Installation Manual
Contents
1. Manual PS600 BADU Top 12 3 OPERATING THE PUMP This explains the function of the switch and SWITCH the indicator lights on the pump controller POWER ON OFF system logic ON POWER Indicator lights OFF SYSTEM green SWITCH OFF ON TO RESET Q TANK FULL TANK FULL red BATTERY LOW TANK LIGHT FLASHES terminals BATTERY LOW tank light flashes Battery systems only battery voltage fell to 44V and has not yet recovered to 48V RPM indication Pump speed can be read off by the flashing sequence of the Pump ON LED LED ON 900 One flash Two flash Three flash Four flash Five flash When switched off on during operation it resets all The controller is switched on and the power source is present In low power conditions the light may Q SYSTEM YS show even if there is not enough power to run the ae pump PUMP ON green Motor is turning Sequence of flashing indicates Q PUMP ON pump speed See below sequence RED PUMP OVERLOAD PUMP OVERLOAD green changes to red Q SOURCE LOW SOURCE LOW red S IOHISTAYS ONIESOURGE A The water source dropped below the level of the low RECOVERS water probe After the water level recovers the pump will restart but this light will slowly flash until the sun goes down power is interrupted or the POWER switch is reset This indicates that the water source ran low at least once since the previous off on cycl2. LORENTZ b PS600 BADU Top 12 Solar operated centrifugal surface pump INSTRUCTION MANUAL INSTALLATION OPERATION SERVICE BERNT LORENTZ GmbH amp Co KG Germany ww lorentz de infolorentzde release 050509 1 P Manual PS600 BADU Top 12 LORENTZ b Contents 1 SYSTEM REPORT FORM uuu unus M 5 2 ELECTRICAL INSTALLATION 222222 IIT oci nca ansann nanana ac suu cou nein ona theccacessdenceucesaeecontentessseecacescees 4 2 1 Pump Controller PS600_ ret ie pter Dite hind redet beet eire gren eit ia dren re Ria ARR eau De 4 2 2 Mechanical Installation BER 4 2 3 Controller Input Wiring u nnns 4 2 4 Electrical Installation Terminals oer Eee C Die ce tete cae ei ece eee iate 5 2 5 Battery Based Systetii ueniret raanei eaoaai reset aep an aidd Rus sassa ERR cc ER apad CO xp ad 5 2 6 Wire SIZ UNG T 5 3 OPERATING THE PUMP criie rtr teca Scene cn kn ems acusa ccu edo utu kis cog aUe Dass esa ns cae made cda ous De vnus a nonae vs 6 4 AUTOMATIC CONTROLL FOR FULL TANK SHUT OFF U u uu uuu u u 8 5 nneluBzeenicqe 9 6 MAINTENACE M 10 7 MCHEUAEMETENTLTECEINIGEOETTHLEELRECOMCRE 10 8 SYSTEM WIRING DIAGRAM
3. circuitry from weather exposure failure to protect from overheating due to sun exposure or other sources of heat failure to protect from salt spray or other corrosive factors failure to seal out insects spiders or rodents lightning flood or other acts of nature or failure of or inap propriate application of peripheral devices including lightning or surge protectors LORENTZ BADU Top pumps are designed for pumping thin clean non aggressive non explosive liquids not containing solid or long firbred particles larger then sand grains Warranty does not cover damage due to sand or abrasive particles in the water or incom patibility of pump materials with corrosive substances or hydrocarbon or petroleum impurities or from running the pump with an insufficient supply of water No specific claim of merchantability shall be assumed or implied beyond what is printed on the manufacturer s or importer s printed literature No liability shall exist from circum stances arising from the inability to use the product or its inappropriateness for any specific purpose It is the user s responsibility to determine the suitability of the product for any particular use In all cases it shall be the responsibility of the customer to ensure a safe installation in compliance with local state and national electrical codes 10 P Manual PS600 BADU Top 12 LORENTZ 8 System Wiring Diagram for Solar direct non battery Sys
4. either 48V use a 20 amp circuit breaker or a time delay slow blow fuse The purpose of this protection is for safety in case of a wiring fault and to provide a means of disconnect when install ing or maintaining the system PS600 controllers have electronic over current protection against motor overload Low voltage disconnect function Lead acid batteries can be permanently damaged by over discharge when the voltage falls below a critical point To prevent this the PS battery system controller will turn off at low voltage and turn back on only after the battery has recovered significantly The set points are 48V SYSTEM OFFat 44V ON at 48V 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 To reverse direction reverse any two wires Max RPM setting Factory setting Maximum 2 06 Wire Sizing Wire Sizing for the DC circuit Wire must be sized for no more than 5 voltage drop at 20 amps starting Refer to a wire sizing chart for 48V or follow these examples Solar Direct Systems 3110 wire to maximum distance of 30 ft Metric 4 sq mm to max 20m Battery Systems 3110 wire to maximum distance of 30 ft Metric 4 sq mm to max 15m GREATER LENGTHS For each 150 increase use next larger wire size Terminals inside the PS XXX controller Max RPM setting is at right To reduce RPM N
5. the use of a float switch or other means to prevent overflow of your tank This will stop the pump when the tank is full then reset when the level drops This con serves ground water prevents overflow and eliminates unnecessary pump wear PS XXX controllers allow the use of small signal cable to a remote float switch even if the tank is a long distance away Float switch requirements 1 A switch must be used not wet electrodes 2 The preferred system requires a float switch to MAKE contact on rise to turn the pump OFF This is called normally open N O It may be commercially labeled as a pump down switch but here it works in reverse to allow pumping up Wiring to the controller The controller offers two options 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 sealed Float switch cable require cable clamp ments 1 Two wires are needed pump off 2 Minimum wire size 18 AWG 1mm This is good for a distance as far as 2000 feet 600 m 3 The cable must be suitable for its environment 4 If it must run a long distance use twisted pair shielded cable to reduce the chance of damage from lightning induced surge Grounding shielded float switch cable If you use shielded cable connect the shield
6. to ground AT THE CONTROLLER ONLY DO NOT ground the shield at the float switch This will reduce surges induced by nearby lightning Remote Float Switch pumping range Wiring a normally open switch Connect the switch to terminals 3 and 4 NO and common and connect terminals 4 and 5 together as illustrated Closing connecting the switch circuit turns the pump OFF Float Switch UP closed DOWN open normally open Wiring a normally closed reverse action switch Connect the switch to termins 4 and 5 Closing connecting the switch turns the pump ON Remote Float Switch if cable is shielded ground this end only Float Switch UP open DOWN closed normally closed Manual PS600 BADU Top 12 5 TROUBLE SHOOTING Please read this section before calling for help If you call for help please refer to the model and serial numbers See SYSTEM REPORT page 3 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 indicates that VOLTAGE is present but in a solar direct system there may not be sufficient power to start the pump It should attempt to start at intervals of 120 seconds Pump attempts to start every 1
7. will be near maximum WARNING Do not apply a direct connec tion or an amp meter between and when the controller is connected A short circuit here will cause a strong discharge 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 release 050509 4 E Manual PS600 BADU Top 12 2 4 Electrical Installation Terminals Power IN For PV direct systems a two pole discon nect switch may be installed between the solar array and the controller Switch it off to prevent shock and arc burn hazard during installation and maintenance or if the system will be shut down for the season For Battery systems Connect 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 20 Amp slow blow fuse must be installed between The controller and the battery Ground Connect the ground wire to the ground connection in the controller Grounding helps to prevent shock hazard if there is a fault in the motor L1 L2 L3 ECDRIVE requires four conductor four wire cable between the controller and the motor The three wires
8. 20 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 controller A solar direct non battery system should start if there is enough sun to cast a slight shadow A battery system should start if the supply voltage is greater than 44V 2 If the pump was recently connected or recon nected to the controller it may be running in reverse direction due to wiring error 3 If the 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 connection or if you accidentally exchanged one of the power wires with the ground wire 4 The pump or pipe may be packed with mud clay sand or debris PUMP OVERLOAD PUMP ON light shows red instead of green The system has shut off due to an overload This can happen if the motor or pump is blocked or very difficult to turn and is drawing exces sive current hard to turn Overload detection requires at least 250 Watt output of the solar array This can be caused by a high concentration 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 system will not reset until the ON OFF switch is turned OFF and ON again See Troubleshooting Section 9 3 HIGHER CURRENT
9. 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 LORENTZ E 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 Pull wires with your hands to check for failed connections Inspect the controller 1 Remove the screws from the bottom plate of the controller Move the plate downward or the controller upward to reveal the terminal block where the wires connect 2 First check for a burnt smell This will indicate a failure of the electronics Look for burnt wires bits of black debris and any other signs of lightning damage 3 Inspect the grounding wires and connections Most controller failures are caused by an induced surge from nearby lightning where the system is NOT effectively grounded Ground connections must be properly made and free of corrosion Check the low water probe system If 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 n
10. L1 L2 and L3 carry power The fourth wire carries ground To reverse direction of rotation reverse any two wires LORENTZ 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 connected 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 remain 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 11 V for a 12 V battery system and 22 V for a 24V battery System in order to protect the battery If the battery voltage increases to 13 or 26 V the motor will be switched ON automatically OQ ojopp lllo RED BLACK YELLOW turn counter clockwise Power In For factory testing only 2 5 Battery Based Systems PS600 pump systems can be operated from batteries Short Circuit protection Install a fuse or circuit breaker near the power source For
11. cient 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 attempt you will see the PUMP ON light come on When pump runs slowly PUMP ON under weak sun conditions 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 falsh for the rest of the solar 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 immediately if sufficient power is present Manual PS600 BADU Top 12 LORENTZ 4 Automatic Control For Full Tank Shutoff We recommend
12. e 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 gt 1200 gt 1600 gt 2000 gt 2400 gt 2800 LORENTZ Manual PS600 BADU Top 12 Operating the Pump continued Starting the pump Be sure there is not a closed valve or other obstruction in the water line Fill the pump with clean water until the water level 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 NEVER LET THE PUMP RUN DRY NOT EVEN FOR THE PURPOSE OF CHECKING THE DIRECTION OF ROTATION 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 start under the following conditions 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 44N When sunshine is insuffi
13. equires no maintenance There are rubber plugs to seal at the bottom unused conduit holes Inspect them to insure that the controller is sealed from moisture insects etc Check that mounting and conduit hardware 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 lubricated 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 periodic measurement of the pump s performance A worn pump end can be replaced in the field 7 WARRANTY BADU Top pump and PS xxx controllers are warranted by the manufacturer to be free from defects in material and workman ship for two 2 years from date of pur chase Failure to provide correct installation opera tion or care for the product in accordance with the instruction manual will void the warranty Product liability except where mandated by law is limited to repair or replacement at the discretion of the manufac turer or importer Neither manufacturer nor importer is respon sible for the labor or other charges necessi tated by the removal transportation or reinstallation of any defective product Warranty does not cover damage due to failure to install the device properly mishan dling or abuse failure to protect
14. inhaerens tots anon sa tease sane aaa san Pi RRE ARE cas SAAANA asananannasaaanaasa 11 WARNING disregard might lead to injury or damage the installation CAUTION recommended to avoid disfunc tion or premature ageing of the pump etc ADVICE x www lorentz de info lorentz de release 050509 2 P Manual PS600 BADU Top 12 2 SYSTEM REPORT FORM System and Components System Voltage Date of Purchase Purchased from Battery System if not Quantity of Solar Modules panels Solar Module Brand Module Model Controller Model Controller Serial Thank you for purchasing a LORENTZ 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 specifications and performance charts end of this manual to be sure the system is appropriate for your applica tion Please fill in the SYSTEM REPORT This will be essential information if any problems occur Read the manuals of pump end charger optionally and other components used in your system L PS600 LORENTZ D Manual PS600 BADU Top 12 2 1 Pump Controller PS600 gt Controlling and monitoring of the motor gt Integrated MPP Tracking gt LVD protection low voltage disconnect for 48V batteries Check and display the operating states Two control inputs for float or pressure switches remote control etc gt 92
15. max efficiency motor controller Adjustable maximum RPM setting 2 2 Mechanical Installation Position f it is outdoors mount the controller in a vertical position to assure that rain will not enter the box Battery system Place the controller near the batteries but safely isolated from the battery termi nals and from corrosive gases Batteries must be in a cool location for best longevity and enclosed for cleanliness and safety Connect the battery directly with the and Terminal of the controller Do not use the load terminals of the charge controller as they maybe not strong enough to allow the start current to flow The PS600 Controller has a low voltage function to protect the batteries from deep discharge The charger additional is only needed for charging the batteries Ne www lorentz de info lorentz de PV max open circuit Voc 150 V DC 4 6 pc of 12V nominal solar panels Input voltage battery 48V DC Input current Power max unlimited Controller regulates max Power Battery low voltage disconnect 44 V DC Restart voltage 48 V DC Output 13 45V EC PWM 3 phase Type of enclosure IP 54 Ambient temperature 20 C to 50 G Weight 4 8 kg Dimensions 425 x 175 x 150 mm LORENTZ E 2 3 Controller Input Wiring WARNING TEST THE VOLTAGE before connecting power to the controller Voltage open circuit must not exceed 150V for PS600 Controller Even in cloudy weather the open circuit voltage
16. ot full inspect the float switch system If your system has a float Switch it will be mounted in the tank If inspection is not feasible you can bypass the switch or test it electrically Force a quick start If you restore a connection or bypass the probe or float switch there is no need to wait for the normal time delay Switch the on off switch or the power source off then on again The pump should start immediately if sufficient power is present 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 Is the solar array receiving shadow free light It only takes a small shadow to stop it Is it oriented properly toward the south and tilted at the proper angle 2 Be sure you have the right pump for the total lift that is required e Be sure all wire and pipe runs are sized adequately for the distance Refer to wire sizing in the pump sizing table 4 Inspect and test the solar array circuit and the controller output as above Write down your measurements 5 There may be a leak in the pipe from the pump 6 There is a max RPM adjustment in the controller It may have been set to reduce the flow as low as 3096 7 Manual PS600 BADU Top 12 6 MAINTENANCE Controller and Pump The controllers electronic has no moving or wearing parts It r
17. tem This is an example using 4 X 12V nominal PV modules Your system may vary in the number voltage and configuration of PV modules If the diagram for YOUR system is not attached here ask your pump supplier The system here below is typical for a PS600 system 4 to 6 modules in Series BLACK YELLOW Pump To reverse direction reverse any two wires D A If you are not using a float switch install a jumper wire between terminals 4 and 5 If you are not using the low water probe install a jumper wire between terminals 1 and 2 To any ground terminal at Earth controller Ground PV Modules Solar Panels Before connecting the array to the controller measure the open circuit voltage It must be within a range of PS600 75 135V DC Float Switch optional Float Switch Kit makes contact on rise to stop pump Connect termins 3 NO and 4 COM and connect terminals 4 and 5 with jumper wire For wire size refer to Pump Sizing Submersible Cable Splice Low Water Probe
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