Lorentz PS200 Installation Operation & Maintenance
Solar water pump systems
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Manual | LORENTZ PS Pump Systems
PS200, PS600,
PS1200, PS1800
Solar Water Pump Systems
Manual for
Installation, Operation, Maintenance
Errors excepted and possible alterations without prior notice.
BERNT LORENTZ GmbH & Co. KG
Kroegerskoppel 7
24558 Henstedt-Ulzburg
Germany
Tel. +49 (0) 4193 7548 - 0
Fax +49 (0) 4193 7548 - 29
www.lorentz.de
Errors excepted and possible alterations without prior notice.
v100820 | page 1
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Summary of Contents for Lorentz PS200
- Page 1 PS200, PS600, PS1200, PS1800 Solar Water Pump Systems Manual for Installation, Operation, Maintenance BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7 24558 Henstedt-Ulzburg Germany Tel. +49 (0) 4193 7548 - 0 Fax +49 (0) 4193 7548 - 29 www.lorentz.de Errors excepted and possible alterations without prior notice.
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Page 2: Table Of Contents
Machine Installation ..................25 Recent Updates ................... 51 Hand Installation ................... 26 Sanitizing the Well ..................26 Operating the Pump ................27 page 2 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... - Page 3 Pump speed indication ................27 Figure 3: Typical assembly of controller and junction box on the solar array mounting Table 4: AC running current PS200 and PS600 systems ......... 32 pole ......................9 Table 5: AC running current PS1200 systems ............32 Figure 5: Two types of PV module junction systems ..........
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Page 4: Introduction
Introduction Warnings Thank you for purchasing a LORENTZ pump system. We set General Warnings Safety Directions for Maintenance, Inspection a new standard for quality and economy in solar pumping. and Assembly Work – It is the user’s responsibility It incorporates the best solar pump technologies that were ... - Page 5 Open circuit (no-load) voltage above 100 V down). If direction is reversed, exchange the for PS200 controllers, above 150 V for PS600 connection of any two of the three power controllers and above 200 V for PS1200 and wires to the pump. See Section 5.8 PS1800 controllers will destroy the controller.
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Page 6: Installing The Solar Array
To obtain reproduction rights, contact: John Veltman PO Sun Compass™ now points to the four direc- Box 23533, Santa Fe, NM 87502, USA tions. page 6 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 7: Setting The Solar Array Tilt Angle
If you use the pump all year but do not want seasonal adjustment to be required, set the angle to year-round compromise (equal to latitude). Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 7... -
Page 8: Electrical Installation
Figure 2: Transportation protection caps and boots rubber boot rubber caps page 8 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 9: Figure 4: Conduit Holes
1 hole for 1 1/4 in conduit (45 mm) Holes are in a removable plate that can be reversed. Rubber plugs are included for unused holes. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 9... -
Page 10: 4.2 Grounding And Lightning Protection
Where the ground gets very dry (poorly conductive), vide adequate electrical grounding. install more than one rod, spaced at least 10 ft (3 m) apart. page 10 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 11: 4.3 Solar Array Wiring
All wiring must be done by qualified personnel, in compliance with local, state, and national electri- cal codes. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 11... -
Page 12: 4.4 Solar Array Disconnect Switch In The Junction Box
Voltage (open circuit) must not ex- between terminals 1 and 2. ceed 100 V for PS200, 150 V for PS600 Ground connections The two ground terminals in the and 200 V for PS1200 systems. (Even... -
Page 13: 4.6 Maximum Rpm Setting
If the drop cable is too large to fit in the crimp connector, cut off some of the wire strands. Use a crimping tool, and observe that the wires are held very securely. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 13... -
Page 14: 4.8 Wiring Order For Correct Rotation
In any case, when you are finished connecting the pump to the controller, test it to assure the proper direction. page 14 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 15: Low-Water Probe For Dry-Run Protection
5.12, Pressurizing Systems Figure 9: Low-water probe installed in the standard position, for a pump that is positioned vertically Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 15... -
Page 16: Automatic Control For Full-Tank Shutoff
This is the general preference in the industry. If you prefer the pump to stop if the connection is broken, use a normally closed (N.C.) float switch instead. page 16 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... - Page 17 Source: Tek Supply, www.teksupply.com (800) 835-7877, Item #WR-1300, or search “Hudson Valve”. WARNING Install an appropriate pressure relief valve for safety, see section 5.12 Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 17...
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Page 18: Battery-Based Systems
For either 24 or 48 V , use a 25 amp battery system controller will turn off at low voltage, and circuit breaker (PS200 or PS600 Systems) or a time-delay turn back on only after the battery has recovered signifi- (slow blow) fuse. -
Page 19: Pressurizing Systems
4.12 Pressurizing Systems LORENTZ PS pump systems are excellent for intended to prevent dry run of centrifugal pumps. The heli- a long distance. See illustration below. Advantage: automatic water pressurizing when powered by a cal rotor pump types will maintain pressure even as it runs the controller stays on all the time. -
Page 20: Preparing To Install The Pump
Figure 15: Assembling the Rotor on the Motor Shaft page 20 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 21: Drop Pipe
See section any plastic pipe components. Figure 16: Hose clamp to reinforce a plastic reducer bushing Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 21... -
Page 22: Safety Rope And Binding
See section 5.9, Low Water Probe tie safety rope here page 22 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 23: Installation In A Surface Water Source
The lift load on the pump is determined by the vertical head of Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 23... -
Page 24: Coping With Dirty Water Conditions
QUESTION What effect does hard, mineralized, alkaline or salty water have? — ANSWER Generally, none. Dissolved minerals and salts are not abrasive. page 24 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 25: Installing The Pump Under A Windmill Or Hand Pump Cylinder
If you do remove it, use a hardening adhesive sealant or epoxy glue when you replace it. See CAUTION in section 9.1 pump Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 25... -
Page 26: Hand Installation
Some installers use a winch with a reel of about 3 ft (1 m) diameter or larger, to pull flexible pipe. page 26 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 27: Operating The Pump
It may make rapid on/off noises and a high-pitched noise, then stop. This does not indicate a problem. The pump will attempt to restart after the normal delay. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 27... -
Page 28: Page 2 | V100820 Errors Excepted And Possible Alterations Without Prior Notice
LED ON. The system will not reset until the ON / OFF switch is turned OFF and ON again. See section 9.3, Troubleshoot- ing: Higher Current page 28 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 29: Trouble Shooting
OFF and ON again. See Troubleshooting, section 9.3, Electrical Testing: Higher Current Many problems can be located by simple inspection. No electrical experience is required. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 29... -
Page 30: Inspect The System
Switch the on/off switch (or the power source) off then on again. The pump should start immedi- ately if sufficient power is present. page 30 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 31: Electrical Testing
It allows you to measure current without breaking connections (cf. Test #6A). Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 31... -
Page 32: Table 4: Ac Running Current Ps200 And Ps600 Systems
Table 4: AC running current PS200 and PS600 systems lift pump [ft] HR03H HR04H HR03 HR04 HR07 10.3 [A AC] HR10 10.3 HR14 10.1 HR20 C-SJ5-8 10.9 10.7 10.7 10.8 10.7 C-SJ8-7 Table 5: AC running current PS1200 systems lift... -
Page 33: If The Pump Runs But Flow Is Less Than Normal
The negative (black) probe ALWAYS goes in the “COM” damage. (common) socket. The + (red) probe input varies, and is specified below. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 33... -
Page 34: Testing The Solar Array (Dc)
ON connection THROUGH your meter. Probe connections must be secure. A clamping device is helpful (split bolt is shown as an example). page 34 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 35: Testing The Pump Circuit (Ac And Resistance)
> 10 kΩ bypassed – pump on nect from controller if b) probe above water or circuit broken – pump off Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 35... -
Page 36: Testing The Full-Tank Float Switch (Or Pressure Switch) Circuit
> 10 kΩ - pump on disconnected from if b) switch open (or circuit broken) controller - pump off page 36 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 37: Maintenance
Solar Tracker If the system uses a solar tracker, lubricate the bearings, check mounting bolts and mechanism. Refer to tracker manufacturer’s instructions. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 37... -
Page 38: Reference Section
AC voltage which is made with PWM sun. technology it cannot be measured with a multimeter. Mo- page 38 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 39: Helical Rotor Models
It is far more reliable than diaphragm and piston-type solar concrete! They have been used for solar pumping since the pumps. 1980s, but were very expensive until the LORENTZ helical rotor pump was introduced. Figure 29: Helical Rotor Pump Head... -
Page 40: Water Pipe Sizing Chart
0.39 0.17 *) 1/2 in data applies to polyethylene pipes only. PVC pipes have a smaller ID of 0.612 in. 0.66 0.27 page 40 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 41: Wellhead Assemblies For Drilled Wells
If you use a weep hole for freeze Figure 33: Pitless Adapter System protection, omit this check valve to allow the pipe to drain. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 41... -
Page 42: Water Storage For Solar Water Pumps
Water Meter Check Valve (optional) (spring-loaded type) Water Well To Water Distribution System Monitoring Valve Pressure Sensor for (optional) Wireless Level Control page 42 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 43: Monitoring A Solar Pump System
A helical rotor pump will not drain back even if the check valve is removed. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 43... -
Page 44: Selecting And Using Meters For Electrical Testing
Always use the LOWEST range that produces a reading (RX1 is the lowest range). An “auto- ranging” meter will adjust its range automatically. page 44 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 45: Glossary Of Solar Electricity And Water Pumping
(or vice-versa). a tank to store water. Transformers work with AC only. For DC, see converter. Mechanical analogy: gears or belt drive. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 45... - Page 46 This is the term used to specify the production rate of the well. page 46 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems...
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Page 47: Calculating Pumping Efficiency And Power Requirement
2.31 ft vertical = 1 PSI. 10 m vertical = 1 bar. See pressure Head - Seevertical lift and total dynamic head. In water distribution, synonym: vertical drop. See pressure. Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 47... -
Page 48: System Wiring Diagram For Solar-Direct (Non-Battery) Systems
PV modules. The system here below is pump leads. Other combinations may cause reverse rotation! For wire size, typical for either PS200 (2 – 4 modules in please refer to sizing table. series), PS600 (4 – 6 modules in series), PS1200 (6 –... -
Page 49: System Wiring Diagram For Battery Systems
PS150 (1 – 2 batteries in series), please refer to sizing table. PS200 (2 – 4 batteries in series), PS600 (4-6 batteries in series), PS1200 (6 – 8 batteries in series), PS1800 (6 – 8 batteries in series). -
Page 50: System Report
82 °F to 108 °F 28 °C to 42 °C Class 4 100 °F to 126 °F 38 °C to 52 °C page 50 | v100820 Errors excepted and possible alterations without prior notice. Manual | LORENTZ PS Pump Systems... -
Page 51: Recent Updates
8, warning to remove transportation protection pag 48, new max. open-circuit voltage 17 Sept 2010 page 4f., extended warning section © 2010 LORENTZ Manual | LORENTZ PS Pump Systems Errors excepted and possible alterations without prior notice. v100820 | page 51...
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