Lorentz PS200 Instructions For Installation Operation Service
  1. Manuals
  2. Brands
  3. Lorentz Manuals
  4. Water Pump
  5. PS200
  6. Instructions for installation operation service

Lorentz PS200 Instructions For Installation Operation Service

Solar water pump systems
Hide thumbs Also See for PS200:
Table of Contents

Advertisement

Quick Links

See also: Installation Operation & Maintenance
PS200
PS600
PS1200
PS1800
SOLAR WATER
PUMP SYSTEMS
INSTRUCTIONS FOR
INSTALLATION
OPERATION
SERVICE
Bernt Lorentz GmbH & Co. KG
Heidekoppel 16
D-24558 Henstedt-Ulzburg
Germany
Tel.
++49.4193.7548-0
Fax
++49.4193.7548-29
www.lorentz.de
release 07/08/05

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PS200 and is the answer not in the manual?

Questions and answers

Related Manuals for Lorentz PS200

Summary of Contents for Lorentz PS200

  • Page 1 PS200 PS600 PS1200 PS1800 SOLAR WATER PUMP SYSTEMS INSTRUCTIONS FOR INSTALLATION OPERATION SERVICE Bernt Lorentz GmbH & Co. KG Heidekoppel 16 D-24558 Henstedt-Ulzburg Germany Tel. ++49.4193.7548-0 ++49.4193.7548-29 www.lorentz.de release 07/08/05...

  • Page 2: Table Of Contents

    Inspect The System ............................42 Electrical Testing ............................43 9.3.1 Table of AC running current for PS200 and PS600 systems ........................ 44 9.3.2 Table of AC running current for PS1200 systems ..........................44 If The Pump Runs But Flow Is Less Than Normal ..................46 Problem Report Form ...........................
  • Page 3 Contents continued MAINTENANCE ..............................54 10.1 Controller and Pump ............................ 54 10.2 Solar Array ..............................54 10.3 Electrical Wiring ............................54 MANUFAC-TURER’S WARRANTY ........................55 STANDARDS, ENVIRONMENTAL AND TEMPERA-TURE SPECIFI-CATIONS ............. 55 REFERENCE SECTION ............................56 13.1 Principles of Operation ..........................56 13.2 Water Pipe Sizing Chart ..........................

  • Page 4: Warnings

    WARNINGS Open circuit (no-load) voltage above 100V for Undersized wire will cause failure to start. PS200-, above 150V for PS600- and above (See Section 5.7.) 200V for PS1200 & PS1800 controllers will Install proper system grounding for safety destroy the controller. This may occur if the and lightning protection (See Section 5.2)

  • Page 5: System Report Form

    Quantity of Solar Modules (panels) Solar Module Brand Module Model # Controller Model PS1200 or PS1800 PS600 PS200 other, i.e.: Controller Serial # Pump End Model # Pump End Serial # Temperature Range Helical rotor pumps (without C in the model number) work optimally only in a specific See Section 12 temperature range.
  • Page 6 System Report Form continued Installation Report Installation Date Well Depth m / ft Pump depth m / ft Additional Vertical Lift (up to top of tank) m / ft Static Water Level m / ft Drawdown level m / ft Drop Pipe (vertical from the pump) Size / inch...
  • Page 7 System Report Form continued Performance Report When the pump is operating, record this data. This will help you to assess its performance and diagnose any problems that may occur in the future. Flow rate observed US-Gal./min / lpm Notes AC current through any one pump wire Amps (See Section 13.7) If these measurements were not taken...

  • Page 8: Introduction

    INTRODUCTION Thank you for purchasing a LORENTZ PUMP. We set a new standard for quality and economy in solar pumping. It incorporates the best solar pump technologies that were very expensive until its introduction in 2002. Before you begin Check the model numbers of all the components of your system, and verify that they are the items that you ordered.

  • Page 9: Photo Gallery

    PHOTO GALLERY A MODEL INSTALLATION A PS600 300Wp solar-direct system Colorado, USA This system was installed by students in a solar water pumping class. The array is set at summer tilt angle. The controller is mounted on the north side of the pole, directly under the array. This shades it from the hot mid-day sun.
  • Page 10 Owners of a domestic water system watch as the pump fills their polyethylene storage tank. The tank was buried later. Photo courtesy of Dankoff Solar Products, NM, USA A tracking solar array The mounting pipe was extended to 11 feet (3 m), by welding it to a larger pipe.

  • Page 11: Installing The Solar Array

    INSTALLING THE SOLAR ARRAY Location of the Solar Array 4.2 Solar Array Assembly Methods Sunlight is the “fuel” that drives a solar pump. There are two ways to install the solar array. Full solar exposure of the solar array is critical 1.

  • Page 12: Orienting The Solar Array To Solar South

    Orienting the Solar Array to Solar South For full performance, your solar array must be oriented within 10° of true (solar) south. Depending on your location, a compass reading may show an error of as much as 20°. To correct this discrepancy, apply the mag- netic declination for your region.

  • Page 13: Setting The Solar Array Tilt Angle

    Setting the Solar Array Tilt Angle Maximum performance is obtained from a Solar Array Tilt solar pump when its photovoltaic array is tilted Angles by t n i i t a t l i t l i e l i (elevated) to face the sun.

  • Page 14: Electrical Installation

    ELECTRICAL INSTALLATION Controller, Junction Box, and Conduit Location Place the controller close to the Electrical conduit is recommended We urge solar array, not the pump. This will reduce the you to use electrical conduit (pipe) to protect risk of lightning damage. outdoor wiring from the weather, from human activities, and from chewing animals.
  • Page 15 Controller, Junction Box, and Conduit continued Typical assembly of controller and junction box on the solar array mounting pole. Boxes are secured using slotted strut and conduit clamps. Mount the controller on the Bare ground wires bond the PV modules to north side of the the controller enclosure, and continue down to pole to reduce...

  • Page 16: Grounding And Lightning Protection

    Grounding and Lightning Protection Surges induced by lightning are one of the 4. If the soil is rocky and doesn’t allow ground most common causes of electronic controller rods to be driven, bury BARE copper wire in a failures in solar water pumps. Damaging trench at least 100 feet (30m) long.
  • Page 17 Grounding and Lightning Protection continued DO NOT GROUND the positive or the nega- Low water probe cable A long horizontal run tive of the power circuit. The best lightning of wire to the low-water probe at the pump protection results from grounding the metal- can pick up damaging surges from nearby lic structure only, and leaving the power lightning.

  • Page 18: Solar Array Wiring

    Solar Array Wiring The solar array can produce hazardous 2 types of PV module junction systems voltage even under low light exposure. To prevent shock hazard while wiring the array, leave one or more wires disconnected or cover it with opaque material. WARNING: The Solar-direct (non-battery) systems use a photovoltaic...

  • Page 19: Solar Array Disconnect Switch In The Junction Box

    Solar Array Disconnect Switch in the Junction Box The disconnect switch satisfies National Electrical Code requirements for a safety disconnect between the solar array and the controller. During installation and mainte- nance, switch off the disconnect switch to prevent shock and arc burn hazard. CAUTION Loose connections are a Disconnect Scwitch...

  • Page 20: Junction Box (Controller Input) Wiring

    Float Switch See Section 5.10, Automatic Do not connect any electrical load to the Control for Full-Tank Shutoff. A connection is solar array if it is not part of the LORENTZ made at the factory between terminals 4 and Pump system. Connection of a battery 5.

  • Page 21: Maximum Rpm Setting

    Maximum RPM Setting All PSXXX controller offer the option of 1. Remove the bottom end of the PS-XXX reducing the maximum speed of the pump. controller enclosure (the end with the conduit openings) This RPM control reduces the maximum speed (RPM limit) to as low as about 30%. It 2.

  • Page 22: Submersible Pump Cable And Splice

    Submersible Pump Cable and Splice Selection of cable Use only an approved Submersible Splice A splice kit includes type of submersible well pump cable, the crimp connectors to join the copper wires, same type that is used for conventional AC adhesive heat-shrink tubing, and instructions.

  • Page 23: Wiring Order For Correct Rotation

    Wiring Order for Correct Rotation The power wires on the pump are black with the direction is wrong, exchange ANY TWO of white lettering to indicate L1, L2 and L3. the power wires at the controller. In any case, WRITE DOWN the colors that you splice to when you are finished connecting the pump L1/ L2 / L3 so you can match them with the to the controller, test it to assure the proper...

  • Page 24: Low-Water Probe For Dry-Run Protection

    Low-Water Probe for Dry-Run Protection Installation The probe is packed with two Potential problems with the low-water stainless steel hose clamps. For a pump that probe in surface water The probe has a is to be installed in a vertical position, clamp it moving float.

  • Page 25: Automatic Control For Full-Tank Shutoff

    5.10 Automatic Control For Full-Tank Shutoff sealed We recommend the use of a float switch or Float switch cable require- cable clamp other means to prevent overflow of your tank. ments This will stop the pump when the tank is full, 1.
  • Page 26 Automatic Control For Full-Tank Shutoff continued If you are not using a float switch, terminals CAUTIONS for the wireless alternative 4 and 5 must be connected. Terminal 3 1. The pump system must be capable of remains disconnected. producing at least 25 PSI (60 feet, 18m) Operation of the float switch system When more than the full lift pressure.

  • Page 27: Battery-Based Systems

    48V SYSTEM: OFF at 44V ON at 48V or 48V , use a 25 amp circuit breaker ( PS200 A controller in disconnect mode can be reset or PS600 Systems) or a time-delay (slow manually by turning off/on, but it will quickly blow) fuse.

  • Page 28: Pressurizing Systems

    5.12 Pressurizing Systems LORENTZ PS-XXX Pump Systems are Pressure tank A pressure tank is required. excellent for automatic water pressurizing We recommend a captive-air pressure tank when powered by a battery system. If you are of 40 GALLONS (150 liters) OR MORE, to...
  • Page 29 Pressurizing Systems continued on the side). It is intended to prevent dry run (minimum #18 AWG) can be run to the of centrifugal pumps. The helical rotor pump pressure switch from a long distance. See types will maintain pressure even as it runs illustration below.

  • Page 30: Preparing To Install The Pump

    PREPARING TO INSTALL THE PUMP WARNINGS about Handling Helical Rotor Pumps WARNING (helical rotor mod- CAUTION (helical rotor mod- els) DO NOT APPLY MACHINE els) BEFORE INSTALLATION, GREASE TO THE PUMP. KEEP THE PUMP OUT OF THE Ordinary machine grease will SUN.

  • Page 31: Drop Pipe

    Drop Pipe PS-XXX Pump Systems can be installed CAUTION Do not assemble iron, using the same pipe components that are steel, or galvanized pipe used for conventional submersible pumps. components in metallic contact WARNING Do Use pipe with a sufficient pressure rating, with brass or copper.

  • Page 32: Safety Rope And Binding

    Safety Rope and Binding Safety rope can prevent loss of the pump. If Bind the submersible cable, the drop pipe breaks, the rope will prevent low-water probe wires and strain on the electrical cable and can be used safety rope to the pipe. to pull the pump out.

  • Page 33: Installation In A Surface Water Source

    Installation in a Surface Water Source This refers to a surface well, spring, pond, Depth of submersion PS-Pumps may be lake, river or tank. submersed as deep as necessary to ensure reliable water supply. The lift load on the Positioning the pump The pump CAUTION The pump is determined by the vertical head of may be placed in an inclined or...

  • Page 34: Deep Well Setting - How Deep

    Coping with Dirty Water Deep Well Setting — How Conditions Deep? PS-Pumps may be submersed as deep as PS-Pumps have good resistance to quanti- necessary to ensure reliable water supply. ties of sand and fine sediment that can The lift load on the pump is determined by normally occur in a well.

  • Page 35: Utilizing A Low-Production Water Source

    Utilizing a Low-Production Installing the Pump Under a Water Source Windmill or Hand Pump Cylinder PS-Pumps can make the best of a limited PS-Pumps can be combined with a classic water source, even if the pumping rate can water-pumping windmill or hand pump, to exceed the recovery rate.

  • Page 36: In-Well Assembly And Installation

    IN-WELL ASSEMBLY AND INSTALLATION SEE REFERENCE SECTION At the end of this manual (Section 13) you will find instruc- tions for wellhead assembly, water storage, control and monitoring of water supply, pipe sizing, freeze protection, and more. Rubber Spacers (Models -07, -10, -14, -20 only) This applies ONLY to models HR-07, 10, 14 and 20 (HR-07, 14 and 20 pump ends) Helical rotor pumps vibrate due to the eccen-...

  • Page 37: Machine Installation

    Machine Installation If you are professionally equipped to install WARNING Hand conventional AC submersible pumps, you can installation and use the same equipment and methods for removal is our pumps. PS-Pumps have no special pipe potentially requirements. You can use any suitable rigid hazardous.

  • Page 38: Sanitizing The Well

    Sanitizing the Well Sanitizing a well will kill bacteria that may have been introduced during the pump installation. This can be done with chlorine bleach or chlorine pellets poured down the well just before or just after a pump is installed.

  • Page 39: Operating The Pump

    OPERATING THE PUMP This explains the function of the switch and SWITCH the indicator lights on the pump controller. POWER ON/OFF When switched off/on during operation, it resets all system logic. Indicator lights SYSTEM (green) The controller is switched on and the power source is present.
  • Page 40 Operating the Pump continued Starting the pump Be sure there is not a Time delays closed valve or other obstruction in the water 1. After pump stops due to insufficient line. Switch on the array disconnect switch in sunshine – 120 SECONDS the junction box, and toggle the power switch 2.

  • Page 41: Trouble Shooting

    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, CAUTION DO page 3.) NOT REMOVE IF THE CONTROLLER MUST BE REMOVED THE CHECK FOR REPAIR OR REPLACEMENT Remove VALVE from the the wires and flexible conduit from the...

  • Page 42: Inspect The System

    Inspect The System Many problems can be located by simple must be able to move up to indicate that it inspection. No electrical experience is is submerged, and down to indicate that it required for this. is dry. Inspect the solar array 3.

  • Page 43: Electrical Testing

    Electrical Testing A “multimeter” is required and a clamp-on Test the motor circuit (resistance test with ammeter is helpful. For advice, see Section POWER OFF), cf. Test #7 13.7, Selecting and Using Meters for Electri- Make this test if there is proper voltage at the cal Testing.

  • Page 44: Table Of Ac Running Current For Ps200 And Ps600 Systems

    9.3.1 Table of AC running current for PS200 and PS600 systems t f i 9.3.2 Table of AC running current for PS1200 & PS1800 systems t f i...
  • Page 45 Electrical Testing continued 2. The total dynamic head (vertical lift plus To bypass the low-water probe (and activate pipe friction) may be higher than you think the pump), connect a small wire between the it is. probe terminals (Test #1 and Test #2) in the junction box.

  • Page 46: If The Pump Runs But Flow Is Less Than Normal

    If The Pump Runs But Flow Is Less Than Normal with debris, or out of its correct position. mechanism) may be worn from too much abrasive particles (sand or clay) in the 1. Is the solar array receiving shadow-free water. light? (It only takes a small shadow to stop it.) Is it oriented properly toward the south, 2.

  • Page 47: Problem Report Form

    Problem Report Form If you need help, this form will expedite Date the trouble shooting process. Please fill it in to the best of your knowledge. Contact Info Dealer Installer System Owner Person responsible for troube shooting How to contact Pump System ID Solar-direct or battery system? Solar-direct...
  • Page 48 There must be NO OTHER electrical load or device connected to the same solar array. This may include an active (electric) solar tracker ( LORENTZ active trackers can work together with our pumps) or an electric fence charger. Disconnect it and try it again.
  • Page 49 Problem Report Form continued Measure each pair L1-L2, L1-L3, L2-L3. These are the “three phases”. EACH READING MUST BE EQUAL. Wait until the pump is up to speed to check for equal. L1-L2 L1-L3 L2-L3 IF THE PUMP RUNS, make the following three tests. If not, skip to RESISTANCE MEASUREMENT below.

  • Page 50: Electrical Testing Illustrated

    Electrical Testing Illustrated These tests are extremely helpful when trying Range If your meter is “auto-ranging”, this to assess the performance of a system, or does not apply. Otherwise, use the range locate a fault. These procedures will help you than the reading you expect.
  • Page 51 Electrical Testing Illustrated continued Test 1 + 2 Test 2a PV discconnect PV discconnect switch ON switch OFF Test 3 Same as Test 1, but disconnect switched ON Test 4 Test 4a PV disconnect PV disconnect switch ON switch ON and pump running and pump running Remove one array wire and re-make the...
  • Page 52 Electrical Testing Illustrated continued Part 2 – Testing the pump circuit (AC and resistance) REFER TO THE NUMBERED PHOTOS ON THE FOLLOWING PAGE a l f a l f a l f " " t i u c i l t i u .
  • Page 53 Electrical Testing Illustrated continued Test 5 Test 6 Other tests Speed indication of Pump. See Section 9.2: By counting the ammount of flashes of the Pump ON LED Check the low- the RPM of the pump can be read off water probe and 900 RPM Pump ON LED is ON check the full-tank...

  • Page 54: Maintenance

    10 MAINTENANCE 10.1 Controller and Pump 10.3 Electrical Wiring Controller and junction box The controller Power wiring Inspect wires and connec- is electronic with no moving or wearing parts. tions carefully. Any wires that are hanging It requires no maintenance. There are rubber loose should be secured to prevent them from gasket seals at the top and bottom, and swinging in the wind.

  • Page 55: Manufac-Turer's Warranty

    11 MANUFAC- 12 STANDARDS, TURER’S ENVIRONMENTAL WARRANTY AND TEMPERA- TURE SPECIFI- CATIONS HR-xx Pumps, ECDRIVES and PS-xxx In all cases, it shall be the responsibility of controllers are warranted by the manufac- the customer to ensure a safe installation in turer to be free from defects in material compliance with local, state and national and workmanship for two (2) years from...

  • Page 56: Reference Section

    13 REFERENCE SECTION 13.1 Principles of Operation Solar array Photovoltaic (PV) cells produce array voltage and boosts the current). Under electricity directly from sunlight (not from low sun conditions, it stays in “low gear” to heat). Light causes electrons to jump from the resist stalling.
  • Page 57 500 have been used for solar pumping since the hours in the test 1980’s, but were very expensive until the lab. The surface LORENTZ helical rotor pump was intro- is almost like new, duced. and the pump performs to full...

  • Page 58: Water Pipe Sizing Chart

    13.2 Water Pipe Sizing Chart Don’t cheat yourself with undersized pipe! Use this chart to determine the additional head imposed on your pump due to pipe friction, based on flow rate, pipe size and pipe length. Consider the TOTAL pipe length from the pump to the pipe outlet to the tank.

  • Page 59: Wellhead Assemblies For Drilled Wells

    13.3 Wellhead Assemblies for Drilled Wells To support the drop pipe and seal the plug wellhead, choose one of these methods: electric cable check valve Well Seal System well These methods are NOT specific to solar seal pumps. The components are available from conventional water well suppliers.

  • Page 60: Water Storage For Solar Water Pumps

    13.4 Water Storage for Solar Water Pumps Storage Tank Capacity Generally, storage Pipe sizing The pipe from the pump to the capacity should equal 3 to 10 days of average tank may need to be larger than the pump water consumption, or more. This depends on outlet, depending on the flow and the length the climate and usage patterns.

  • Page 61: Monitoring A Solar Pump System

    13.5 Monitoring a Solar Pump System Monitoring the pump Will you be able to Monitoring the water level in your storage observe the output of your pump at the point tank Will you be able to observe the level of of discharge? If not, you may not know if it water in your tank? If you cannot easily see malfunctions.

  • Page 62: Selecting And Using Meters For Electrical Testing

    13.7 Selecting and Using Meters for Electrical Testing Most on-site trouble shooting requires a test (RX1 is the lowest range). An “auto-ranging” instrument called a multimeter which can be meter will adjust its range automatically. obtained from an electric supply, electronic Zero adjustment Some meters have a zero- WARNING Read supply, automotive or hardware store.

  • Page 63: Glossary Of Solar Electricity And Water Pumping

    13.9 Glossary of Solar Electricity and Water Pumping Basic Electricity used for large industrial motors, variable- speed motors, and brushless solar water pump motors. Analogy: 3-cylinder engine. AC - Alternating Current, the standard form Transformer - An electrical device that steps of electrical current supplied by the utility grid up voltage and steps down current proportion- and by most fuel-powered generators.
  • Page 64 Glossary of Solar Electricity and Water Pumping continued PV Array - A group of PV (photovoltaic) responds to changes in water level. It may be modules (also called panels) arranged to used to prevent overflow of a tank by turning a produce the voltage and power desired.
  • Page 65 Glossary of Solar Electricity and Water Pumping continued Pump Jack - A deep well piston pump. The transformer. Mechanical analogy: automatic piston and cylinder is submerged in the well transmission. Also called pump controller. water and actuated by a rod inside the drop See pump controller .
  • Page 66 Glossary of Solar Electricity and Water Pumping continued Well Seal - Top plate of a well casing that Total Dynamic Head - vertical lift + friction provides a sanitary seal and support for the loss in piping (see vertical lift and friction drop pipe and pump.

  • Page 67: Calculating Pumping Efficiency And Power Requirement

    Glossary of Solar Electricity and Water 13.10 Calculating Pumping Pumping continued Efficiency and Power Requirement Pressure Tank Precharge - The pressure This formula lets you calculate the wire-to- of compressed air stored in a captive air water energy efficiency of any electric pump- pressure tank.

  • Page 68: System Wiring Diagram For Solar-Direct (Non-Battery) System

    PV modules. The system here below is typical for either a PS200 (2-4 modules in Series) or PS600 (4-6 modules in Series) or PS1200 ( 6-8 modules in Series) or PS1800 (6-8 modules in series)

This manual is also suitable for:

Ps600Ps1200Ps1800

Table of Contents