PS150 BooSt Solar Water Pump Systems
Contents
1. PS150 pumps require different current depending on speed 6 Om 008 0000 0000 and lift When low light conditions are present the PV array J Y r s EES loat switch 3 cannot supply the required current If you dont use a con E enr a eee this terminal 2 2 85E troller the voltage will drop to nearly zero and the pump 1 617 will stall like a truck trying to start in 4th gear The pump controller also called linear current booster LCB in cluding Maximum Power Point Tracking MPPT acts like a gear box in your car This device will match the power source to the load by transforming the voltage down while increasing the current delivered to the motor like an auto matic transmission BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice Sun Water Life LOB8OLLA lt 11 Trouble Shooting Please read this section before calling for help If you call for help please refer to the model and seri al numbers If The Pump Does Not Run Most problems are caused by wrong connections in a new installation or failed connections especially where a wire is not secure and falls out of a terminal The System ON light will indicate that system is switched on and connected to the controller It in2. Do not attempt to use the controller for any purpose other than LORENTZ PS pump systems Do not attempt to run the motor without controller Ensure all power sources are disconnected when working on the system Follow all appropriate electri cal codes There are no user serviceable parts inside the motor or the controller WARNING disregard might lead to injury or damage the installation CAUTION recommended to avoid disfunction or premature ageing of the pump etc Sun Water Life lt 3 Product Description PS150 BOOST is a highly efficient pump system which pro vides city water pressure It is economical for domestic wa ter supply drip irrigation livestock water transfer to re mote places and many other applications It is a surface pump which must not be submersed The pump of PS150 BOOST is a positive displacement vane type pump The PS150 BOOST brushless DC motors are specially made for this system The motor is using very advanced raw earth magnet technology handmade wiring for highest copper density and does not need wearing brushes This results in an exceptionally high efficiency with low temperature dis sipation PS150 BOOST can either be used in a battery system with voltages of 12V DC or 24V DC or as a solar direct system Both modes use the same controller PS150 In battery mode the solar battery is charged during day light hours using an independent charge controller T
3. No 1 and 2_ In order to protect the pump from being damaged by dry running connect one well probe cable to each terminal If dry run protection is not needed short cut these two terminals No 3 4 and 5 Connect any kind of external switch NO or NC type for remote control of the controller In case no switch is used the terminals No 4 and 5 have to be con nected with a short cable factory setting In case a NO switch is used connected to the terminals No 3 and 4 the short cable connecting the terminals No 4 and 5 must re main installed No 6 and 7 Connect these two terminals to switch the controller to battery mode The motor will be switched OFF by the controller if the input voltage is below 11V DC for 12V DC systems or 22V DC for 24V DC systems respec tively in order to protect the battery If the battery voltage increases to 12V DC for 12V DC systems or 24V DC for 24V DC systems respectively the motor will be switched ON automatically Figure 1 Terminals of PS150 controller Terminals of the controller Remote max Float Switch 50 V Do not connect this terminal low water 5 7 Battery based Systems Short circuit protection Install a fuse or circuit break er near the power source Use a 30A circuit breaker or a time delay slow blow fuse installed into a rain tight dis connect switch The purpose of this protection is for safety in case of a wiring fault and to provide a means
4. the switch turns the pump ON w i Le ys SE ys oo r I T float switch connect to bypass N NO Ww ia Connect H A Switch NC o For factory e2 I O js Nee EENE WA as kopiaren ma E he a J il if cable is shielded UP open ground this end only DOWN closed normal closed BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice Sun Water Life LO8OLLA lt 8 Pressurising Systems A PRESSURE TANK IS REQUIRED with a boost er pump system Pressure tanks are available from lo cal water supply dealers Use the largest tank you are will ing to buy 1501 40 US gal size is typical it allows you about 451 12 US gal of water between pump cycles Those 451 12 US gal may be drawn at a higher flow rate than the pump produces A large pressure tank will minimize on off cycling of the pump In a typical household of more than four people a tank of at least 2301 60 US gal is recom mended More than one tank may be connected They need not be the same size A PRECHARGED CAPTIVE AIR TANK is recommend ed Cheaper galvanized tanks require periodic recharg ing store less water between cycles and do not last as long PROPER PRECHARGE IS ESSENTIAL to proper opera tion Follow the instructions that come with your pressure tank Wit
5. www lorentz de Errors excepted and possible alterations without prior notice LORENTZ You can also use the pressure switch to switch the main power supply of the pump But the recommendet way is to avoid any switch power losses and to use the float switch terminals of the PS controller to start and stop the pump WARNING INSTALL THE PRESSURE A RELIEF VALVE INCLUDED WITH YOUR PUMP Some PS150 BOOST pumps for city water pressure systems are supplied with a 6 bar 85 PSI pressure relief valve as a safety feature If your pressure switch fails EXCESSIVE PRESSURE may cause your tank of piping to burst and flood your home pressure tank house pressure nese plumbing relief bib valve Sun Water Life LORENTZ 9 Maintenance Controller The controllers electronic has no moving or wearing parts It requires no maintenance There are rubber plugs to seal at the bottom unused conduit holes Inspect them to insure that the controller is sealed from mois ture insects etc Check that mounting and conduit hard ware is tight Motor The motor requires no maintenance It has no brushes or other frequently wearing parts Pump end The pump mechanism pump end is lubricat ed only by water and requires no maintenance It may wear after some years especially if there are abrasive solids in the water If sand accumulates in the storage tank or pipes as a result of normal pumping it is best to take per
6. a INLINE FILTER is best installed close to the pump s intake If filters are ex pected to clog often maintenance may be minimized by plumbing two or more filters in parallell The INLINE FILTER has a clear bowl so its condition may be observed CAUTION KEEP SPARE CARTRIDGES HANDY Filter cartridges are available from your dealer or the factory 9 7 8 inch cartridges for the INLINE filter may also be obtained from local water system suppliers The 10 20 micron spun polypropylene type is best Paper fil ters have less capacity The kind that looks like string has more resistance to flow Carbon taste and odor cartridges have less capacity for dirt more resistance to flow and cost more 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 fibers 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 your pump runs quietly the filter is OK Use pump noise to indicate the need to change cartridges Iron pipes or fittings will introduce abrasive rust parti cles if installed on the intake side of the pump they rust every if galvanized Pipe that is dirty inside even new pipe or has mineral deposits in it will also introduce dirt Dirt is introduced as pipe joints are assembled especial ly in a trenc
7. of discon nect when installing or maintaining the system PS150 con trollers have electronic over current protection against mo tor overload Low voltage disconnect function Lead acid batter ies can be permanently damaged by over discharge when the voltage falls below a critical point An additional charg er is needed for charging the batteries To prevent this the PS battery system controller will turn off at low voltage and turn back on only after the battery has recovered sig nificantly The set points are System Voltage OFF ON 12V DC 11VDC 12VDC PS150 Boost 24V DC 22VDC 24V DC A controller in disconnect mode can be reset manually by turning off on but it will quickly disconnect again if the battery is not gaining a substantial recharge BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ 5 8 Grounding and Lightning Protection WARNING Install proper grounding for safety and lightning protection A long wire run may act like an antenna receiving induced surges of high voltage when lightning is present Proper grounding will greatly reduce risk of lightning damage to your power system A proper ground system consists of a minimum of one 2 5m 8 ft copper plated ground rod driven into the ground preferably in a moist spot close to the PV arr
8. required 3 Be sure all wire and pipe runs are sized adequate ly for the distance Refer to wire sizing in the pump sizing table 4 Inspect and test the solar array circuit and the con troller output as above Write down your measure ments 5 _ There may be a leak in the pipe from the pump There is a max RPM adjustment in the control ler It may have been set to reduce the flow as low as 30 WARNING For all repairs Do never use force Sun Water Life LORENTZ 12 Dimensions Dimensions for BOOST 60 BOOST 125 and BOOST 240 330 in mm in OUTLET INLET 3 8 in 18 NPT 3 8 in 18 NPT 1 2 in 14 NPT 1 2 in 14 NPT 65 2 7 86 3 5 es es 38 1 6 48 2 0 gueno 26 1 1 32 1 3 M20 x 1 5 4 x 8 5 0 35 112 4 6 126 5 1 7 T 100 4 1 130 5 3 210 8 6 BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice Sun Water Life LOB8OLLA lt System and Components Date of purchase Dealer full contact details System System Controller serial Motor serial PV generator PV modules PV module brand PV module model Vmp Voc Quantity wired Battery system Battery system If yes System voltage Capacity of battery bank T
9. the controller indicates SOURCE LOW when the pump is in the water inspect the low water probe 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 full tank float switch If the controller indicates TANK FULL when the storage tank is not full inspect the float switch system If your sys tem has a float switch it will be mounted in the tank If in spection 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 Switch the on off switch or the power source off then on again The pump should start immediately if sufficient pow er is present BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ If the pump responds to the bypass tests above 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 1 Is the solar array receiving shadow free light It only takes a small shadow to stop it Is it oriented prop erly toward the south and tilted at the proper angle 2 Be sure you have the right pump for the total lift that is
10. 5 ambient operation of controller C 20 to 50 temperature operation of pump C 0 to 50 PV modules at standard test condition AM 1 5 E 1 000W m cell temperature 25 C BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice Sun Water Life lt 5 Installation 5 1 General WARNING All electrical connections should be performed by a qualified experts only Please make sure that the electrical installation has a dis connecting device which allows disconnecting from the power supply with a minimum of 3 mm contact gap at each pole This pump is built according to Protection Class 1 WARNING The ambient temperature must not exceed max 50 C 5 1 Filtering WARNING Your pump is a PRECISION A MACHINE Traces of sand clay rust or other solids will cause rapid wear or immediate damage If your water is CRYSTAL CLEAR ALL THE TIME our fine in take strainer will provide sufficient protection If you have an intake strainer already it is probably not fine enough openings must be no more than several hairs wide or ad ditional filtration is required Since water conditions are subject to change it is good insurance to use a filter re gardless A 30 INCH INTAKE FILTER FOOT VALVE is necessary for pumps lowered into wells Otherwise
11. LOB8OLLA PS150 BOOST Solar Water Pump Systems Manual for Installation Operation Maintenance Contents 1 Introduction 0 0 0 cee ees 2 IMPORTANT SAFETY INSTRUCTIONS 3 Product Description 0 0 0 4 Placement 4 1 Location RE aE aiaa RR Eia E GaN 4 2 Installation Position 5 Installations oii aana 5 1 General 5 1 Filtering aee ae eaae eteo a eE 5 2 Plumbing Design f 5 3 Installation in Drilled Wells 5 4 Freeze Protection 2 0 0 cece eee ee 5 5 Controller Input Wiring lt e o se o oe eee 5 6 Electrical Installation Terminals 5 7 Battery based Systems 5 8 Grounding and Lightning Protection 5 9 Wire SWING lt cras cosas esses esen en cnenod 6 Operating the Pump 0 0 eee ee 7 Automatic Control For Full Tank Shutoff 8 Pressurising Systems ao aea ee eee ee Pressure Switch Wiring s aee cece cece tee ee Pressure Setting 0 20 cece cee cece ee en eee 9 Maintenance a a aa ec a 10 System Wiring EET 10 1 12V DC Battery ry System 10 2 24V DC Battery System 10 3 System Wiring for 12 24V Dc Systems i in PV di rect Operation 11 Trouble Shooting a o ae a aa aeaa aa 12 Dimensions 00 ea 13 System Report 0 0c cee ee www ADDADUUUAERDARA Koj 10 11 ied 1 a12 13 14 15 1 Introduction Thank you for purchasing a LORENT
12. Z PUMP Before you begin Check the model numbers of all the components of your system and verify that they are the items that you ordered Also check against the pump speci fications and performance charts end of this manual to be sure the system is appropriate for your application Please fill in the SYSTEM REPORT This will be essen tial information if any problems occur Read the manuals of pump end charger optionally and other components used in your system BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ Sun Water Life LOBOLLA READ AND FOLLOW ALL INSTRUCTIONS When installing and using this electrical equip ment basic safety precautions 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 super A the resistances do not exceed the local codes SAVE THESE INSTRUCTIONS WARNING To reduce the risk of electric shock replace damaged cord immedi ately WARNING It must be assured that all grounds are connected properly and that 2 IMPORTANT SAFETY INSTRUCTIONS The manual contains basic instructions which must be observed during mounting operation and maintenance Therefore the manual should be carefully read before instal
13. ar day or until power is disrupted or the controller is turned off on 4 Battery systems after low voltage disconnect point is reached delay to stop pump a few SECONDS After voltage recovers delay to re connect a few SECONDS To force a quick start To test or observe the system you can bypass the normal time delays Switch the POWER switch off then on again The pump should start immedi ately if sufficient power is present LEDs for Monitoring Remote Float Switch for battery Connect mode BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice E SYSTEM E PUMP ON E OVERLOAD E WELL DRY E TANK FULL RPM L1 L2 L3 Sun Water Life LORENTZ 7 Automatic Control For Full Tank Shutoff We recommend the use of a float switch or other means Float switch cable requirements to prevent overflow of your tank This will stop the pump when the tank is full then reset when the level drops This 1 Two wires are needed conserves ground water prevents overflow and eliminates 2 Minimum wire size 18 AWG 1mm2 This is good unnecessary pump wear PS controllers allow the use of for a distance as far as 2 000 feet 600 m small signal cable to a remote float switch even if the tank 3 The cable must be suitable for its envir
14. ation for best lon gevity and enclosed for cleanliness and safety A A Operating noises Make sure by applying appropriate measures that the environment will not be impaired by any sound produced by the pump WARNING HUMIDITY If the pump is installed in a humid space effective ventilation and aeration must be provided for in order to prevent condensation WARNING COOLING In case of very small installation spaces the natural cooling of the air may be so insignificant that also there ventilation and aeration is necessary in order not to exceed the environmental temperature of 50 C Space During installation make sure that there is enough space available to permit subsequent disassembly of the motor unit LORENTZ A Connecting the pump to the foundation Fastening the pump to the foundation should be effected exclusive ly by means of bolts threads or dowels in order to avoid blocking the removal of the motor unit A 4 2 Installation Position WARNING Pump might heat up in operation Pump must not be installed on combustible dangerous surface but e g on cement surface or marble surface WARNING Inlet and outlet pipes must be mounted to the pump housing free of tension The pump may be mounted horizontally or vertically A Rigid mounting is not required in most installations In a non battery system starting is gradual and the pump does not jerk with the start In a battery system it wi
15. ay Or if you have a steel well casing drill and tap a bolt hold to make good contact to it In a dry lightning prone location use more than one ground rod at least 3m 10ft apart Bury bare copper wire between them Use min 4mm 8 ground wire larger for distances exceeding 6 m 20 ft In a rocky location where ground rods can t be driven bury as much as feasible 45 m 150 ft total of bare cop per wire radiating out in two or more directions from the PV array Try to contact moist earth as much as possible A Connect your ground system to the METALLIC FRAME of your PV array via min 4mm 8 copper wire Also ground metallic support structures and electrical enclosures WARNING Use only the copper or bronze electrical connectors designed for grounding application and BE SURE ALL CONNECTIONS ARE TIGHT 5 9 Wire Sizing Do not use undersized wire Splice it to a larger size of wire if your wire run is longer than 2 m 7 ft Refer to a wire siz ing table Consult a low voltage wire size chart to size the cable size from the array to the controller or call your deal er or the factory for recommendations Excessive voltage drop will slow the pump down but if it is unavoidable It will NOT cause any harm to the motor Wire sizing for the DC circuit Wire must be sized for no more than 5 voltage drop at 30A starting Refer to a wire sizing chart for 12V DC or 24V DC or follow these examples PV direct syste
16. be observed Basi cally all work on the machine is to be performed while the machine is not in operation The sequence for shutting the machine down described in the manual must be strictly observed Pumps or pump units han dling hazardous liquids must be decontaminated Im mediately upon completion of the work all safety and protective equipment must be restored and activated Unauthorized Changes and Manufacturing of Spare Parts Any conversion or changes of the ma chine may only be undertaken after consulting the manufacturer Original spare parts and accessories au thorized by the manufacturer guarantee operation al safety Using non authorized parts may void any lia bility on the part of the manufacturer in case of conse quential damage Unauthorized Operation The operational safety of the machine delivered is only guaranteed if the ma chine is used in accordance with the directions con tained in manual Limits stated in the data sheets may not be exceeded under any circumstances Cited Standards and other Documentations DIN 4844 Part 1 Safety marking Safety symbols W 8 2 Supplement 13 DIN 4844 Part 1 Safety marking Safes ty symbols W 9 Supplement 14 Transportation and Intermediate Storage Pro longed intermediate storage in an environment of high humidity and fluctuating temperatures must be avoid ed Moisture condensation may damage windings and metal parts Non compliance will void any warranty
17. blocking the water flow Be sure to leave some space be low it for a pan to catch water when replacing the filter cartridge Sun Water Life LOBOLLA Foot valve The foot valve is a check valve installed at the water intake It is required in any case where the pump is located higher than the low water level in the source A high quality spring loaded type is recommended to avoid loss of prime A check valve allows water to flow one way and not the other Be sure to install it the right way Priming the Pump Priming a pump means filling its in take and suction line completely 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 high est point is in the suction plumbing Prime the pump and intake line by pouring water into the opening until it is completely full Your foot valve prevents loss of prime by not allowing water to flow back into the water source The pump will create enough vacuum to self prime to around 3m 10ft less at high elevations but only when it is in new condition and wet inside A priming plug is always rec ommended if the pump is to be located higher than the water source Using a good quality ball valve instead of a plug is recommended especially if frequent priming is ex pected Check Valve at the pump outlet A check valve at the pump outlet is required if there is more than a 10 m 30ft lift above the pump or in any p
18. ce although it is best to keep it short Use large pipe for the intake 1 to 11 2 for larger booster pumps Slope the intake line from the water source UP to ward the pump Avoid humps in the intake line They trap air pockets which can block the flow CAUTION Avoid leaks in suction line Otherwise the pump will prime insuffi ciently or not at all Leaks in the suction line are hard to locate and will cause constant problems The intake pipe must be sized generously to allow no more than a slight pressure drop at peak flow rate or pump will be noisy and will wear rapidly Use pipe reducer fittings to adapt your pump s inlet or out let to larger pipe size where necessary Excessive pipe siz ing will do no harm WARNING Intake must not be restricted by undersized pipe excessive suction lift or a clogged filter WARNING Excessive suction at the A pump intake causes cavitation forma tion and implosion of vapor bubbles This causes very loud buzzing noise and radid pump wear A slight buzzing noise is acceptable if it cannot be avoided CAUTION Do not use thin wall hose or soft tubing on the pump s intake It may collapse under suction and restrict the flow CAUTION Do not use polyethylene pipe black flexible for the suction either It is prone to slight leakage at the fitting Inline filter should be mounted HORIZONTALLY and as low as possible This prevents any air trapped in it from
19. dicates that VOLTAGE is present but in a solar direct system there may not be sufficient pow er to start the pump It should attempt to start at intervals of 120 seconds Pump attempts to start every 120 seconds but doesn t run The controller makes a slight noise as it tries to start the pump The pump will start to turn or just vibrate a little 1 There may be insufficient power reaching the control ler A solar direct non battery system should start if here is enough sun to cast a slight shadow A bat ery system should start if the supply voltage is high er than 12 24V DC 2 If the pump was recently connected or reconnected o the controller it may be running in reverse direc ion due to wiring error 3 Ifthe motor shaft only vibrates and will not turn it may be getting power on only two of the three motor wires This will happen if there is a broken connec tion or if you accidentally exchanged one of the pow er wires with the ground wire 4 The pump or pipe may be packed with mud clay sand or debris A CAUTION If the pump seizes it has to be cleaned Repeated starting of a blocked pump may cause damage to the motor In that case any guarantee is voided PUMP OVERLOAD PUMP ON light shows red in stead of green The system has shut off due to an over load This can happen if the motor or pump is blocked or very difficult to turn and is drawing excessive current hard to turn Overload detection req
20. e manual existing national regula tions for the prevention of accidents as well as internal working operational and safety regulations of the operator user must be observed at all times General Safety Directions for the Operator User If hot or cold machine parts pose a dan ger such parts must be protected by the operator user against contact with personnel Protective cov ers for moving parts e g coupling must not be re moved when the machine is running Leakages e g at the shaft seal of hazardous pumping media e g ex plosive toxic hot liquids must be disposed of in such a way that any danger for personnel and the environ ment is removed All government regulations must be observed at all times Any danger to persons etc by electrical energy must be excluded For details see e g regulations of VDE and the local utilities BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ Explanation of Warning Symbols A A Safety Directions for Maintenance Inspection and Assembly Work It is the user s responsibili ty to make sure that all maintenance inspection and assembly work is performed exclusively by authorized and qualified experts sufficiently informed through careful perusal of the Operating Instructions The acci dent prevention regulations must
21. e tank INSTALL THE PRESSURE RELIEF VALVE near your pres sure tank Run a pipe or hose from its outlet to a drain or drain pipe or to the outdoors where water can drain away safely A GATE VALVE and DRAIN VALVE are recommended for convenience during system shut down The drain valve is simply a garden hose outlet which allows easy draining of the system It also allows water delivery by hose while wa ter is shut off to the house during installation or repairs to plumbing INSTALLATION KIT IS AVAILABLE If you have not yet purchased the small parts you need to install your booster pump you can save time and confusion by purchasing our convenient parts kit All components are selected for maxi mum quality and convenience Pressure Switch Wiring 1 Connect to Float switch terminal 4 of PS Controller 2 Connect to float switch terminal 5 or 3 depending of NC or NO function 3 Setting of cut in pressure Earth terminals 5 Setting of pressure differential Pressure Setting 1 Completely release nut for setting of differential 5 2 Adjust nut 3 until required cut in pressure is ob tained 3 Tighten nut 5 until required cut out pressure is ob tained CAUTION You need a pressure gauge to A find the right setpoints for your application priming plug inline filter PS150 Boost BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29
22. er wire on terminal 6 and 7 must be taken out for solar direct mode Remote Tank Float Switch Connect float switch to ter minals 4 5 of the pump controller when it breaks contact on rise to turn the pump OFF Otherwise use terminals 3 4 for opposite function Solar Tracking Use stranded wire for flexibility Secure the wires to tracker with plenty of tape Leave a good slack loop to allow free motion of tracker low water sensor 1 PV module 12V or 2 PV modules 12V in series array The lifetime of the battery will be increased consider ably as cycling is avoided 10 4 Jumper Setting for PS150 Boost Mode Jumper Jmp2 i g Make sure the two left pints are not Before start up check that the controller connected for PS150 Boost mode is in PS150 Boost mode i e that jumper Jmp2 is NOT set cf sketch on the right www LORENTZ de 3 DO oO Oo 0 BOE 10 5 High run Mode sien on gat In order to set the battery high run mode set the jump Hae er Jmp1 as shown in above picture This will increase the e 2 Low Voltage Disconnect LVD settings to 12 3 24 6V and the re start voltages to 13 3 26 6V to allow pumping only gE when the batteries receives charging current from the solar 8 8 p Er ABEE H occooo pg P i m 10 6 Power Control for PV direct Operation Jumper Jmp1 Set to activate High run Mode
23. h CAUTION Make sure inlet lines and fittings are FLUSHED CLEAN before hooking up to pump The INLINE FILTER may have a red push button valve to re lease pressure for maintenance If filter is placed more than a few feet higher than water source at lowest level the suction may pull the valve open and introduce air Prevent this by sealing around the push button with silicone sealant or epoxy or replace the button with a nut tightened down BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ 5 2 Plumbing Design WARNING New pumps are packed with foam plugs to prevent contamination REMOVE FOAM PLUGS BEFORE CON NECTING PIPES HANDLE YOUR PUMP CAREFULLY Never A hammer on it clamp it in a vice or drop it Minimize suction lift to max 3 m total pressure loss 2m for pumps with flow rate greater than 400 l h The practi cal suction limit for any pump is 6m 20 vertical ft at sea level subtract 0 3 m 1 ft for every 300 m 1 000 ft of eleva tion The more you minimize suction lift the more relia ble and quiet your pump will be Just be sure the motor will not be submerged if the water level rises or it will be ru ined Your pump may be placed downhill from your water source if feasible Intake Pipe The intake pipe may run any reasonable hor izontal distan
24. h pressure discharged from the tank adjust pre charge to about 0 2 bar 2 PSI below cut in pressure PRESSURE SWITCH ADJUSTMENT Switch settings de termine the pressure range of your system To conserve energy set the pressure as LOW as feasible This will also prevent the motor from overheating if you run it for long periods sprinkling for example Low pressure even 1 1 5 bar 15 20 PSI may deliver excellent water flow if your plumbing and hoses are sized larger than minimum If not yet plumbed use at least one size larger pipe than con ventional and avoid restrictive connections such as 3 8 tubing often used to feed sinks Adjustment Start with the standard setting usual ly 2 0 3 5 bar respectively 30 50 PSI Reduce the pressure according to your requirements if you wish It is wise to measure the current used by your pump with an amp me ter in series with the line your system metering Current draw will rise in direct proportion to outlet pressure CAUTION Pressure should NOT be set A beyond 4 5 bar 50 PSI maximum or loss of efficiency and motor over heating will result CAUTION After any change to your cut in pressure you need to readjust the pressure tank precharge If you are raising water vertically AND pressurizing Exam ple A pump that lifts 3 m 10 vertical feet and pressurizes to 2 1 bar 30 PSI must pump a total of 2 4 bar 35 PSI Total lift vertical distance from water surface to pres sur
25. he charger works effectively during reduced sunlight condi tions when direct pump operation is not possible The en ergy stored in the battery is available to operate the pump at any time day or night and during periods of bad weath er Extended bad weather periods with water demands of up to 10m per day will be reliably bridged due to the high system efficiency even with low capacity batteries The pump is manufactured from non corrosive material stainless steel brass aluminum Table 1 Technical Data of Controller 4 Placement 4 1 Location A Controller Location Place the controller close to the so lar array not the pump This will reduce the risk of lightning damage If it is outdoors mount the controller in a vertical position to assure that rain will not enter the box WARNING PS150 Boost pumps must NOT be submerged in water or rained or dripped on Protection from heat Electronic devices are most reliable when they are protected from heat Mount the controller in the shade of the mid day sun An ideal location is directly under the solar array or in a nearby shaded location An al ternative is to fold a piece of sheet metal so that it mounts behind the controller and curves over it to provide shade This provides protection in extremely hot climates Battery system Place the controller near the batteries but safely isolated from the battery terminals and from corro sive gases Batteries must be in a cool loc
26. iod ic measurement of the pump s performance A worn pump end can be replaced in the field WARNING If there is danger of freezing the pump must be drained ahead of time Also drain all pipes subject to freezing BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice Sun Water m Life LO8OLLA LORENTZ 10 System Wiring 10 1 12VDC Battery System Remote MAX Do not connect Float Switch this terminal 12V system Voltage from panels will read 22 25 V when disconnected open circuit Connect the pump controller directly to battery bank Remote Tank Float Switch Connect float switch to ter minals 4 5 of the pump controller when it breaks contact on rise to turn the pump OFF Otherwise use terminals 3 4 for opposite function Grounding Connect either battery minus or solar minus to ground never connect both to ground low water sensor Solar Tracking Use stranded wire for flexibility Secure the wires to tracker with plenty of tape Leave a good slack loop to allow free motion of tracker 1 battery 12V 1 PV module 12V 10 2 24V DC Battery System LOBOLLA 24V system Wiring scheme shows serial wiring for a sys tem of 24V nominal Voltage from panels should read 45V when disc
27. ion The cable ends are labelled 1 2 3 Con nect them in this sequence with the pump controller to have the correct direction of turning clockwise Check from the fan of the motor Looking on the fan of the mo tor the direction is counter clock wise see also the arrow Changing the polarity of the DC plus and minus input of the controller will not change the direction of turning Only changing two of the three motor phases will do WARNING TEST THE VOLTAGE before A connecting power to the controller Voltage open circuit must not exceed 50V DC Even in cloudy weather the open circuit voltage will be near maximum Some thin film PV modules may produce excessive voltage specially when they are new If the open circuit voltage exceeds 50 V DO NOT connect power to the controller Contact your supplier WARNING Do not apply a direct connection or an amp meter between and when the controller is connected A short circuit here will cause a strong discharge A WARNING SOLAR DIRECT systems only Do not connect any electrical load to the solar array if it is not part of the LORENTZ pump system Connection of a battery charger active solar tracker controller electric fence charger or other load simultaneously with LORENTZ PS systems may confuse the controller and prevent proper operation gt WARNING A cord and plug connected unit shall be provided with a permanent ly attached flexible cord
28. lation and start up by the person in charge of the installation as well as by all other technical personnel op erators and should be available at the installa tion site at all times Personnel Qualification 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 supervi sion of such personnel must be strictly regulated by the user Should the available personnel be lacking the necessary qualification they must be trained and in structed accordingly If necessary the operator may re quire the manufacturer supplier to provide such train ing Furthermore the operator user must make sure hat the personnel fully understands the contents of he manual Dangers of Ignoring the Safety Symbols Ignor ing the safety directions and symbols may pose a dan ger to humans as well as to the environment and the machine itself Non observance may void any warran ies Non observance of safety directions and symbols may for example entail the following Failure of im portant functions of the machine plant failure of pre scribed methods for maintenance and repair endan germent of persons through electrical mechanical and chemical effects danger to the environment because of leakage of hazardous material danger of damage to equipment and buildings Safety oriented Operation The safety directions contained in th
29. ll jerk slightly but simply mounting it to a small wooden board is sufficient to stabilize it The pump may be hung vertically on a rope Observe the pump and see that it is not likely to overstress or loosen pipes as it starts A Changing the pump head position If you wish to face the pump s fittings sideways or downwards please do You may rotate pump head to a different position by loosen ing the clamp screw that secure the pump to the motor BE FORE installing the pump drop a teaspoon of water into the inlet and run the pump WARNING If vertically FACE THE PUMP HEAD DOWNWARD CAUTION Do not mount the pump directly to a wall or wood floor in your home It will increase the noise It may be installed either max 3 m below gravity feed or above suction mode of the water level Thereby the geo detic head between liquid level and pump inlet must not exceed 3 m The suction lift may be significantly reduced by flow resistance in the suction line if the pipes are very long and or insufficiently dimensioned system PS150 Boost 60 125 240 330 max power input Vmp VDC gt 34 motor power w 250 open circuit voltage Voc VDC 50 input voltage battery VDC 12 24 battery low voltage disconnect VDC 11 22 battery restart voltage VDC 12 24 controller IP54 weatherproof NEMA type 3R enclosure type motor IPX4 weatherproof NEMA type 3 storage C 30 to 5
30. ms AWG 10 wire to maximum distance of 50 ft Metric 4mm to max 15m Battery systems AWG 10 wire to maximum distance of 65 ft Metric 6 mm to max 20m GREATER LENGTHS For each increase by 50 use next larger wire size Sun Water Life lt LORENTZ 6 Operating the Pump WARNING NEVER LET THE PUMP RUN A DRY NOT EVEN FOR THE PURPOSE OF CHECKING THE DIRECTION OF ROTATION Water is the lubricant for your pump If it runs completely dry it will overheat and fail As an option you can install a well probe to terminals 1 2 to shut the pump off if water source is low WARNING Make sure pump turns A freely especially after extended periods of down time Make sure the mechanical seal does not leak This explains the function of the switch and the indicator lights on board of the pump controller See figure 2 SWITCH POWER ON OFF When switched off on during operation it resets all sys tem logic INDICATOR LIGHTS SYSTEM green The controller is switched on and the power source is present In low power conditions the light may show even if there is not enough power to run the pump PUMP ON green Motor is turning Sequence of flashing indicates pump speed See below sequence OVERLOAD red WELL DRY red The water source dropped below the level of the low water probe After the water level recovers the pump will restart but this light will slowly flash until the sun g
31. oes down power is interrupted or the POWER switch is reset This in dicates that the water source ran low at least once since the previous off on cycle TANK FULL red Pump is turned off by action of the remote float switch or pressure switch or manual switch whichever is wired to the remote float switch terminals Figure 2 Monitoring SI Do not connect this terminal 21s BATTERY LOW tank light flashes Battery systems only battery voltage fell to 11V DC 12V DC systems or 22V DC 24V DC systems and has not yet recovered to 12VDC 12V DC systems or 24VDC 24V DC systems RPM indication Pump speed can be read off by the flashing sequence of the Pump ON LED Indication RPM LED ON gt 300 one flash gt 500 two flashes gt 750 hree flashes gt 1 000 our flashes gt 1 250 ive flashes gt 1 500 Starting the pump 1 Be sure there is not a closed valve or other obstruc tion in the water line 2 Fill the pump with clean water until the water lev el reaches the inlet connection Coat the O ring seal with vaseline close the lid by hand and make sure that it is well in the housing groove Otherwise the pump will prime insufficiently or not at all 3 Switch on the array disconnect switch and toggle the power switch on the controller It is normal to leave the switches on at all times unless you desire to have the system off A solar direct pump should sta
32. of a water re sistant type Type SEW SEOW SJW SJOW SJEW SJEOW SJTW SJTOW SOW STW or STOW When the pump is connected by cable at field use extra hard type cable for connections Sun Water Life LOBOLLA 5 6 Electrical Installation Terminals See figure 1 Power IN For PV direct systems a two pole disconnect switch may be installed between the solar array and the controller Switch it off to prevent shock and arc burn haz ard during installation and maintenance or if the system will be shut down for the season For battery systems Con nect the controller directly to the plus and minus terminals of the battery Do not connect to the load terminals of the charger as they may be not strong enough to provide the starting current A 30A slow blow fuse must be installed between the controller and the battery a Ground Connect the ground wire to the ground connec tion in the controller Grounding helps to prevent shock hazard if there is a fault in the motor 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 wires No disconnect switches must be installed A in power wires between motor pump controller Connecting the motor wire to the switched on controller might irreparably damage it Such damages are excluded from the warranty
33. onment position is a long distance away 4 If it must run a long distance use twisted pair shield pump off ed cable to reduce the chance of damage from light Float switch requirements ning induced surge pumping 1 A switch must be used not wet electrodes Grounding shielded float switch cable If you use H onga 2 The preferred system requires a float switch to MAKE shielded cable connect the shield to ground AT THE CON r contact on rise to turn the pump OFF This is called TROLLER ONLY DO NOT ground the shield at the float normally open N O It may be commercially la switch This will reduce surges induced by nearby lightning beled as a pump down switch but here it works in reverse to allow pumping up Wiring to the controller The controller offers two op tions for connection of a remote switch These allow the use of either a normally open N O or a normally closed N C switch Normal refers to the status of the contacts when the switch is DOWN and calling for water a float switch Se mee OT C to bypass TA TI oOo e e e e e e e e e e e e e e e e e e e eee N I Ol Ill N KN NO oO toa P ist ed A Switch NC on For factory e2 l Oje Z e rr ee 1 aed UP closed n f cable is shielded DOWN apeh ground this end only hornal et Wiring a normally closed reverse action switch Connect the switch to termins 4 and 5 Closing connect ing
34. onnected open circuit Remote Tank Float Switch Connect float switch to ter minals 4 5 of the pump controller when it breaks contact on rise to turn the pump OFF Otherwise use terminals 3 4 for opposite function Grounding Connect either battery minus or solar minus to ground never connect both to ground Solar Tracking Use stranded wire for flexibility Secure the wires to tracker with plenty of tape Leave a good slack loop to allow free motion of tracker 2 batteries 12V in series Do not connect this terminal Remate Float Switch o Connect E OVERLOAD EF WELL DRY EJ TANK FULL BATTERY LOW IF FLASHES charge controller external 2 PV modules 12V in series BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice low water sensor Sun Water Life LORENTZ 10 3 System Wiring for 12 24V DC Systems in PV direct Operation Solar direct system Voltage from panels will read Remote 22 45 V when disconnected open circuit Use the left ie Do net connect Float Switch this terminal 5 gt power terminals to connect the solar array with the con a ge L a8 eas troller 35 2 2 5 1 2 3 4 5 6 7 The jump
35. ressurizing system This al lows the pump to start easier It also prevents back flow when changing filter cartridges Pipe Unions If you run rigid piping copper or PVC direct ly to the pump unions are required Unions make pump re placement 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 5 3 Installation in Drilled Wells Inside a 6 inch well casing special elbow adapters are re quired The elbows fit 12 polyethylene black flex pipe Measure carefully to determine the length of pipe you need Substract 1 5 to allow for pipe and rope stretch A priming plug is not needed Before lowering the pump place the intake into a bucket of clean water and run the pump until water exits Now it is primed A pitless adapt er may be optimum for freeze protection Check with your local well supplier for details Polyethylene pipe comes in rolls and is inexpensive and quite freeze tolerant Use with plastic adapters and secure with all stainless hose clamps obtain such clamps from a pipe supplier rather than automotive supplier If pipe does not stretch tightly over fittings warm it with a torch or hot water then tighten clamps firmly with a wrench Keep extra clamps handy in case you strip one 5 4 Freeze Protection To prevent freezing of exposed pipes consider the sim ple method of drilling a small weep hole in the outle
36. rt under the following con ditions 1 clear sunshine at an angle of about 20 or more from the surface of the solar array 2 cloudy conditions if the sunshine is bright enough to cast some shadow 3 low water probe submersed in the water source or bypassed in the controller Water low light OFF 4 full tank float switch is not responding to a full tank Tank Full light OFF 5 battery system only voltage is higher than the low voltage disconnect point of 11 VDC 12V DC sys tems or 22V DC 24V DC systems When sunshine is insufficient When sunshine on the array is present but too weak for the pump to run it will attempt to start about every 120 seconds During each at tempt you will see the PUMP ON light come on When pump runs slowly PUMP ON under weak sun con ditions the pump may spin without lifting water all the way to the outlet This is normal When pump stops from a sudden shadow on the solar array If a shadow suddenly passes over the array like if you walk in front if it the controller will lose track of the input voltage This does NOT indicate a problem The pump will attempt to restart after the normal delay Time delays 1 After pump stops due to insufficient sunshine 120 seconds 2 After full tank float switch resets 2 to 3 seconds 3 After low water probe regains contact with water in the source 20 minutes but the indicator light will slowly flash for the rest of the sol
37. t pipe below ground level The pipe will drain when pump ing stops but a small amount of water will be wasted dur ing pumping Set the outlet pipe to spill into the top of the tank so that the tank will not drain or install a check valve and vacuum breaker to allow pipe to drain Water will drain back through the pump if allowed to but it will do so slowly If this is desired do not use any check valves or foot valve Pump must have suction draw of no more than about 3 m 10 ft however If pump drainage is re quired position pump vertically head downward or hori zontally with intake and outlet facing downward freezes but a hard freeze may damage it WARNING If you insulate your pump for freeze protection keep the motor exposed so it won t overheat WARNING Take every precaution to prevent pump freezing The forged brass pump head will survive most light BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice LORENTZ 5 5 Controller Input Wiring WARNING Do not touch the controller input or motor wires together to test for a spark Connect the battery 12V DC or 24V DC directly with the and terminal of the controller Do not use the load terminals of the charge controller as they may be not strong enough to allow the start current to flow Motor direct
38. uires at least 125W output of the PV array This can be caused by a high concentra tion of solids in the pump The controller will make 3 start attempts before shutting down the system The System ON LED will be OFF and the red OVERLOAD LED ON The sys tem will not reset until the ON OFF switch is turned OFF and ON again Inspect the solar array 1 Is it facing the sun 2 Is there a partial shadow on the array If only 10 of the array is shadowed it can stop the pump Inspect all wires and connections 1 Look carefully for improper wiring especially in a new installation 2 Make a visual inspection of the condition of the wires and connections Wires are often chewed by animals if they are not enclosed in conduit pipe 3 Pull wires with your hands to check for failed con nections Inspect the controller 1 Remove the screws from the bottom plate of the controller Move the plate downward or the control ler upward to reveal the terminal block where the wires connect 2 First check for a burnt smell This will indicate a fail ure of the electronics Look for burnt wires bits of black debris and any other signs of lightning dam age 3 Inspect the grounding wires and connections Most controller failures are caused by an induced surge from nearby lightning where the system is NOT effec tively grounded Ground connections must be proper ly made and free of corrosion Check the low water probe system If
39. ype of batteries Quantity wired 13 System Report PS150 Boost 60 PS150 Boost 125 PS150 Boost 240 PS150 Boost 330 VDC VDC serial parallel yes no VDC Ah serial parallel LORENTZ Installation Installation date Installer full contact details Head Suction Suction head Max suction head drawdown Positive suction head Max positive suction head drawdown Suction pipe Size Type Length Drop pipe Size Type Length Pump cable Wire size Length Controller to pump Max RPM control Factory setting is max If this setting was reduced enter setting here BERNT LORENTZ GmbH amp Co KG Kroegerskoppel 7 24558 Henstedt Ulzburg Germany Tel 49 0 4193 7548 0 Fax 29 www lorentz de Errors excepted and possible alterations without prior notice mm in m ft mm AWG m ft Sun Water Life
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