpScanner manual It is available on partnerNET NOTE Always make sure that the latest version of PumpScanner is installed on your device Make sure that the DataMod ule is equipped with the latest firmware version The firmware can be checked and updated using PumpScanner Check whether the latest version of PumpScanner is installed on your android device Check the PumpScanner manual for help 1 Make sure that the physical installation is completed and that all connections have been double checked for correct connection 2 Connect the power to the PS controller but leave the ON OFF toggle switch of the PS controller in position OFF The pump must not run at this point 3 Connect to the pump controller using PumpScanner as per the PumpScanner manual 4 Check the PS controller Firmware version as per the PumpScanner manual and update it if asked by PumpScanner to do so 5 Click on Pump profile in PumpScanner to access the parameter
46. mpMANAGER service combine to offer customers a cost effective full man agement and monitoring system for their LORENTZ pump estate This is attractive to commercial farms industrial processes government or NGO monitoring and anywhere that water is critical to people livestock or crops The PS Communicator sends data from each pump across the cellular mobile data network to a secure central web server application called pumpMANAGER The pumpMANAGER application can be accessed from any web connected device anywhere in the world making access to information and control of your solar pumps simple and convenient As the connection is two way the pumps can be programmed speed controlled or switched off providing full remote control The pumpMANAGER application also monitors the status of your LORENTZ pump systems and will alert you if there are any unexpected events You can login to pumpMANAGER at www lorentz de using your standard partnerNET credentials and see the demo fea tures today without any addtional equipment or investment Figure 28 pumpMANAGER view of installation site Figure 29 pumpMANAGER view of system details 4OMENTI 12 Troubleshooting Please read this section carefully in case you experience any problems with the pump system and follow the checklists Should technical support by LORENTZ become necessary please provide the model and serial numbers 12 1 Pump does not run Most pr
47. ng to allow correct wiring Connect the wires using this sequence 1 Motor cable L1 2 Motor cable L2 3 Motor cable L3 GND The submersible pump must be submerged in water before checking the correct rotational direction The correct rotation direction for submersible pumps is counter clockwise viewed from the top It is also labelled with an arrow on the pump end The testing process for rotational direction depends on the pump type Please refer to the next page for detailed instructions on testing helical rotor HR and centrifugal submersible pumps To determine which type of pump you have please refer to 3 3 Naming on page 8 HR Pumps The HR pumps are positive displacement pumps and hence will only deliver flow rate when running with correct rotation direction They will be damaged when running in reverse A new pump out of the box is shipped from the factory with a lubrication film on the rotor which allows a test run of max 5 seconds in total without submerging the pump Once the pump came in contact with water it must not be operated without being completely submerged Submerging only the inlet is not sufficient and will result in damage to the pump end Check the rotational direction as follows 1 Connect the pump to the controller and power supply 2 Observe the information regarding HR pump testing above and follow them strictly 3 Start the pump and check the rotation direction by
48. nt disassembly of the motor unit WARNING The pump might heat up in operation It must be installed on a non flammable surface Connecting the pump to the foundation Fastening the pump to the foundation should be done exclusively by using bolts threads or dowels in order to avoid blocking the removal of the motor unit CAUTION Inlet and outlet pipes must be attached to the pump free of tension Figure 21 LORENTZ boost pump Pump Installation 49 8 5 2 Pump Motor Wiring L1 L2 L3 ECDRIVE requires four conductor four wire cable between the controller and the motor The three wires L1 L2 and L3 carry power The fourth wire carries ground To reverse direction of rotation reverse any two phases CAUTION No disconnect switches must be installed between motor and pump controller Connecting the motor wire to the switched on controller can cause damage Such damage is excluded from the warranty 50 Pump Installation 8 5 3 Installation Position The pump may be mounted horizontally or vertically CAUTION When installing the pump vertically the pump head must be facing downwards Rigid mounting is not required in most installations In a non battery system the pump starts gradually and does not jerk with the start In a battery system it will jerk slight ly but can be stabilized by mounting it to a small wood en board The pump may be hung vertically on a rope O
49. oblems are caused by either wrong cable connec tions in a new installation or failed connections especially insufficiently tightened cables that come loose from the terminal Please check the wiring The System ON light will indicate that the 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 In this case it will attempt a restart every 120 seconds Troubleshooting 12 2 Pump attempts a Restart every 120 Seconds The controller will emit a low noise as it tries to start the pump The pump will start to turn or only vibrate a little 1 There may be insufficient power reaching the controller A solar direct non battery system should start if there is sufficient sun to cast a slight shadow A battery system should start if the supply voltage is higher than what is listed in Table 7 Set points for low voltage disconnect on page 30 2 If the pump was recently connected or reconnected to the controller it may be running in reverse direction due to a wiring error 3 If the motor shaft only vibrates but does not turn it may have power on only two of the three motor wires This will happen if there is a broken connection or if you accidentally interchanged one of the power wires with the ground wire 4 The pump or pipe may be blocked by mud clay sand or debris CAUTION if the pump is blocked i
50. observing the motor shaft at the pump inlet 4 Compare to the indicated rotation direction on the pump end 5 In case the direction is wrong switch off immediately and change two of the three phase leads e g red and yellow 6 Start the pump again and check the rotation direction Do not exceed 5 seconds of combined testing time 7 The pump will only deliver water flow when running with correct rotation direction Pump Installation 39 Centrifugal Pumps Check the rotational direction as follows 1 Connect the pump to the controller and power supply 2 S 3 S fa 4 S 5 S p art the pump and check the delivered flow rate op the pump disconnect the power supply and hange two of the three phase leads e g red and yellow art the pump again and check the delivered flow op the pump disconnect the power supply and com are the flow rates from point 2 and 4 The wiring with the better flow rate has the right rotational direction 40 Pump Installation 8 3 2 Installation and Handling To lower the pumps into the borehole a crane or hoist is Round off the edges of a flange to prevent damage to the recommended depending on your pump system cable Do not fix the cable tightly Leave space for the pipes to expand The cable needs to get fixed every 3 m All parts have to be strong enough to withstand the weight of the pump the motor the motor cable and the pipe NOTE Me
51. of the PS controller Controller Installation 19 7 4 Technical Data of the Controller Refer to Table 2 Technical data of the PS controller on page 19 for an overview of the most important technical specifications of the PS controller Model Pump motor Affiliated pump Max DC input Min recommended Max output rated power motor voltage Vmp current kw V v A P5150 0 3 ECDRIVE 150 Boost 50 17 18 Boost PS150 0 3 ECDRIVE 150 C 50 17 18 PS200 0 3 ECDRIVE 200 HR 100 34 11 ECDRIVE 600 HR PS600 0 7 ECDRIVE 600 C 150 68 13 ECDRIVE 600 CS F ECDRIVE 1200 HR PS1200 1 7 200 102 9 5 ECDRIVE 1200 C ECDRIVE 1200 HR PS1800 id ECDRIVE 1200 C 200 102 14 ECDRIVE 1800 CS F ECDRIVE 4000 HR PS4000 3 5 ECDRIVE 4000 C 375 238 15 ECDRIVE 4000 CS F 20 Controller Installation 7 5 Controller Placement The controller must be protected from water moisture and animals so keep the controller box sealed Place the control ler in a dry and sufficiently ventilated environment Place the controller close to the solar array not the pump to reduce the risk of lightning damage The controllers input circuitry is more sensitive to surges than its output There fore it is safest to minimize the length of the input wiring Electronic devices are most reliable when they are protected from heat Mount the controller where it is shaded from the midday sun An ideal location is directly under the PV generator I
52. oint tracking MPPT Each LORENTZ pump system consists of a pump end pump motor and a controller This modular concept keeps all electronics above ground even for submersible pumps simplifying servicing and lowering cost of ownership 8 Product Specification 3 3 Naming Pump model definition for submersible pumps For centrifugal pumps C SJ 60 2 For helical rotor pumps HR 23 H HH L rm nN 1 number of small impellers stages rated flow m3 h submersible centrifugal temperature class high lift very high lift long rotor rated flow cm3 revolution helical rotor pump Pump model definition for surface pumps For CS F1 to CS F20 pumps CS F 4 3 For CS F32 to CS F85 pumps CS F 32 60 2 m For boost pumps Boost 330 stages rated flow m3 h vertical multistage pump centrifugal surface number of small impellers stages x 10 rated flow m3 h vertical multistage pump centrifugal surface rated flow GPH positive displacement vane type surface pump Operating Conditions 9 4 Operating Conditions Ambient requirements PS pump systems can be oper ated up to 3000 meters above sea level and at an ambient temperature of up to 50 C The PS controller is designed for use in environments classified as pollution degree 3 in accordance with IEC 664 1 Conductive pollution occurs or dry non conductive pollution which becomes conducti
53. otherwise the pump will not prime or will prime insufficiently CAUTION The pumps are shipped with plastic covers on the pump inlet and outlet Remove them before connecting the pipes to the pump Pump Installation Check valve A check valve at the inlet pipe is needed to assure that the pump and its suction pipeline remains completely water filled during the time the pump is switched OFF Always install a check valve with one inch 1 larger diameter than the suction pipe in order to avoid too much suction pressure drop For example if the suction pipe size is 3 then a 4 check valve should be installed Figure 18 Strainer unfiltered flow filtered flow filter element particle accumulation Figure 19 Pipe expansion joints 45 46 Pump Installation 8 4 4 Suction Head The maximum suction head is limited by the local air pres sure the water temperature of the medium the pipe losses and the NPSH value of the pump CAUTION If the suction pressure in the pump is lower than the vapor pressure of the fluid cavitation will occur Cavitation creates noise and will damage the pump Damage due to cavitation is not subject to warranty To avoid cavitation the pressure of the fluid must be maintained above its vapor pressure at all points as it passes through the pump The maximum suction head H must be calculated in advance The LORENTZ pump sizing software
54. r Original spare parts and accessories authorized by the manufacturer guarantee operational safety Using non authorized parts may void any liability on part of the manufacturer There are no user servicea ble parts inside the motor or the controller Unauthorized operation The operational safety of the equipment delivered is only guaranteed if the equip ment is used in accordance with the directions contained in this manual Limits stated in the data sheets may not be exceeded under any circumstances RETAIN THESE INSTRUCTIONS FOR FUTURE USE 11 12 Pump System Sizing amp Layout Diagrams 6 Pump System Sizing amp Layout Diagrams 6 1 Pump System Sizing To professionally size and install a water pumping system depending on the pump type and application various variables need to be taken into consideration Static head Vertical height from the dynamic water level to the highest point of water delivery Suction head Vertical height from the water level to the pump inlet where the water level is below the pump inlet Pressure losses Loss of water pressure due to pipe length and friction caused by pipe material and additional pipe line elements like elbows valves For solar water pumping additionally local irradiation levels are necessary to calculate the available power during each day and the effect on water output To easily manage and consider the different variables LORENTZ strongly advises to si
55. rotector at all sensor inputs is recommended damaged inputs due to electric surges are not covered by the warranty Figure 22 Well probe fixing Pump Accessories Installation 9 1 Well Probe The well probe contains a mechanical float with a magnet inside When the probe is submerged the float rises and the magnet actuates a switch The switch closes makes contact to indicate the presence of water If the water level drops below the probe the float drops and the switch opens breaks contact The controller will stop the pump When the water level recovers and the switch closes again the controller will delay the restart for 20 minutes for the water level to recover To force a quick restart turn the controller off then on again The switch is sealed so the contacts never touch the water Submersion depth The maximum submersion depth is 50 meters Fixing Along with the probe two cable ties are provided For a pump that is to be installed in a vertical position clamp the probe to the pipe just above the pump outlet as shown in Figure 22 Well probe fixing Splice the two wires of the probe using the splice kit components that are packed with the probe The assembly procedure is the same as the main pump splice Wiring to the controller The well probe must be wired to the controller at terminal 1 and 2 cf 7 7 1 3 Pump Accessories Wiring on page 28 Plug controller The well probe m
56. should always be followed including the following WARNING To reduce the risk of injury do not permit children to use this product unless they are closely supervised at all times WARNING The appliance is not to be used by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they are instructed and closely supervised WARNING To reduce the risk of electric shock replace damaged cords immediately WARNING It must be assured that all grounding connections are properly made and that the resistances meet local codes or requirements The manual contains basic instructions which must be observed during installation operation and maintenance Before installation and start up the manual should be carefully read by the person in charge of the installation The manual should also be read by all other technical personnel operators and should be available at the installation site at all times Personnel qualifications and training All per sonnel for the operation maintenance inspection and installation must be fully qualified to perform that type of job Responsibility competence and the supervision of such personnel must be strictly regulated by the operator Should the available personnel be lacking the necessary qualification they must be trained and instructed accord ingly If necessary the operator may request the manu acturer supplier
57. ssive suction lift or a clogged filter CAUTION Excessive suction at the pump intake causes cavitation resulting in noise and rapid pump wear CAUTION Do not use thin wall hose or soft tubing on the pumps intake It may collapse under suction and restrict the flow CAUTION Do not use polyethylene pipe for the suction side It is prone to leakage at the fitting Inline filter Inline filters should be mounted horizontal ly and as low as possible This prevents any air trapped from blocking the water flow Foot valve The foot valve is a check valve installed at the water intake It is required in any situation where the pump is located higher than the lowest water level of the wa ter source A high quality spring loaded type is recommend ed to avoid loss of prime A check valve allows water to flow one way only Priming the pump Priming a pump means complete ly filling its intake and suction line with water This must be done if the pump is mounted higher than the water source A removable plug or a valve must be installed at the highest point in the suction plumbing Prime the pump and intake line by pouring water into the opening until it is filled com pletely Your foot valve prevents loss of prime by not allow ing water to flow back into the water source The pump will create sufficient vacuum to self prime to around 3 m 10ft less at high elevations but only when it is in new condition and
58. stem Layout Surface Pumps ooo 14 6 4 System Layout Surface Boost Pumps 2 ee 15 7 Controller Installation oo me 16 7 1 General aai sa dn a Led ds Gord Oke hehe a fc T 16 7 2 Controller TYPES esas a a eee ee ia A A S 18 13 Controllerilementsis sr d sss aoa aaa sal E Y 19 7 4 Technical Data of the Controller 2 ooo 19 7 5 ControlleniPlacementiss i 4 su ar a dk de O a Ges ee E R a ee 20 7 6 Mounting Space and Ventilation Requirements 2 a a 20 7 7 Witing the Controllers 44 du aa E an e hee S he Ae ee ee a E 22 7 7 1 Controllers without pre wired Plugs o oa a 22 7 7 1 1 Terminal Descriptions 2 ee 22 Teak PUMP WING 4 S05 da whe aa a a a a A wo 27 74 1 3 Pump Accessories WING os sa wa se ae we ee ee k 28 7 7 1 4 Input Wiring for Solar direct Systems 2 a 29 7 7 1 5 Input Wiring for Battery based Systems 2 ee 30 LANO Grounding ass se OS ee Rw Ya ea a aoe os 31 7 7 2 Controllers with pre wired Plugs e coeca aaa aaa 32 78 Jumper Settings PS150 only 2 ss eae ew a A ee ee oS 35 8 Pump Installation lt o ia saa a ee 36 8 1 General INstruictions he burda a e na bh bbe ls e dd dl do a A 36 8 1 1 EEE 36 8 1 2 CableSplicMO iu se eh a a ats es A lt 4 a A a a 37 8 2 Pump System Type saab ebeieurpaasbsecbcaabtiabtesaaicideees iain 37 8 3 Submersible PUMPS sis mirror e aeii St 38 83 1 Witingthe Pump bosco 38 8 3 2 Installation and Handling ie
59. stems on page 30 Figure 10 MC4 plug for power input Figure 11 Plug W for motor cable Figure 12 2 pin plug Controller Installation 35 7 8 Jumper Settings PS150 only NOTE The following chapter to adjust jumper settings is relevant for PS150 controllers only Before start up check the setting of jumper Jmp2 For standard PS150 systems centrifugal mode Jmp2 must be set For PS150 Boost systems make sure Jmp2 is not set if necessary remove it Please refer to Figure 13 Jumper Jmp2 on PS150 controller boards on page 35 To access the mainboard in non UL controllers unscrew the plastic cover in UL controllers unscrew the top cover Jumper Jmp2 Make sure the two left pins are not connected for PS150 Boost mode or connected for centrifugal mode The two right pints are not connected Figure 13 Jumper Jmp2 on PS150 control ler boards 36 Pump Installation 8 Pump Installation 8 1 General Instructions WARNING All electrical connections must be performed by qualified experts only WARNING Before starting any work on the pump motor make sure that the electricity supply has been switched off and that it cannot be accidentally switched on CAUTION Before you start the assembly make sure that all parts were delivered and have not been damaged during transport 8 1 1 Pipe Sizing LORENTZ pump systems are extremely efficient It is impor tant to keep this effi
60. switched OFF ON during operation it resets the system LED status E Battery status indication with TANK FULL LED PS150 to PS1800 only TANK FULL BATTERY LOW LIGHT FLASHES UNTIL BATTERY HAS RECOVERED www lorentz de v110901 10 1 LED Status Operating the Pump 61 green light Power is present controller is switched on ES System status of controller no light System turned off or powerless Pump is on green light e Flashing indicates pump rpm ag Running and shutdown indicator light for pump no light Pump isnot running Pump is off due to overload red light Flashing indicates overtemperature of the controller Water sensor has detected a low water f source 3 red light CERE a er Low water source indicator submersible pumps Flashing indicates source low incident A_ Dry run protection surface pumps during the day no light Water source is OK red light Event triggered pump stopped eee Tank full or other connected external remote ES switch triggered red light flashing Battery low not PS4000 62 Operating the Pump Status Description SYSTEM green The controller is switched on and power is available In low power conditions the light may show even if there is not enough power to run the pump PUMP ON green Pump is turning The sequence of flashing indicates pump speed RPM RPM can be read off by the flashing sequence of the
61. t has to be cleaned Repeated starting of a blocked pump may cause damage to the motor This will void the warranty 67 68 Troubleshooting 12 3 Pump Overload Pump ON LED is red The system has shut down due to an overload This can hap Check the controller pen if the motor or pump is blocked or very hard to turn and is drawing excessive current Overload may not be triggered 1 Remove the screws from the bottom plate of the when the irradiation is low controller and slide out the backplate to access the terminal block where the wires connect This can be caused by a high concentration of solids in the pump The controller will make 3 start attempts before 2 Check for a burnt smell This will indicate a failure shutting down the system The System ON LED will be OFF of the electronics Look for burnt wires bits of black and the red OVERLOAD LED will be ON The system will not debris and any other signs of lightning damage reset until the ON OFF switch is manually switched OFF and ON again 3 Inspect the grounding wires and connections Most controller failures are caused by an induced surge from Check the PV generator nearby lightning where the system is not effectively grounded Ground connections must be properly made Make sure the PV generator is facing the sun and there is no and free of corrosion partial shading of the array A partial shading of as little as 10 of the arrays surface can stop the pump
62. t is required the max RPM adjustment in the controller is not set to limit the pump the solar array is receiving sufficient sun light without shading on the modules the PV generator is oriented properly and tilted at the correct angle Inspect and test the PV generator circuit and the controller output as stated Take notes of your measurements 4 all wires and pipe runs are sized adequately for the respective distance 5 there is no leak in the output pipe from the pump Could the issue not be resolved please raise a service case with LORENTZ including the service support forms available on partnerNET model and serial numbers and your measurements 69 150318 Installation details Sun Water Life Site System r name nom nombre U Pump setting in bore Profondeur de la pompe Profundidad de la bomba J Static head Perte de pression statique Altura estatica J Pipe length Longueur de canalisation Longitud de la tuber a J Pipe size Diam tre du tuyau Tama o del tubo J Water temperature Temp rature de l eau Temperatura del agua J Product labels Number of Modules Nombre de panneaux N mero de paneles Power module wp Puissance module wp Potencia m dulo wp Total power Wp Puissance totale Wp Potencia total Wp Number of strings Nombre de strings N mero de strings PS Controller Pump end a a XR Pi
63. ter 9 5 Pressure Sensor Installation The LORENTZ range of liquid pressure sensors are used to measure the pressure in a pipe The sensors are commonly used to measure the pressure at a well head or feeding into irrigation systems The liquid Pressure Sensor must be used with a PS DataModule equipped controller For more information about the pressure sensor please refer o the COMPASS datasheet Ensure that the pressure sensor is suitable for your application regarding pressure range and emperature resistance 9 6 Level Sensor Installation The LORENTZ range of liquid level sensors use pressure to measure the level or water in a well or tank The sensors can be used for long term water level monitoring and also or pump control in applications where a well probe cannot be used The liquid Level Sensor must be used with a PS DataModule equipped controller For further information about the Level sensor please refer to the COMPASS datasheet 9 7 Sacrificial Anode The LORENTZ Sacrificial Anode is designed for use with LORENTZ pump ends Where solar pump ends operate in ag gressive water conditions acidic water can attacks the pas sive layer of the high quality steel pump end This corrosion reduces the life time of the product The LORENTZ Sacrificial Anode contributes to the protection of the pump system from this type of corrosion and extends the pumps life For further information about the Sacrificial Anode please refer to t
64. to provide such training Furthermore he operator user must make sure that the personnel fully understand the contents of the manual Dangers of ignoring the safety symbols Ignoring he safety directions and symbols may pose a danger o humans as well as to the environment and the equipment itself Non observance may void the warranty Non observance of safety directions and symbols may or example entail the following Failure of important unctions of the equipment plant failure of prescribed methods for maintenance and repair danger to persons hrough electrical mechanical and chemical effects dan ger to the environment because of leakage of hazardous material danger of damage to equipment and buildings Safety oriented operation The safety directions contained in the manual existing national regulations for the prevention of accidents as well as internal guidelines and safety regulations for the operator and user must be observed at all times General safety directions for the operator user If hot or cold equipment parts pose a danger then they must be protected by the operator user against contact with people Protective covers for moving parts e g couplings must not be removed when the equipment is running Leaks e g at the shaft seal of hazardous pumping media e g explosive toxic hot liquids must be disposed of in such a way that any danger to personnel and the environment is removed All government
65. trol and monitor the pump system with the LORENTZ Pump Scanner application CAUTION Only connect a suitable pressure sensor to terminals 10 and 11 Never create a short circuit A short circuit will damage the DataModule immediately and will void the warranty Observe the polarity of the pressure sensor 7 7 1 4 Input Wiring for Solar direct Systems WARNING Beware of high voltage Electric shock hazard Hazardous electricity may be present and can shock burn or cause death Authorised qualified personnel only The PV generator can produce hazardous voltage even un der low light exposure To prevent shock hazard while wiring the array leave one or more wires disconnected or cover the solar array with opaque material Table 6 Max power input Controller Max DC input voltage PS150 50 VDC PS200 100 VDC PS600 150 VDC PS1200 200 VDC PS1800 200 VDC PS4000 375 VDC A Controller Installation 29 CAUTION An input voltage higher than specified in Table 6 Max power input on page 29 will damage the controller and void the warranty Damage may occur if the solar generator array is wired incorrectly Measure the voltage and confirm the polarity before connecting the power to the controller Connect the positive terminal of the PV modules to and the negative terminal of the PV modules to Connect the protective ground wire to an appropriate ground system Refer to 7 7
66. ust be connected to the controller at socket B2 cf 7 7 2 Controllers with pre wired Plugs on page 32 Potential problems with the well probe in surface water The probe has a moving float It is highly resistant to deposits and debris However the float can become stuck where algae or water creatures are present in surface water Possible solutions are Fix the probe independently of the pump and pipe clamped to a weight but not to the drop pipe This way it can be pulled out for inspection or cleaning without the need to lift the pump This may not be feasible if the well casing is smaller than 6 in Pull the probe out periodically with the pump if neces sary for testing and inspection The pump should stop a few seconds after the probe leaves the water Wrap the probe in a protective screen fiberglass window screen for example Use a different type of float switch You can use any switch that makes contact on rise normally open Use an encapsulated switch instead of the well probe if there is enough space for it to operate properly for example the LORENTZ float switch CAUTION Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires a dry run protection for every pump system CAUTION The well probe must be positioned vertically within 10 If the pump is not to be installed vertically find an alternative way to mount or suspend the probe so
67. valve and introduce air Prevent this by seal ing the surrounding area of the push button with silicone sealant or epoxy or replace the button with a nut tight ened down 51 Pump Installation 8 5 5 Plumbing Design CAUTION New pumps are covered with foam plugs to prevent contamination Remove the foam plugs before connecting pipes CAUTION Handle the pump with caution never use force on it Minimize suction lift to max 3 m total pressure loss 2 m for pumps with flow rate greater than 4001 h 105 US Gal The less suction lift the more reliable and quiet the pump will be The motor may not be submerged this will damage the pump Intake pipe The intake pipe may run any reasona ble horizontal distance although it is best to keep it short Use large pipe for the intake 1 to 11 for larger booster pumps Slope the intake line from the water source up to wards the pump Avoid humps in the intake line that cause air pockets which can block the flow CAUTION Avoid leaks in the suction line The pump will prime insufficiently or not at all The intake pipe must be sized generously to avoid high pressure drop at peak flow rate or the pump will be noisy and will wear rapidly Use pipe reducer fittings to adapt the pumps inlet or outlet to larger pipe size where necessary Larger pipe sizing does not have a negative effect CAUTION The intake must not be restricted by undersized pipe exce
68. ve due to condensation is to be expected Fluid LORENTZ PS Helical Rotor HR and Centrifugal pumps can be used for drinking water supply livestock watering and irrigation applications not containing solid or long fibred particles larger than sand grains with a max grain size of 2 mm The max permitted sand content is 50 ppm a higher sand content will reduce the pump life con siderably due to wear The max salt content is 300 500 ppm at max 30 C 85 F Defects due to pumping other liquids are not covered by the warranty LORENTZ PS BOOST pumps can be used for clean water ap plications only The water must not contain any abrasive par ticles It is highly recommended to install an intake strainer to protect the pump from any dirt ingress Please refer to 8 5 4 Filtering on page 51 for further information Fluid temperature Depending on the type of your LORENTZ pump system different requirements for fluid temperatures apply PS centrifugal submersible The maximum fluid temper ature for centrifugal submersible pumps is 50 C PS centrifugal surface The maximum fluid temperature for centrifugal surface pumps is 70 C PS boost surface The maximum fluid temperature for boost pumps is 80 C PS helical rotor HR submersible Designing and building helical rotor pumps for a narrow range of fluid temperature is important to ensure the best possible effi ciency LORENTZ PS helical rotor pumps are available
69. wer after correct wiring or the controller might get damaged CAUTION Do not install disconnect switches in the power wires between the motor and pump controller Connecting the motor wires to a switched on controller may cause irreparable damage Such damage is excluded from the warranty CAUTION Solar direct systems only Do not connect any electrical load to the PV generator other than the LORENTZ pump controller Connection of a battery charger active solar tracker controller electric fence charger or other load simultaneous ly with LORENTZ PS systems may interfere with the controller and prevent proper operation CAUTION Measure the voltage before connecting power to the controller Voltage open circuit must not exceed the max DC input refer to Table 2 Technical data of the PS controller on page 19 Controller Installation 23 Terminal Description PS150 to PS200 non UL Figure 4 Terminal PS150 to PS200 non UL Saa gt D D Table 4 Terminal explanation Socket Terminal Connection connect to positive terminal of PV module POWER IN connect to negative terminal of PV module 1 connection to NC Well probe 2 connection to COM 3 connect N O Float switch 4 connect ground 5 connect N C Jumper 6 connect cable jumper for battery mode Battery Mode 7 connect cable jumper for battery mode L1
70. wet inside A priming plug is always recommended if the pump is installed above the water source Using a good quality ball valve instead of a plug is recommended espe cially if frequent priming is expected Check valve at the pump outlet A check valve at the pump outlet is required if there is more than a 10m 30ft lift above the pump or in any pressurizing system This allows a more easy start of the pump It also prevents back flow when changing filter cartridges Pipe unions If you run rigid piping copper or PVC di rectly to the pump unions are required Unions make pump replacement easy without the need to cut and re solder or re glue the pipe Copper Flex Connectors commonly used for water heaters may be used instead Pump Installation 53 8 5 6 Freeze Protection A CAUTION The pump must be protected from freezing Freezing may damage the pump CAUTION When insulating the pump for freeze protection the motor must be excluded to prevent overheating 54 9 Pump Accessories Installation CAUTION Installing a SunSwitch is mandatory for all PS1800 CS F and all PS4000 pump systems Operating without a SunSwitch can lead to increased wear or damage the pump Such damage is excluded from the warranty CAUTION Never let the pump run dry Dry running will damage the pump and void the warranty LORENTZ requires a dry run protection for every pump system CAUTION Installing a surge p
71. wrong order the motor will run in reverse and may damage the pump Never let the pump run dry not even for the purpose of checking the direction of rotation Check the correct rotation direction after the pump is filled with water see chapter 8 4 5 2 Rotary Direction on page 48 8 4 3 Installation and Handling Handling When lifting the pump use the eyebolts at the motor housing If that is not possible lift the pump at the motor flange by using a holder or straps Strainer If pipelines are welded together metal pieces might be present in the pipeline Before pump installation the inlet pipeline must be carefully cleaned It is recom mended to install a strainer about 1m 3 ft in front of the pump inlet to avoid pump damage due to any kind of im purities cp Figure 18 Strainer The pressure drop of the strainer must be considered in the suction lift calculation Pipe system We advise that pipe expansion joints are used close to the pump on both inlet and outlet to reduce noise and vibration cp Figure 19 Pipe expansion joints It is recommended that you install a gate valve in the suction and discharge pipeline close to the pump to avoid draining of the pipe while cleaning e g filters repairing servicing or replacing the pump system WARNING Inlet and outlet pipes must be mounted to the pump housing free of tension CAUTION Make sure that the suction pipe is sealed with no leaks
72. y on solar power They are typically used Engineered in Germany using high quality non in irrigation projects and for wide area drinking water corrodible materials applications where they reliably meet the most demanding P65 NEMA 3A corrosion resistant controller housing requirements economically without pollution and withouta Pump control based on power available grid connection or diesel generator ECDRIVE DC Brushless motors specifically designed for solar operation with up to 92 efficiency A typical solar pumping system is composed of a PV gen Controllers with DataModule D name tag erator array a pump and a solar pump controller Based on Monitoring and management including on board record the design philosophy that it is more efficient to store water ing of up to 5 years of performance data smart device rather than electricity there is no energy storing device such access via PumpScanner Android App and integration as a storage battery in a typical solar pumping system to LORENTZ pumpMANAGER remote management service optionally available The PV generator an aggregation of PV modules connected in series and in parallel absorbs solar irradiation and con verts it into electrical energy providing power for the whole system The pump controller controls and adjusts the system operation and adjusts the output frequency in real time according to the variation of sunlight intensity to realize the maximum power p
73. ze pump systems with LORENTZ COMPASS the solar pump planning software Figure 1 COMPASS sizing COMPASS is the LORENTZ tool for designing planning and specifying solar pump systems It is available for download to all LORENTZ partners on partnerNET COMPASS is a PC based tool to simply specify solar pumping systems in real time It is based on NASA weather data and uses precise algorithms for even the most complex calculations By selecting the location from a list of more than 250 000 cities entering the total dynamic head TDH and the necessary amount of water per day the software will automatically show suitable pump systems and the necessary size of the PV generator For more complex situations COMPASS offers features from suction head calculation to pipe type specific pressure loss calculation NOTE Always ensure the values used for A sizing with COMPASS match the conditions on site Incorrect parameters can lead to a wrong sizing report perth ing a E ow j i i ES LORENTZ Pump System Sizing amp Layout Diagrams 13 6 2 System Layout Submersible Pumps CAUTION This graphic is an exemplary pump system layout diagram and for ease of understanding only For system installation and wiring read and follow the detailed instructions given in this manual PV generator PV module PV disconnect PS controller float switch for SunSwitch o water meter pressure s

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