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SubDrive Solar Manual - Solar Pumping Systems

1. Flow Switch Pressure Rating vs Water Temperature Maximum Water Temperature C Gauge Pressure bar Gauge Pressure psi 20 18 261 25 15 75 228 30 13 5 196 35 11 25 163 40 9 131 45 6 75 98 50 4 5 65 55 2 25 33 60 0 0 Table 1 Flow Switch Pressure NOTE Pressure at the flow switch can be reduced by eliminating plumbing restrictions including reductions in pipe diameter downstream of the flow switch On the F21 paddle style flow switch the paddle must be trimmed to allow it to fit into the plumbing The paddle should be trimmed so that it is as long as possible but not closer than 4 mm 160 to the pipe walls when installed A longer paddle length will increase flow switch sensitivity and therefore water delivery at low power conditions Additional installation instructions including mounting orientation paddle trimming other plumbing requirements etc are included with the flow switch Follow the installation instructions included with the packaging of the flow switch for installation and maintenance information Flow Switch Operation At start up the flow switch naturally detects no flow If the flow switch detects flow before the controller starts the motor then the flow switch wiring is faulty or the paddle is stuck and the controller stops displaying an E4 error The state of the switch must show no flow in order for the drive to attempt to start After the controller starts the motor it expects the
2. NOTE All dimensions are approximate Table 9 SubDrive Mounting Hole Dimensions Diameter RS 485 Communication Addendum Solar Panels Wired in Series When solar panels are wired in series the positive terminal of one solar panel is wired to the negative terminal of the next solar panel When panels are connected in series 1 Make sure the unit is disconnected from the power 2 Connect the wires from the communication device to the Terminal Block on the COMM board labeled RS 485 to terminals B A and GND Figure 1 Torque specification 15 in Ibs 1 7 N m Figure 14 RS 485 Wiring Connections 35 36 System Information Registers The following registers are used for reading or setting the SD XXXX for system information This includes information needed to uniquely identify the drive Modbus address and the RTC H Register Description Data Range R W Factory R W Public 000 Device type SD 0x5344 R R 001 Serial Number 1 XXXXX R R A January B February C March D April E May 002 Month Manufactured i S aune R R G July H August J September K October L November M December XXXX 003 Year Manufactured 2010 R R Communications software version ane Version 2 1 0x0201 1290 E R Drive software version oP Version 2 1 0x0201 la j R 006 Drive part number ASCII R R Modbus address 1 127 007 unit also
3. Table 5 Wire Sizing Charts Maximum cable length from the drive to the motor is 1000 ft 305 m External filtering is required for motor cable lengths exceeding this maximum distance or nuisance tripping might occur 25 26 Motor Lead Installation NOTE The included motor in the SubDrive SolarPAK does come with a factory installed individual conductor lead To replace or install a new lead please follow these steps 1 Remove the plastic bag from the lead connector and spread the lubricant evenly around the lead prong 2 Align the orientation key on the lead connector with the slot in the motor end bell and press the lead connector firmly into the socket 3 Start the jam nut into the connector threads ensuring that the threads are properly engaged 4 Using a 19 mm 3 4 open ended wrench tighten the jam nut until it is snug Recommended torque 20 27 N m 15 20 Ib ft DO NOT OVER TORQUE Fault Codes and Troubleshooting The SubDrive Solar controller will attempt to operate the pump to deliver water even under adverse conditions To ensure years of reliable service it must also protect the system components from conditions that might result in equipment damage When adverse conditions arise the controller will continue to deliver as much water as possible at a reduced output if necessary and will shut down only in extreme cases Full operation will resume automatically whenever abnormal conditions subside Error con
4. Alternate AC Power Optional 2 Level Control Switch Operation Pump Check Valve Requirements NOTICE In order to ensure maximum system reliability and water delivery check valves must be installed in the drop pipe The first check valve must be installed at the pump the 18 70 LPM 5 25 USGPM pumps have a built in check valve in the pump discharge and additional check valves should be installed every 30m 100 ft of vertical pipe after the pump See the pump owner s manual for additional information Features System Diagnostics The SubDrive Solar controller continuously monitors system performance and can detect a variety of abnormal conditions In many cases the controller will compensate as needed to maintain continuous system operation however if there is high risk of equipment damage the controller will protect the system and display the fault condition If possible the controller will try to restart itself when the fault condition subsides See Troubleshooting section for a list of Fault Codes and corrective actions Motor Soft Start Normally when there is a demand for water and power is available the SubDrive Solar will be operating Whenever the SubDrive Solar detects a need for water the controller always ramps up the motor speed through a gradual increase of motor voltage resulting in a cooler motor and lower start up current compared to conventional water systems In cases where the demand for water is low
5. 6 mm or M6 mounting screws not included The top mounting holes are slotted in order to hang the drive in place while the bottom fasteners are inserted to secure the unit from ever sliding up 3 If the mounting surface is narrower than the outer mounting slots use the top center and bottom center mounting holes and secure using 3 8 8 mm or M8 mounting screws not included Wiring Connections A WARNING Serious or fatal electrical shock may result from failure to connect the ground terminal to the motor the SubDrive Solar controller metal plumbing and all other metal near the motor or cable to a proper earth ground in accordance with local codes using wire no smaller than motor cable wires To minimize risk of electrical shock disconnect power before working on or around the SubDrive Solar system Do not use motor in swimming areas CAPACITORS INSIDE THE SUBDRIVE SOLAR CONTROLLER CAN STILL HOLD LETHAL VOLTAGE EVEN AFTER POWER HAS BEEN DISCONNECTED ALLOW FIVE MINUTES FOR DANGEROUS INTERNAL VOLTAGE TO DISCHARGE BEFORE REMOVING SUBDRIVE SOLAR COVER The SubDrive Solar controller is not protected against a bolted short to ground at the motor cable terminals Ensure that the motor leads have been checked for a possible short to ground BEFORE operating the drive 1 Verify that the power has been shut off 2 Remove the SubDrive Solar lid 3 Remove the bottom gland plate from the SubDrive Solar enclosure and drill or p
6. at mpp 95 330 V DC 190 330 V DC 190 330 V DC Max Amps Input 8 7 A DC continuous 7 A DC continuous 12 A DC continuous Power at mpp Up to 1400 watts Up to 2000 watts 2000 3500 watts Alternate AC Generator Input voltage 230 V AG single phase 230 V AG single phase 230 V AG single phase Max Amps RMS 9 7 A DC continuous 16A 25A Power and VA capability Follow Instruction Manual for proper Generator Sizing Data Follow Instruction Manual for proper Generator Sizing Data Follow Instruction Manual for proper Generator Sizing Data Controller Size Centimeters 53 34 X 25 87 X 21 87 cm LXWXD 53 34 X 25 87 X 21 87 cm LXWXD 53 34 X 25 87 X 26 31 cm Inches 21 00 X 10 19 X 8 61 21 00 X 10 19 X 8 61 21 00 X 10 19 X 10 36 Operating Conditions Temperature Range 25 C to 50 C 40 C max when using AC generator 13 F to 122 F 104 F max when using AC generator 25 C to 50 C 40 C max when using AC generator 13 F to 122 F 104 F max when using AC generator 25 C to 50 C 40 C max when using AC generator 13 F to 122 F 104 F max when using AC generator Relative Humidity Range 0 to 100 Condensing 0 to 100 Condensing 0 to 100 Condensing The 0 55 kW drive will attempt to start the pump motor with input voltage as low as 95 V and attempt
7. Solar Controller has AC wiring connections for use with a generator when Solar DC power is not available 1 Make sure the generator is powered off 2 Make sure the external DC disconnect switch is off 3 Connect the cables from the generator to the Terminal Block labeled Back up AC and marked L1 L2 and GND Figure 6 Torque specification 15 in Ibs 1 7 N m Figure 6 AC Wiring Connection ry till Flow Switch Wiring Connections The SubDrive Solar Controller makes use of a flow switch to protect the controller and motor when there is not enough power to generate proper flow The flow switch and sensor cable is included with the SubDrive Solar QuickPAK and is required on all installations 1 Connect the cables from the Flow Switch terminals NO and COM and to the SubDrive Solar terminal block labeled TRIP Figure 7 Figure 7 Flow Switch Wiring Connection CAUTION Failure to properly install the included flow switch will result in reduced system performance and may result in system damage 17 18 Flow Switch Plumbing Installation A WARNING Hazardous Pressure Present Pressure at the flow switch must be limited according to the water temperature that the flow switch will see in service Note that this includes the temperature that the water could reach due to heating by the surrounding environment Pressure at the flow switch must be limited according to the following table
8. flow switch to detect flow within an interval that depends on power being delivered If the flow switch detects flow within that interval then the controller operates normally If the flow switch does not detect flow the controller enters a deadhead mode displaying E4 and alternately runs the motor and pump then allows them to cool The time intervals during deadhead mode depend on the power being provided by the controller For power less than 1200 Watts the overall repeat time interval is approximately 11 minutes For power greater than 1200 Watts the repeat time interval is approximately 14 minutes The run time and cool down portions within each repeat time interval are controlled to limit the total energy supplied to the motor pump within each interval and are thus dependent on the controller output power Pump Motor Wiring Connections 1 Connect the cables from the Pump Motor Assembly to the Terminal Block labeled MOTOR and marked BLK RED YEL and GND Figure 8 Torque specification 15 in Ibs 1 7 N m 2 Motors with international leads use Table 2 for motor lead color information to ensure correct installation US Black BLK Red RED Yellow YEL Ground GND International Gray GRY Black BLK Brown BRN Ground GND Table 2 US and International Wire Color Chart Figure 8 Motor Wiring Connection e vella BLK RED YEL GRY BLK aO CAUTION For retrofit application make sure
9. for a few seconds and then restart This is normal operation and is used to look at the system open circuit voltage to derive a max power point While running on AC generator power the drive will shut down approximately every 30 minutes for a few seconds and restart This is normal operation the drive is just attempting to find adequate DC power input As soon as DC power becomes available the system will then change over to the array power If DC power is not available or is not adequate the system will continue to run on AC power CAUTION The SubDrive Solar controller s display is protected by a sliding metal shield After reading the display ensure that the shield covers the display Failure to do so could result in damage and will result in yellowing of the view pane and can eventually render the display unreadable NOTE For optimal operation results it is recommended to flush the bore well system until the water being discharged is clear and free of debris This will reduce the chances of the flow switch being clogged by sediment and debris during initial start up 21 22 User Definable Parameters The following explains the menu structure and User Defineable Parameters that are effective on SubDrive Solar controllers with software versions 1 4 4 COMM Board 2 11 and 2 12 main controller and later versions Pressing the Menu button from the normal operating display enters the User Defineable Parameters menu Pressi
10. intensity than voltage Once the current demand exceeds or nears the current available the voltage drops quickly along the flat portion of the amp Volt IV curve see example array curves on the following page This drop in voltage then causes an E2 fault condition and will stop the motor After approximately one minute the drive will power up again to check if illumination is sufficient enough to run the motor This cycling of E2 fault conditions is normal during the morning and evening hours and other times of non peak illumination Measuring the open circuit voltage alone is not always a good indication of the suitability of sufficient solar power since the voltage will change when the motor begins to run The SubDrive Solar controller will operate the motor in the widest possible range of power from the PV array Example Solar PV Array Curves Displaying Diminishing Solar Light Intensity Current Voltage and Power Voltage curves for a PV array containing six generic 180 Watt PV panels in series Each panel having the following values at standard test conditions STC of 1000 W m 25 deg C panel temp Isc 5 0 A Voc 50 Vdc Imp 4 6 A Vmp 40 Vdc Curves calculated for five different light levels 200 to 1000 W m in 200 W m steps at constant 25 deg C panel temperature Current Voltage curves for PV array Output current amps 0 100 200 300 Output voltage volts Power Voltage curves for PV array Output powe
11. responds to address 222 57 Default 1 j RW RTC absolute time in seconds since Jan 1 1970 008 UINT_32 lower order 2 bytes 0 OxFFFFFFFF R W R W Time is lost when power removed RTC absolute time in seconds since Jan 1 1970 009 UINT 32 lower order 2 bytes Time is lost when power removed 010 Drive part number 1st character ASCII 021 Drive part number 12th character ASCII Current Status Registers The following registers are used for the SD XXXX for current operational status H Register Description Data Range R W Factory R W Public 100 Buss Power Daily uint 16 0 9999 kwh 101 Buss Power Cumulative uint 32 lower word 0 999 999 kwh 102 Buss Power Cumulative uint 32 upper word 103 Buss Power instantaneous uint 16 0 9999 watts 0 Standby 104 Drive State uint 16 1 Running 2 Error 0 None 1 Underload 2 Under voltage Error State uint 16 3 Locked rotor 105 4 Miswired DTR update with new error 5 Open phase 6 Short phase 7 Over temp 8 Internal error 106 Motor speed uint 16 0 9999 Hz 107 Buss Voltage uint 16 0 999 Vdc 108 Smart Reset Rule Time Method uint 16 e Dynamic 1 Fixed 109 FIXED_RULE_TIME uint 16 est Increments of 5 110 UNDERLOAD TRIP LEVEL uint 16 30 100 111 Demand input mode v g Dual input 1 Single input 112 Current uint 16 0 99 9 amps 113 Run time uint 32 lower word Minutes 114 Run time uint 32 u
12. to check integrity of power and motor leads This requires measuring the insulation resistance with the suitable megohmmeter Reference the Franklin Electric AIM for correct measures See Table 4 Motor Specifications pg 25 Control Switch Wiring Connections Optional The SubDrive Solar Controller can be operated with control switches to control the ON OFF pumping range Use a normally closed low voltage control switch with a contact rating suitable for instrumentation use i e Max 24 V 15mA 1 Connect the cables from the STOP control switch to the Terminal Block labeled STOP 2 Connect the cables from the RUN control switch to the Terminal Block labeled RUN Figure 9 19 20 Figure 9 Control Switch Wiring Connection 2 Control Switch Operation The SubDrive Solar is designed to utilize up to two control switches for operation When both switches are installed the controller starts to pump and waits to shut off until both switches read OPEN Once it shuts off the controller then waits to run again until both switches read CLOSED An example application Figure 10 is to use separate level switches to indicate high and low water levels Two pressure switches one with a high pressure cut out in the STOP input terminal and a second low pressure cut in switch in the RUN input terminal can also be used to manage the system in applications that do not have an open discharge P
13. to continue to run the pump motor as low as 75 V input voltage However 75 Vdc should not be interpreted as an adequate rated PV array output voltage for any installation The recommended Vmpp minimum for the system s solar PV array is 110 Vmpp Maximum open circuit voltage input to the controller is 410 Voc See the PV Solar Array Specifications and System Sizing program for indication of adequate array voltage to provide useful pumping capability The 1 1 and 2 2 kW Drive will attempt to start the pump motor at 190 V DC and attempt to continue operation down to 150 V DC The recommended Vmpp minimum for the system s solar PV array is 225 Vmpp Maximum open circuit voltage input to the controller is 410 Voc Table 7 SubDrive Solar Drive Specifications 29 Electrical Diagram Input Power Solar Primary DC TN a Bridge ee Backup AC Rectifier TN L2 e ee g o TN lt e N a1 D1 Contactor 1 C1 Q2 D2 Contactor 2 PV Solar Array Specifications Absolute maximum array voltages Vmpp 330 Vdc Voc 410 Vdc maximum operating voltage at max power point of PV source maximum open circuit voltage Minimum array voltage at minimum array peak power provides max of 25 of rated system pumping power at STC System size Minimum PV array voltage Minimum PV array power 0 55 kW 95 Vdc 250 Wp 1 1kW 190 Vdc 500 Wp 2 2 kW 190 Vdc 875 Wp Array voltage and power fo
14. use interface is provided to enhance configurability and enable remote system monitoring e A three digit seven segment display provides a detailed indication of system status e A small keypad offers flexibility for selection of user options e A continuous data connection for remote telemetry is made available via an RS 485 port e If using remote telemetry follow the register information found in the RS 485 addendum Protection Features Electronic monitoring gives the controller the capability to monitor the system and automatically shut down in the event of e Dry well conditions with smart pump monitoring e Bound pump with auto reversing torque High Voltage Surge Low Input Voltage e Open motor circuit Short circuit e Over heat e Dead head no flow conditions NOTE This drive provides motor overload protection by preventing motor current from exceeding SFA and by limiting the duty cycle in the event of no water flow This drive does not provide over temperature sensing of the motor How it Works The SubDrive Solar system serves to provide water in remote applications where electrical grid power is either unreliable or unavailable The system pumps water using a high voltage DC power source such as an array of solar panels Since the sun is only available during certain hours of the day and only in good weather conditions the water is generally pumped into a storage tank Two level switches can be installed inside the
15. HE INABILITY TO USE THE PRODUCT AND THE BUYER AGREES THAT NO OTHER REMEDY SHALL BE AVAILABLE TO IT THE WARRANTY AND REMEDY DESCRIBED IN THIS LIMITED WARRANTY IS AN EXCLUSIVE WARRANTY AND REMEDY AND IS IN LIEU OF ANY OTHER WARRANTY OR REMEDY EXPRESS OR IMPLIED WHICH OTHER WARRANTIES AND REMEDIES ARE HEREBY EXPRESSLY EXCLUDED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT EITHER APPLIES TO A PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIODS OF THE EXPRESSED WARRANTIES GIVEN ABOVE RON DISCLAIMER Any oral statements about the product made by the seller the Company the representatives or any other parties do not constitute warranties shall not be relied upon by the buyer and are not part of the contract for sale Seller s and the Company s only obligation and buyer s only remedy shall be the replacement and or repair by the Company of the product as described above Before using the user shall determine the suitability of the product for his intended use and user assumes all risk and liability whatsoever in connection therewith Some states and countries do not allow the exclusion or limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above exclusion or limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from stat
16. SubDrive Solar Installation Manual SubbriveSolar Franklin Electric SUBDRIVE SOLAR INSTALLATION MANUAL TABLE OF CONTENTS OVErvIeWi s ze kesilir sel met mesken endte 5 Descriptions and Features sionerien acii a D eya an alyan Ga mn menne 5 HON ENGS 6 Rea tes ae Ild dedikere 8 Install tiony u jus sassanidene 12 ControllerlocationsSelection aiid aaa 13 Mo unting Procedure Lura tease a sa lasa a ki 14 Wiring Connections mnrrnnrnrrvvvennnrnnnrvnnnnrnnrrennnrtnnrnnnnttnnnrenntttnnrnennttnnnnnnnnttnnnnnnntetnnnnnnneennnnnnnetennnnnnneennnnnnnnn 14 Gland Plate TerminallocationTemplate A memememem e gt Z gt Z Z Z Z n II gt gt annen nennnnrnnnnnnnnenn 15 DG Wiring Connections siiri cia eldir ie cdi ae ee hee 16 AC WiringConnections Optional eee 17 Fow5SwitchWiringConnections aa 17 Flow Switch InstallatitonandOperation A A m m gt e gt e gt e gt z gt Z gt Z gt Z I anna nnnnnnrnnennnnnnnnrresnnnnnnennn 18 Pump Motor WiringConnections a 19 Run Control Switch WiringConnections Optional 19 ControlSwitchOperation aaa 20 Start Up and Operation sx vss seed da lama amda madan akan rada akman ellisini ene wetness 21 User Defin ble Parameters aein Mie aplik ekenler al
17. TION When using an alternate AC power source the ambient temperature is limited to 104 F 40 C for full power delivery 1 The unit should be mounted on a sturdy supporting structure such as a wall or supporting post Please take into account the weight of the unit 2 The electronics inside the SubDrive Solar are air cooled As a result there should be at least 45 7 cm 18 inches both above and below to allow for air flow and proper cooling If the SubDrive Solar is mounted under the PV solar array make sure that it is at least 45 7 cm 18 inches beneath the array 3 The SubDrive Solar should be mounted with the wiring end oriented downward The controller should not be placed in direct sunlight Placing the controller in direct sunlight or high ambient temperatures could result in reduced performance due to temperature foldback protection For optimum performance maximize the shading of the controller Additional Considerations for NEMA 3 IP55 Enclosures To ensure maximum weather protection the unit must be mounted vertically with the cover properly aligned and secured with all lid screws Strain relief fittings or IP55 rated liquid tight conduit fittings should be used to bring the wires inside the enclosure Minimum 18 in 45 7 cm Heat Sink Minimum 18 in 45 7 cm Figure 4 Controller Location 13 Mounting Procedure 1 Disconnect all electrical power supply 2 Install the unit to a secure post using 1 4
18. TRIC A WARNING SERIOUS OR FATAL ELECTRICAL SHOCK MAY RESULT FROM FAILURE TO CONNECT THE MOTOR CONTROL ENCLOSURES METAL PLUMBING AND ALL OTHER METAL NEAR THE MOTOR OR CABLE TO A PROPER EARTH GROUND IN ACCORDANCE WITH LOCAL CODES USING WIRE NO SMALLER THAN MOTOR CABLE WIRES TO REDUCE RISK OF ELECTRICAL SHOCK DISCONNECT POWER BEFORE WORKING ON OR AROUND THE WATER SYSTEM DO NOT USE MOTOR IN SWIMMING AREAS A CAUTION Use the SubDrive Solar controller only with Franklin Electric 4 inch submersible motors as specified in this manual see Table 6 pg 28 Use of this unit with any other Franklin Electric motor or with motors from other manufacturers may result in damage to both motor and electronics A WARNING High voltages both AC and DC capable of causing severe injury or death by electrical shock are present in this unit More than one disconnect switch may be required to de energize the equipment before servicing This unit should only be installed or serviced by technically qualified professionals Anytime working on or near the SubDrive Solar controller or system e Securely cover the solar array with an opaque tarp e Turn OFF the external DC rated disconnect from the solar array to the SubDrive Solar controller e Ensure AC power has been disconnected from the SubDrive Solar controller if used e Wait a minimum of 5 minutes after removing power from the SubDrive Solar controller before servicing A WARNING Solar pane
19. a DC rated disconnect box be used to disconnect the incoming DC power from the SubDrive Solar controller during installation and maintenance Use a Volt Meter to confirm the absence of voltage in the line before proceeding with installation or maintenance e The DC disconnect should be sized to be capable of adequately disconnecting the output open circuit voltage Voc and short circuit current Isc of the solar array Keep all flammable materials away from the assembly site including dry brush and vegetation For optimal performance avoid placing the PV solar array around any objects that can cast shadows or reduce sunlight to the array Install the SubDrive Solar controller out of direct sunlight to prevent overheating and reduced performance The optimum location is on the mounting pole for the PV Solar Array underneath the array for protection from the sun heat and weather elements e Keep the surrounding area clear of vegetation e Do not block airflow around the SubDrive Solar controller heat sink Limit access of animals to the system e Protect wires from damage from wildlife and weathering by using conduit For additional protection bury the conduit in the ground Controller Location Selection The SubDrive Solar controller is intended for operation in ambient temperatures up to 122 F 50 C The following recommendations will help in the selection of the proper location for the SubDrive Solar controller Figure 4 CAU
20. arameter 1 should be changed to 2 in the menu controls SEE USER DEFINABLE PARAMETERS in operation section of manual for instructions 1 Control Switch Operation Alternatively the SubDrive Solar controller may be configured to control water level by using a single input switch Once properly configured for a single active input with a control switch installed the controller starts to pump and waits to shut off until the active switch reads OPEN Once it shuts off the controller then waits to run again until the switch reads CLOSED An example application Figure 10 would be to use a single contact level switch that keeps the storage tank as full as possible without overflowing A single pump control pressure switch can be used to control the pressure range between an adjustable range i e 30 50 psi pressure switch For single level switch control use only the RUN terminal connections Parameter 1 should be changed to 1 in the menu controls SEE USER DEFINABLE PARAMETERS in operation section of manual for instructions 0 Control Switch Operation Lastly the SubDrive Solar controller may be configured to not use a control switch The SubDrive Solar controller is default to parameter 1 setting of 0 control switch inputs In this configuration the SubDrive Solar will always try to run the motor and pump water as long as there is sufficient power from the solar array or alternate AC power source Control Switch St
21. at no damage has occurred during transit Descriptions and Features The SubDrive Solar system controller is based on a standard SubDrive platform controlling a Franklin Electric 4 inch three phase motor driving a 4 inch submersible centrifugal pump powered by a DC solar array or an optional AC generator back up The SubDrive Solar controller continuously monitors system performance and incorporates a number of features for pump system protection In the event of a fault the SubDrive Solar will indicate the type of fault through the three seven segment displays The SubDrive Solar system is optimized for pumping under adverse input power conditions unique to solar arrays e Internal diagnostics will tolerate a lower input voltage e Whenever possible the controller attempts to regulate the pump load in a manner that optimizes for maximum power transfer from the solar array e The drive automatically switches to AC back up power when available if the DC primary source is unable to support pump operation The controller construction is ruggedized for hostile environmental conditions e The case is constructed of heavy gauge zinc plated steel to resist rain animal intrusion and prolonged direct exposure to sunlight e The seals are designed for NEMA 3 IEC rating IP55 dust tight withstands directed jets of water e For maximum protection against dust there is no external cooling fan or other external moving parts An easy to
22. balda Al ab Dad g lde ZA Hi ilki 22 Generator SizingforSubDriveSolar A AMMA e gt mZme gt m m annn nnnn nnmnnn nnn 24 GeneratorSelectioninformation 1 aaa 24 Three PhaseMotorSpecifications A 1 11 nen nnnennennnresnnnnennnne 25 Fault Codes and Troubleshooting arsrrrrrrrnnnnnvnnnrrrnannnvnnnnnrnnnnnnnnnn vanen nnnnnnnnnennnr anna nnnnnnnnnennnnnnnnrretnnnnnnennn 26 SubbriveSolarSpecifications nesen nennrnnrrnennnnnnnnernneennneennenenn 29 SolarArraySpecifications aaa 30 Solar Panel WiringConfigurations A gt m m gt m m 31 SubDrive Solar Dimensions unnarennet sireni Yonga abu asalak adaleli ded 33 SubDrive Solar MountingDimensions nunnu nnne 34 Addendum RegistryValuesforRS485PortConnection 35 IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES AND WITHIN FRANKLIN ELECTRIC RECOMMENDATIONS MAY RESULT IN ELECTRICAL SHOCK OR FIRE HAZARD UNSATISFACTORY PERFORMANCE AND EQUIPMENT FAILURE FRANKLIN INSTALLATION INFORMATION IS AVAILABLE FROM PUMP MANUFACTURERS AND DISTRIBUTORS AND DIRECTLY FROM FRANKLIN ELEC
23. ditions may suspend certain features reduce output or shut down operation of the system for varying amounts of time depending on the nature and severity of the error Problems that merely reduce features or performance generally restore full operation when the trouble condition subsides without stopping the pump or flashing an error code If an error requires stopping the motor a stop delay of at least 30 seconds will accompany the fault The error code is shown on the seven segment display If the drive has stopped to indicate a fault code on the display the associated time out delay will vary depending on the nature of the fault The number following the E symbol corresponds to the error code for the offending condition Undervoltage E2 The SubDrive Solar controller displays an E2 fault when the input voltage is at an unacceptable level However measuring the input voltage may reveal a voltage well within the normal operating range yet the drive still displays the E2 fault This is commonly due to the characteristics of the solar PV array Virtually any illumination solar intensity will result in the array producing full or near full open circuit voltage when under no electrical load However with low illumination when the drive begins to draw power to run the motor the voltage on the array will fall quickly due to a lack of available current from the PV array The current capacity of the PV solar array is affected much more by solar
24. ductance rating of 15 ampere rms current continuous for 1 1 kW e Minimum 0 4mH inductance rating of 10 ampere rms current continuous for 0 55 kW Line reactors are typically available as three phase line reactors Follow the manufacturer s instructions for use in single phase application The reactors can be mounted at the generator using the proper enclosure rating determined to be adequate for the generator Three Phase Motor Specifications MOTOR RATING FULL LOAD MAXIMUM LINE FOLINE kya LOAD RESISTANCE MODEL CODE HP KW VOLTS HZ S F AMPS WATTS AMPS WATTS OHMS 2349029204 0 75 0 55 100 60 1 5 6 9 830 8 6 1185 1 1 1 4 N 2345049203 1 5 1 1 200 60 1 3 5 8 1460 6 8 1890 2 5 3 0 2343062604 3 2 2 200 60 1 15 10 9 2920 12 5 3360 RS 17 Table 4 Motor Specification Data Maximum Motor Cable Length in feet AWG Copper Wire Size 75 C Insulation Drive Model ii 14 12 10 8 6 4 SD Solar 0 55KW N3 0 75 130 220 340 530 830 SD Solar 1 1KW N3 1 5 310 500 790 1000 SD Solar 2 2KW N3 3 0 180 290 470 740 1000 Maximum Motor Cable Length in meters Square Millimeter Copper Wire Size 75 C Insulation Drive Model jr 1 5 2 5 4 6 10 16 SD Solar 0 55KW N3 0 55 20 40 70 110 190 300 SD Solar 1 1KWN3 1 1 70 120 190 290 305 SD Solar 2 2KWN3 2 2 30 60 100 160 260 305
25. e running Over Current terminal or within motor cable b Check pump b debris in pump Cycle input power to reset If problem persists check motor cable and pump E7 Overheated Controller Unit in direct sunlight Shade unit High ambient temperature Clean any debris from heat sink fins on Obstruction of air flow rear of enclosure This fault automatically resets when temperature returns to safe level E9 Internal Error Controller internal processing has Cycle input power encountered an incorrect value Table 6 Fault Code Troubleshooting Cycle input power means disconnecting PV and generator power if used for at least five minutes then re connecting power SubDrive Solar Specifications Absolute maximum input voltages PV DC 410 V open circuit Back up generator 260 VAC rms NOTE Suitable for use on a photovoltaic circuit capable of delivering not more than 50 DC amps short circuit current or on a backup AC generator capable of delivering not more than 5000 amps symmetrical rms current 0 55 kW model 1 1 kW model 2 2 kW model Controller Model No 5870300553 5870301113 5870301223 Output Output voltage max 100 V AC 3 phase 200 V AC 3 phase 200 V AC 3 phase Max Amps RMS 8 6 A each phase 6 8 A each phase 12 5 A each phase Output Frequency 30 60 Hz 30 58 Hz 30 68 Hz Efficiency at Max Power 96 96 96 PV source Input Voltage
26. e to state and country to country Franklin Electric in its sole discretion may update this limited warranty from time to time Any conflicting information relating to warranty procedures whether in a user manual or otherwise is hereby superseded by this document Nonetheless all references to the term or length of a warranty term will remain consistent with the warranty in place at the time of purchase Contact Franklin Electric Co Inc Export Division for International Warranty NOTES FE Australia Submersible Service Hotline 1 300 FRANKLIN 1 300 372 655 FE USA Submersible Service Hotline 1 800 348 2420 Franklin Electric 9255 Coverdale Road Fort Wayne IN 46809 Tel 260 824 2900 Fax 260 824 2909 ka 225991101 Rev 3 01 15
27. es in the gland plate WARNING Do not drill holes that extend into the shaded area This will diminish the seal integrity of the enclosure Gland plate seal O o Z O U 15 16 DC Wiring Connections 1 Make sure that the external disconnect switch is off 2 Make sure that AC power is disconnected if installed 3 Make sure that all wires are properly identified and marked e the cable from the PV to the external DC disconnect switch e the cable from the external DC disconnect to the SubDrive Solar controller 4 Connect the cables from the external DC disconnect to the terminal block labeled Solar Primary DC and marked and GND Figure 5 Torque specification 15 in Ibs 1 7 N m Figure 5 DC Wiring Connection SOLAR PRIMARY DC CAUTION Only connect a photovoltaic solar array to the DC input of the SubDrive Solar controller This controller is suitable for use on a PV circuit capable of delivering not more than 50 DC amps short circuit current In this drive the integral solid state short circuit protection of motor wiring does not provide circuit protection of wiring for input power Input wiring protection must be provided in accordance with all applicable national and local electrical codes In addition follow any manufacturer s recommendations for protection of a photovoltaic PV array and protection of a generator if used AC Wiring Connections Optional The SubDrive
28. generators for Franklin s three wire single or three phase motors This is a general chart The generator manufacturer should be consulted whenever possible especially on larger sizes Follow generator manufacturer s recommendations for de rating at higher elevations or using natural gas MOTOR RATING MINIMUM RATING OF GENERATOR EXTERNALLY REGULATED HP KW KW KVA 0 75 0 55 2 5 3 1 1 5 1 1 5 6 25 3 2 2 10 12 5 Table 3 Generator Sizing Generator Selection Information Not all AC generators will perform sufficiently with the SubDrive Solar product Always consult the generator manufacturer for application specific information In a SubDrive Solar controller AC input current flows directly through the input rectifier into a storage capacitor with no active power factor correction PFC circuitry Because of variation of generator performance when connected to an input circuit like this it is recommended that a suggested minimum kVA rating be obtained from the generator supplier for this type of application input rectifier to capacitor no PFC The AC input of a SubDrive Solar controller draws current only near the peaks of the sine wave generator voltage This pattern of current peaks may distort an input sine wave voltage limiting the generator s ability to maintain the voltage level required by the drive This behavior is typical for equipment without dedicated power factor correction circuit
29. ls that have been exposed to full solar insolation for an extended period of time can achieve high temperatures and could be a potential source of burns to exposed skin if contacted Use caution when working around solar arrays Overview The SubDrive Solar controller is a variable speed motor drive designed to run a Franklin Electric three phase submersible induction motor The SubDrive Solar provides water to remote locations by converting high voltage direct current from a solar array into alternating current to run a standard AC submersible motor When solar power is not available the controller can automatically switch to an alternate single phase AC input such as a generator or inverter from battery if available The controller provides fault detection motor soft start and speed control The SubDrive Solar is designed to provide these features with the plug and play ease of installation similar to a single phase control box The SubDrive Solar is designed with the high standard of reliability expected of Franklin Electric products The controller attempts to drive the pump and motor to deliver water even under adverse conditions reducing output as necessary to protect the system components from damage and only shutting down in extreme cases Full operation is restored automatically whenever abnormal conditions subside Inspection Before you begin receive and inspect the SubDrive Solar unit Verify that the part number is correct and th
30. minimum off e off time of the system 1 Select Minimum Off Time P6 10 e Only effects operation if P5 ON Interval e 1 10 60 by 10 minutes 60 Figure 11 shows the layout of the user interface on the COMM Board Using the soft buttons and the seven segment display the user defined parameters can be changed comm COMM STATUS Figure 11 COMM Board User Interface NOTE The COMM Board User Interface is the only piece in the SubDrive Solar controller that can be touched while power is applied to the drive The COMM board is low voltage and electrically isolated from the high voltage portions of the drive A WARNING Do NOT touch any other piece inside the SubDrive Solar controller while power is applied To service any other areas of the drive disconnect ALL power sources and wait five minutes before continuing Example process for changing Software Parameters Run Status Parameter Value New Parameter Run Status kW Number Now Value Number kW Display Reading FILE AEE gt BEE BEG gt BERE gt DOG MENU DN 3X SELECT UP 3X SELECT MENU Button yar The previous example changes the fixed underload time out setting from 50 minutes to 65 minutes and demonstrates how to change any of the listed parameters 23 24 Generator Sizing for SubDrive Solar Table 3 lists minimum generator sizes based on typical 80 C rise continuous duty
31. ng the up and down arrows will cycle through the parameter list To enter a parameter press the Select button on the desired parameter The display shows the last saved value Use the Up Down arrows to change the parameter to the desired value Confirm the selection by pressing the Select button The display will then alternately flash between the new selected value and the parameter number three times and ultimately return to the normal operating display Factory default settings are shown as BOLD Description Parameter Values yes e Restores User Defineable Parameters to factory default settings Factory Reset rSt e Flashes no after yes is selected no e Indicates this value as well as others has been reset to factory default 2 e Sets number of control switches if used of Control Switch Inputs P1 1 e If only one switch is required it must go in the Run terminal o e Count should include only run stop control switches but not the flow switch 100 Underload Trip P2 50 e Sets the underload trip sensetivity Sensitivity e Up Down 30 100 by 1 30 on e Fixed Reset Rule ON Select Reset Rule Type Pa off e Dynamic Reset Rule OFF Turns on off fixed reset rule Select Fixed Reset Rule Time P4 gt Only effects operation if P3 ON 5 e Up Down 5 80 by 5 minutes Enable Minimum Off Time P5 on e on selection enables user to select a
32. op Pumping Range Control Switch Run Pumping Range Control Switch Run 2 Control Switch Operation 1 Control Switch Operation Figure 10 Control Switch Operations NOTE All control switch configurations are superseded by the Flow Switch If the flow switch detects low flow it will OPEN and override the run signals sent by the control switches to protect the motor and drive Start Up and Operation After all appropriate connections have been made apply power to the controller A steady green light in the Power DC Polarity location indicates that the SubDrive Solar controller has either AC or DC power connected A red light in the Power DC Polarity location indicates that the positive and negative connections have been reversed The seven segment display will power on shortly after power is applied to the controller It will flash the current software version of the main controller then the software version of the COMM board processor and finally to the normal operating display The display will show an E2 fault on the display if the polarity is reversed By default the seven segment display shows motor frequency during operation The display can also show the system power in kW or a rotating segmented graphic signifying the pump motor is running These different display modes can be cycled through using the up and down soft buttons While running on DC power approximately every eight minutes the system will shut down
33. pper word 115 Drive status flags uint 16 B3 DC power B4 AC power B5 Flow switch B6 Stop switch B7 Run switch LIMITED WARRANTY THIS WARRANTY SETS FORTH THE COMPANY S SOLE OBLIGATION AND PURCHASER S EXCLUSIVE REMEDY FOR DEFECTIVE PRODUCT Franklin Electric Company Inc and its subsidiaries hereafter the Company warrants that the products accompanied by this warranty are free from defects in material or workmanship of the Company The Company has the right to inspect any product returned under warranty to confirm that the product contains a defect in material or workmanship The Company shall have the sole right to choose whether to repair or replace defective equipment parts or components The buyer must return the product to an authorized Franklin Electric Distribution outlet for warranty consideration Returns to the place of purchase will only be considered for warranty coverage if the place of purchase is an authorized Franklin Electric Distributor at the time the claim is made Subject to the terms and conditions listed below the Company will repair or replace to the buyer any portion of this product which proves defective due to materials or workmanship of the Company The Company will consider products for warranty for 12 months from the date of installation or for 24 months from the date of manufacture whichever occurs first The Company shall IN NO EVENT be responsible or liable fo
34. r watts 09 100 200 300 Output voltage volts 27 28 Display Fault Possible Causes Corrective Action E1 Motor Underload Air locked pump Overpumped or dry well Worn pump damaged shaft or coupling blocked pump or pump screen Wait for well to recover and auto restart to occur See description of Underload Smart Reset If the problem persists check pump and motor E2 Undervoltage Misconnected or loose input leads Tighten any loose input connections Low sunlight to PV array Wait for more intense sunlight Generator voltage too low Follow generator troubleshooting guide E3 Locked Pump Motor pump misaligned Unit will attempt to free a locked pump Pump bound up with sand or If it is unsuccessful check the motor abrasive and pump Dragging motor or pump E4 External Trip Water flow too low to adequately Check that trip terminal is correctly cool pump and motor wired to flow switch Flow switch miswired Check that flow switch is properly installed in pipe discharge Check that pipe discharge is not blocked Wait for sufficient solar power to pump adequate water E5 Open Circuit Loose or open connection to motor Check motor cable connections Defective motor or cable Cycle input power to reset If problem persists check cable and motor E6 a At power up Short Circuit a short in motor connections at a check motor connections at terminal b Whil
35. r full system capability provides 100 of rated system pumping power at STC System size Target PV array voltage PV array power 0 55 kW 150 Vdc 1400 Wp 1 1 kW 300 Vdc 2000 Wp 2 2 kW 300 Vdc 3500 Wp See Solar Array Specification Software for target PV array power for specific design requirements STC Standard Test Conditions 30 Solar Panel Wiring Configurations Solar Panels Wired in Series When solar panels are wired in series the positive terminal of one solar panel is wired to the negative terminal of the next solar panel When panels are connected in series e Voltage accumulates adds for each panel in series e Wattage accumulates adds for each panel in series e Current Amps remains the same as a single panel in the series Solar Panels Wired in Parallel When solar panels are wired in parallel the positive terminal of one solar panel is wired to the positive terminal of the next solar panels Likewise the negative terminals are connected together to the negative terminals of the next solar panels When panels are connected in parallel e Voltage remains the same as a single panel in the parallel connection e Wattage accumulates adds for each panel added e Current Amps accumulates adds for each panel wired in parallel fel 4 31 32 Solar Panels Wired in Combination Series parallel combination wiring requires that at least two sets or strings or panels wired in
36. r the cost of field labor or other charges incurred by any customer in removing and or affixing any product part or component thereof The Company reserves the right to change or improve its products or any portions thereof without being obligated to provide such change or improvement to previously sold products THIS WARRANTY DOES NOT APPLY TO products damaged by acts of God including lightning normal wear and tear normal maintenance services and the parts used in connection with such service or any other conditions beyond the control of the Company THIS WARRANTY WILL IMMEDIATELY VOID if any of the following conditions are found Product is used for purposes other than those for which it was designed and manufactured Product was not installed in accordance with applicable codes ordinances and good trade practices Product was not installed by a Franklin Certified Contractor or Product was damaged as a result of negligence abuse accident misapplication tampering alteration improper installation operation maintenance or storage nor to an excess of recommended maximums as set forth in the product instructions NEITHER SELLER NOR THE COMPANY SHALL BE LIABLE FOR ANY INJURY LOSS OR DAMAGE DIRECT INCIDENTAL OR CONSEQUENTIAL INCLUDING BUT NOT LIMITED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR LOST PROFITS LOST SALES INJURY TO PERSON OR PROPERTY OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL LOSS ARISING OUT OF THE USE OR T
37. s A generator s ability to provide low distortion voltage during such operation is limited by a generator parameter called sub transient output reactance The lower the sub transient output reactance the better the generator can maintain a low distortion sine wave output voltage Generators with the following ratings are expected to be capable of providing adequate voltage to SUBDRIVE Solar drives at rated power of the drives For SubDrive Solar Model 5870300553 3 1kVA less than 25 sub transient reactance For SubDrive Solar Model 5870301113 5 5 kVA less than 25 sub transient reactance For SubDrive Solar Model 5870301223 9 kVA less than 20 sub transient reactance The above information is a guideline for selecting a generator based on best known practice Not all AC generators will perform satisfactorily with the SubDrive Solar product and can result in but not limited to nuisance tripping unsatisfactory performance or drive damage Always consult the generator manufacturer for best use practices Generator Line Reactor Specifications A single phase line reactor is recommended when using a back up generator source located between a generator and the controller for both 1 1 kW and 2 2 kW units Without a line reactor the drive can experience excessive heating and will reduce performance or stop to protect itself e Minimum 0 4 mH inductance rating of 25 ampere rms current continuous for 2 2 kW e Minimum 0 4 mH in
38. s moving Continuous operation in a deadhead condition may overheat the pump motor and subsequently the plumbing since no moving water carries away the heat This flow switch overrides the RUN command from any other control switches The flow switch detects adequate flow permitting continuous operation or detects zero or low flow enabling a deadhead operation mode which alternates a run time interval and a cool down interval to avoid overheating the motor and pump See pages 17 amp 18 for more information on Flow Switch Operation After a certain run time duration if the flow switch does not detect flow it will present an E4 fault code The durations of the run time and cool down intervals depend on the power being supplied by the controller the more power going to the motor the shorter the on time and longer the cool down The controller will operate indefinitely in deadhead mode until available power either increases sufficiently to move adequate water or it decreases sufficiently that the controller is no longer able to spin the motor The SubDrive Solar controller will not operate with the flow switch bypassed or jumpered The controller is required to see no flow before attempting to start the motor or a fault will occur 11 12 Installation A WARNING High voltages both AC and DC capable of causing severe injury or death by electrical shock are present in this unit This unit should only be in
39. series are connected in parallel When panels are connected in combination e Voltage accumulates adds for each panel in a single series circuit but does not accumulate for additional strings wired in parallel e Wattage accumulates adds for each panel in a single series string AND each string in parallel circuit all panels in the array contribute additively to the total wattage e Current Amps remains the same for single panels in a series but accumulates adds for additional strings connected in parallel A lt 4 gt 8 Bd 6 7 A A A B D c 1 1 1 G 1 T ee Se J 9 9 ks y v E Figure 12 SubDrive Solar Controller Line Drawing Suk Drive Solan A B c D E F G1 G2 Dimension Inches 10 20 18 30 21 00 20 00 6 00 3 00 8 70 10 40 Centimeters 25 80 46 40 53 30 50 80 15 25 7 60 22 00 26 50 G 1 0 55 amp 1 1 kW SubDrive Solar G 2 2 2 kW SubDrive Solar NOTE All dimensions are approximate Table 8 SubDrive Solar Controller Dimensions 34 Figure 13 SubDrive Solar Controller Mounting Hole Drawing SubDrive Solar b ef de Dimension Inches 0 63 0 75 0 40 0 28 Centimeters 15 9 19 1 10 3 7 1
40. stalled or serviced by technically qualified professionals Anytime working on or near the SubDrive Solar controller or system e Securely cover the solar array with an opaque tarp Turn OFF the external DC rated disconnect from the solar array to the SubDrive Solar controller e Ensure AC power has been disconnected from the SubDrive Solar controller if used e Wait a minimum of five minutes after removing power from the SubDrive Solar controller before servicing READ THESE INSTRUCTIONS COMPLETELY BEFORE INSTALLATION Note During installation if a conflict arises between this manual and local or national electrical codes the applicable local or national electrical codes should prevail e The longevity and performance of the SubDrive Solar package may be adversely affected by improper installation e The solar PV array structure modules and wiring harness must be properly assembled according to the manufacturer s installation instructions before installing the SubDrive Solar controller e Wiring Requirements Use 75 C rated wire sized for a maximum voltage drop of 3 per local electric codes Installation Preparation and Requirements When installing the SubDrive Solar controller be aware that e High voltage is present in the SubDrive when powered on use caution when live DC power is on e Do not allow any unauthorized persons near the solar array and connection sites while power is applied It is strongly recommended that
41. tank to regulate the water level A flow switch detects if flow is below critical levels while the pump is still running This serves as an indication that the well has run dry or that insufficient power is available to continue pumping The system will shut down to protect the pump and motor until the well or adequate electric power has recovered The SubDrive Solar controller runs at variable speed to match the changing power available from the PV solar array Variable speed operation means there is no in rush or surge of energy during the pump motor start up helping to eliminate wear on the motor and pumping system A leading cause of pump motor failure is the stress applied to the motor during a full voltage start up The SubDrive Solar variable speed operation ramps up the speed smoothly which eliminates starting stress This feature enhances long term motor reliability pg 8 The Franklin Electric SubDrive Solar is designed to be part of a system that consists of A Solar Pump and Motor B SubDrive Solar Controller C Solar Array not included D Flow Switch with sensor cable E Control Switches optional not included F AC Generator optional not included G DC Rated Disconnect Per applicable codes H Line Reactor not included B t 3 ee oe Figure 1 SubDrive C Controller Solar System Flow Switch DC Power Solar PV Array 30A 2 Pole DC Rated Disconnect Pump Motor
42. tate of each of the dry contacts NO NC in the two operating modes Adequate DC Power NO Closed NC Open Inadequate DC Power NO Open NC Closed To start a back up AC generator through a closed circuit use the NC Normally Closed and the COM Common dry contact flag terminals 10 Underload Smart Reset Dynamic Factory Setting If a motor underload fault condition occurs the most likely cause is an over pumped or dry well The underload trip level is defined as a percentage of rated load at rated speed the default being 50 which can be adjusted via the COMM Board user interface Once tripped the timeout applied before a restart attempt varies according to the Dynamic Smart Reset schedule The intent is to adjust the Off Time as a function of the level of water in the well using the formula Off Time Rule Time Run Time Figure 2 gH gt K Run Time Minutes Off Time Minutes Figure 2 Dynamic Reset Model For wells having a slower recovery rate an extendable Rule Time that adjusts automatically is used The Rule Time is initially set to 5 minutes when the drive is first activated However if after restarting from an underload the drive quickly trips again arrow 1 the Rule Time is extended This process continues until the Rule Time grows long enough to keep the Off Time near the center range arrow 2 up to a maximum of 80 minutes If later on the well begins to recover more quickly the sys
43. tem runs longer between trips and the Rule Time is gradually reduced in 5 minute increments arrow 3 This adaptive process allows for seasonal changes in well behavior Fixed The SubDrive Solar controller can be set to a fixed Off Time rule via the COMM Board user interface It is factory preset to a fixed time of 5 minutes In this mode the controller will wait 30 seconds to 5 minutes determined by duration of the previous run time before restarting the motor For example the first time the fault occurs the controller will wait 30 seconds before attempting to restart the pump If the system would then run for one minute and an underload fault recurs the controller will wait four minutes before attempting to restart the pump This schedule allows for the minimum off time possible based on the recovery time of the well The fixed Off Time can be set from five to 80 minutes in five minute increments NOTE The fixed Off Time will only take effect if Parameter 3 is set to 1 Fixed Figure 3 0 1 2 3 4 5 6 7 8 Run Time Minutes Figure 3 Fixed Reset Model Flow Switch A flow switch comes with the SubDrive Solar package to detect low flow or no flow conditions and prevent damage to the pump motor and plumbing At times of limited sunlight a point will be reached where there is not enough solar power available to provide adequate flow The pump will reach a deadhead condition meaning the pump is spinning but no water i
44. the system may cycle on and off Due to the controller s soft start feature this will not harm the motor Over Temperature Foldback The SubDrive Solar controller is designed for full power operation from a DC solar array in ambient temperatures up to 122 F 50 C Under extreme thermal conditions the controller will reduce output power in an attempt to avoid shutdown Full pump output is restored when the controller temperature cools to a safe level Pressure or Level Control Switch A pressure or level control switch can be wired into the SubDrive Solar controller for water level or pressure control This is optional and is not required to run the SubDrive Solar controller The controller can be used with none one or two control switches This provides the user maximum adjustability when using the SubDrive Solar controller See INSTALLATION section for more information on installing and using control switches Automatically Switching to Back up AC Power The SubDrive Solar controller includes a secondary input power terminal that may be used with a back up 230 V AC power source If there is sufficient voltage measured from the primary source Solar Array the drive will attempt to draw from it to run the pump The controller will automatically switch to the alternate backup supply input if 1 The PV Photovoltaic Solar Array input cannot provide sufficient Vdc after a number of attempts to successfully start the motor AND 2 Genera
45. tor back up power is available at the AC back up terminals When the system is running on back up AC power the drive will shut down for a few seconds every 30 minutes to check the primary DC input terminals for sufficient power If the primary DC power is available it will switch sources and attempt to run on DC If the primary power is still insufficient during this check it will resume running on back up AC power Call For Generator Dry Contacts The SubDrive Solar controller has a set of dry contacts that can be used as a Call for Generator function There are three flag terminals inside the controller two of which must be used NO normally open NC normally closed choose NO or NC based upon switch being used or common state desired and COM which is the common These flag terminals are located in between the AC terminal connections and the RUN STOP TRIP terminal connections When the drive no longer has adequate DC power it will then look for power at the AC terminal block At the same time the state of those contacts changes one will open the other will close based upon which contact terminal is used This can then be read by an external switch This is not a powered contact it only either opens or closes a circuit In order to recognize this change a switch controller with an independent power source must be utilized for example an external battery that can be charged once a generator is turned on Shown below is the s
46. unch the necessary sized holes for the appropriate cord grips or conduit fittings to feed through Do not attempt to drill holes with the gland plate on the enclosure Damage could occur to internal electronics or metal shavings could short out electronics inside the drive 4 Use appropriate strain relief or conduit connectors For NEMA 3 IP 55 Type B liquid tight fittings are recommended for maximum weather protection 5 Make the appropriate wiring connections in the following instructions and install per all applicable local and national codes a Select wire gauge based on code recommendations for the maximum operating currents listed in Table 7 page 29 Verify that any protection devices such as fuses or circuit breakers are appropriately sized and installed per local and national code 6 Replace the gland plate on the bottom of the enclosure Do not over tighten the screws a Torque screws to 1 7 N m 15 in Ibs 7 Replace the cover Do not over tighten the screws a Torque screws to 1 7 N m 15 in Ibs b NOTE DO NOT SHIFT CUT OR DAMAGE THE SEALS WHEN REPLACING THE GLAND PLATE AND COVER DOING SO WILL RESULT IN LACK OF WEATHER PROTECTION AND LOSS OF NEMA AND IP RATINGS NOTE Ensure that the system is properly grounded Improper grounding may result in the loss of voltage surge protection and interference filtering Gland Plate Terminal Location Template Use the template as a guide for locating where to drill hol

SubDrive Solar Manual - Solar Pumping Systems

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