SAJ PDS33 Series User Manual
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SAJ PDS33 Series User Manual

Solar pump controller
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PDS33 Solar Pump Controller
User Manual
Version code：6.0004.0358-00-PDS33-E-V03-1907

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Summary of Contents for SAJ PDS33 Series

  • Page 1 PDS33 Solar Pump Controller User Manual Version code：6.0004.0358-00-PDS33-E-V03-1907...

  • Page 2: Preface

    PDS33 Series Preface Thank you for using PDS33 series products. This manual provides you with relevant operation instructions and detailed description of parameters. Please read this manual carefully before installation, running, maintenance or inspection. Please make sure the wiring and the pump’s rotation direction is correct before using.

  • Page 3: Table Of Contents

    PDS33 Series Contents Preface......................... - 1 - Notes for Safe Operation..................- 5 - ■Before Installation.................... - 5 - ■ Installation...................... - 5 - ■ Operation......................- 6 - ■ Maintenance and check................. - 6 - ■ Others......................- 6 - Chapter 1 How It Works..................- 7 -...
  • Page 4 PDS33 Series 2.5.1 Outline &installation dimensions diagram........... - 16 - Chapter 3 Mechanical and Electrical Installation.........- 19 - 3.1 Mechanical Installation................- 19 - 3.1.1Overheat protection..................- 19 - 3.1.2 Location Selection..................- 19 - 3.2 Electrical Installation................. - 21 - 3.2.1 Terminals....................- 21 - 3.2.2 Power in DC Wiring................
  • Page 5 PDS33 Series 4.3 Trial operation.................... - 28 - 4.4 User Definable Parameters................ - 30 - Chapter 5 Diagnostics and Troubleshooting..........- 40 - 5.1 Fault Codes....................- 40 - 5.2 Common Faults and Remedies..............- 44 - Chapter 6 Protocol..................- 46 - 6.1 Address of control orders................

  • Page 6: Notes For Safe Operation

    PDS33 Series Notes for Safe Operation ■Before Installation WARNING Do not install or operate the controller which is damaged or has missing parts. Otherwise, it may result in equipment damage or life harm. ■ Installation CAUTION ◎ Hold the bottom of the controller when installing or moving the controller, you must just hold the shell，in order to prevent the injury or breaking of controller.

  • Page 7: Operation

    PDS33 Series ■ Operation CAUTION ◎ Do not open or remove the front cover during operation. Otherwise it may cause an electrical shock. ; you cannot make the pump dry-run for a long Before testing the pump must be installed ◎...

  • Page 8: Chapter 1 How It Works

    PDS33 Series Chapter 1 How It Works The PDS33 solar pumping system serves to provide water in remote applications where electrical grid power is either unreliable or unavailable. The controller can convert DC power from the PV array to AC power ， and drive variable kinds of pumps.
  • Page 9 PDS33 Series B. DC Breaker or Disconnecting Switch C. PDS33 series Solar Pump Controller D. Pump and Motor E. Water Source Level Switches (optional) F. Tank Level Switches (optional) The PDS33 solar pump controller runs at variable speed while matching the changing power provided by the solar array.

  • Page 10: Features

    PDS33 Series 1.1 Features System Diagnostics The PDS33 solar pump controller continuously monitors system performance and detects 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.
  • Page 11 PDS33 Series The PDS33 solar pump controller’s input power terminal may be switched manually to a backup AC power source. Note: Depending on the model number, PDS33 solar pump controllers support power input either 220VAC single phase, or 380VAC three phase, Please contact controller manufacturer or authorized agencies for details.

  • Page 12: Chapter 2 General Information

    PDS33 Series Chapter 2 General Information The PDS33 solar pump controller is a variable speed motor drive designed to run any IEC three-phase asynchronous motors. The PDS33 solar pumping system provides water to remote locations by converting high voltage, direct current from a solar array into alternating current to run a standard three-phase asynchronous motor.

  • Page 13: Protection Features

    PDS33 Series a solar array or an optional AC generator backup. The PDS33 solar pump controller continuously monitors system performance and incorporates a number of features for pumping system protection. In the event of a fault, the PDS33 solar pump controller will indicate the type of fault through the LED display mounted on the front cover of controller.

  • Page 14: Pds33 Solar Pump Controller Model Description

    PDS33 Series 2.4 PDS33 Solar Pump Controller Model Description 2.4.1 Model Description PDS33 - 4 T 5R5 ① ② ③ ④ ⑤ Segment Description Options PDS series ① 3: Series of 3rd generation. Series ID ② 3: Apply to three-phase induction motor Rated Output 2: 220V three phase;...

  • Page 15: Pds33 Solar Controller Input And Output Data

    PDS33 Series 2.4.3 PDS33 Solar Controller Input and Output Data PDS33-2SXX/4TXX Input and Output Data Controller Model PDS33-2S2R2 PDS33-4T2R2 PDS33-4T004 PDS33-4T5R5 Input Data Max Input Voltage(Voc) DC 450V DC 800V Recommended Voltage, at MPP DC 275-380V DC 500-750V 2.7～3.5 2.7～3.5 4.8～6.4...
  • Page 16 PDS33 Series Controller Model PDS33-4T022 PDS33-4T030 PDS33-4T037 PDS33-4T045 Input Data Max Input Voltage(Voc) DC 800V Recommended Voltage, at MPP DC 500-750V Recommended PV Array Power[kW] 26.4～35.2 36～48 44～59.2 54～72 Alternate AC Generator Input Voltage Three Phase AC 380V(±15%) Max Amps(RMS)[A] 46.5...

  • Page 17: Outline &Installation Dimensions

    PDS33 Series 2.5 Outline &Installation Dimensions 2.5.1 Outline &installation dimensions diagram Figure 2 2.2kW-7.5kW Outline Dimension Outline Dimension Installation Dimension Hole Size Type PDS33-2S2R2 PDS33-4T2R2 PDS33-4T004 PDS33-4T5R5 PDS33-4T7R5 - 16 -...
  • Page 18 PDS33 Series Figure 3 11kW-37kW Outline Dimension Outline Dimension Installation Dimension Hole Size Type PDS33-4T011 PDS33-4T015 PDS33-4T18R5 PDS33-4T022 PDS33-4T030 PDS33-4T037 - 17 -...
  • Page 19 PDS33 Series Figure 4 45kW-110kW Outline Dimension Outline Dimension Installation Dimension Hole Size Type PDS33-4T045 PDS33-4T055 PDS33-4T075 PDS33-4T093 PDS33-4T110 - 18 -...

  • Page 20: Chapter 3 Mechanical And Electrical Installation

    PDS33 Series Chapter 3 Mechanical and Electrical Installation 3.1 Mechanical Installation 3.1.1Overheat protection Install the PDS33 solar pump controller in a control box with control terminals and power wiring. Install the control box out of direct sunlight to prevent overheating and reduced performance.
  • Page 21 PDS33 Series The PDS33 solar pump controller must be installed into a control box which has a tight enclosure to avoid direct sunshine, rain, dust, moisture, animals, plants, etc. The control box should have a bottom gland plate for installing wire cord or conduit.

  • Page 22: Electrical Installation

    PDS33 Series 3.2 Electrical Installation 3.2.1 Terminals The following are typical figures of terminal blocks. Note: Terminals are different in shapes and combinations, depending on different sizes of PDS33 Solar Controllers. Pump AC INPUT PowerIn The DC and AC can't...

  • Page 23: Power In Dc Wiring

    PDS33 Series 3.2.2 Power in DC Wiring For Solar Pumping Systems, a two-pole DC disconnecting switch must be installed between the solar array and the PDS33solar pump controller. Connect the cables which comes from the two-pole DC disconnect Switch downstream terminals marked with “+” and “-” (positive and negative poles of Solar panel output), to PDS33 solar pump controller’s terminals block labeled as...

  • Page 24: Ground Wiring

    PDS33 Series 3.2.4 Ground Wiring Ground terminal (GND) is labeled as this icon . Please refer to the instruction to this icon, or other equivalent icon or sign by local electrical codes or international standard. Correct grounding helps to prevent shock hazard if there is a fault in the motor.

  • Page 25: Water Tank Level Float Wiring (Optional)

    PDS33 Series 3.2.7 Water tank level float wiring (optional) Use a floating ball switch to prevent reservoir overflow is recommended. When the reservoir is full, the pump will stop; when the water level is lower than the low level, the pump will be restarted. It can prevent the overflow, limit the unnecessary pump wear.

  • Page 26: Electrical Conduit

    PDS33 Series 3.2.8 Electrical conduit When the system installed in the outdoor, electrical conduit can be used to protect the outdoor electric wires, so as to avoid the impact from the weather, human activities, chewing animals. If you do not use the electrical conduit, use the higher quality outdoor wire.

  • Page 27: Chapter 4 Start-Up And Operation

    PDS33 Series Chapter 4 Start-up and Operation 4.1 Keypad Description Figure 12 Keypad Schematic Diagram Item Name Function HZ: Frequency unit； A：Current unit； V：Voltage Unit indicator light unit； RPM（Hz+A）：Speed unit；%（A+V）：Percentage RUN: On/Running；Off/Stopped Indicator FWD/REV： On/FWD； Off/REV； Flickering/Switching light between FWD & REV Status indicator light TUNE/TC：Flickering /Fault status...

  • Page 28: Keypad Operation Process

    PDS33 Series Item Name Function In the stop display interface and the running display interface, the display parameters can be selected >>（Shift key） cyclically; when the parameters are modified, the modified bits of the parameters can be selected. In keypad control mode，it can start the controller...

  • Page 29: Fault Reset

    PDS33 Series 4.2.2 Fault Reset After the controller has failed, the controller will display the relevant fault code information. The conventional fault code (Err02/3/4/5/6/7/8/9/10/11/12/18) can automatically reset after 10s operation, and can also choose to reset the STOP/RESET on the keyboard. If the conventional failure persists, the controller will reset once every 10s.
  • Page 30 PDS33 Series If the pump is in dry-run, the maximum operating time cannot exceed 15seconds; otherwise it may cause damage to the pump. If the pump steering error, close the DC switch, according to the pump / motor wiring to change the wiring of the motor section of the two leads.

  • Page 31: User Definable Parameters

    PDS33 Series 4.4 User Definable Parameters ○：The parameters can be modified at stop or running status. ●：The parameters cannot be modified at running status. ◎ ： The parameters which are actual-detecting record value and cannot be modified. Function Factory Modification...
  • Page 32 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address frequency type Acceleration Due to F0.18 0.0s ～ 6500.0s 0.1s F012 ○ time 1 type Deceleration Due to F0.19 0.0s ～ 6500.0s 0.1s F013 ○ time 1...
  • Page 33 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address Function of 9： Error Reset （ RESET） F5.02 F502 ● 11：External error input （NO） Function of F5.03 F503 ● 44：Input of well low level Function of F5.04...
  • Page 34 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address protection gain Early warning coefficient of FA.02 50% ～ 100% FA02 ○ motor overload protection Gain of over FA.03 voltage stall 0 ～ 100 FA03 ○...
  • Page 35 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address 0：(8.N.2)no check 1：(8.E.1) even check FC.02 Data bit check FC02 ○ 2：(8.O.1) odd check 3：(8.N.1) no check Communicatio FC.03 n response 0ms ～ 20ms FC03 ○...
  • Page 36 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address Water shortage FD.10 0.0s ～3600.0s 0.1s 0.0s FD0A ○ detect time Water shortage FD.11 detect 1.00Hz ～ F0.12 0.01Hz 45.00Hz FD0B ○ frequency Water shortage FD.12 detect current 0.0% ～...
  • Page 37 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address FD.24 MPPT flag FD18 ◎ MPPT FD.25 0.0V～1.0V 0.1V ○ FD19 voltage added FE Group：Parameters management FE.00 User password 0 ～ 65535 FE00 ○ Fault FE.01 record display 0 ～...
  • Page 38 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address 16：Communication abnormal（Err16） 17： Relay failure （ Err17） 18：Current detection failure（Err18） 19：Motor tuning failure （Err19） 21： Parameters writing & reading failure（Err21） 22：EEPROM checking failure（Err22） 23：Motor short to ground（Err23）...
  • Page 39 PDS33 Series Function Factory Modification Communicati Function Description Unit Code setting Type on Address current fault Controller’s E0.07 status record of E007 － － － ◎ current fault Time record of current fault E0.08 E008 （Calculated － － － ◎...
  • Page 40 PDS33 Series will still run FD.10 time, after that it will appear the water shortage fault Err24.The fault will be reset and the controller will restart automatically after 20 minutes. If there is no water shortage but fails Err24, it may appear false; then you can simply reduce FD.12 value.

  • Page 41: Chapter 5 Diagnostics And Troubleshooting

    PDS33 Series Chapter 5 Diagnostics and Troubleshooting The PDS33 solar pump controller will attempt to drive 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.
  • Page 42 PDS33 Series Fault Fault description Possible causes Remedy code Replace with higher-rating Lower-rating controller controller Abnormal input voltage Check input power Over-voltage during Err05 Restart the motor when Avoid prompt restart when acceleration instantaneous trip-off occurs trip-off Too-fast deceleration Add proper braking units...
  • Page 43 PDS33 Series Fault Fault description Possible causes Remedy code Power board or control board Look for technical support failure Broken wires in the output cable Broken wires in the motor Check the wiring and Err13 Output phase loss winding installation...
  • Page 44 PDS33 Series Fault Fault description Possible causes Remedy code Power circuit abnormal Motor tuning Incorrect settings of motor Set motor parameters Err19 failure parameters according to motor plate Parameters writing Change another board or Err21 Control board failure. & reading failure...

  • Page 45: Common Faults And Remedies

    PDS33 Series Fault Fault description Possible causes Remedy code fault Keypad failure Look for technical support 5.2 Common Faults and Remedies Fault Order Possible cause Remedy phenomenon Check whether input voltage is in Abnormal input voltage normal range Poor contact between...
  • Page 46 PDS33 Series Fault Order Possible cause Remedy phenomenon Replace the air switch (without Installed leakage switch leakage) or replace the air switch or air switch overload with a larger capacity Switch trip Check input power and eliminate Abnormal input power...

  • Page 47: Chapter 6 Protocol

    PDS33 Series Chapter 6 Protocol The PDS33 series product provides an RS485 communication interface and supports the MODBUS-RTU communication protocol. The users can set the inverter to start and stop, modify or read the function code parameters, and read the working status and fault information of the inverter.
  • Page 48 PDS33 Series DO flag 1009H AI1 voltage 100AH 0.01V AI2 voltage 100BH 0.01V Set voltage 100CH 0.1V PV input power 100DH 0.01kW PV input current 100EH 0.1A Motor speed 100FH 1rpm Inverter temperature 1010H 1℃ Set frequency 1011H 0.01Hz Max frequency 1012H 0.01Hz...

  • Page 49: Description Of Controller's Status And Faults

    PDS33 Series 6.3 Description of controller’s status and faults Communication Attributes of Description Command content address read or write 0001：FWD running 0002：REV running 0003：Stand-by Controller’s 3000H status 0004：Fault 0005：Under voltage 0006：Exchanging between 0000：No error 0001：Reserved 0002 ：Over current during acceleration 0003 ：Over current during...
  • Page 50 PDS33 Series Communication Attributes of Description Command content address read or write 0012 ： Current detection failure 0013：Motor tuning failure 0015： Parameters writing & reading failure 0016 ： EEPROM checking failure 0017 ： Motor short to ground 0018: Water shortage 001A ：...

  • Page 51: Chapter 7 Regular Maintenance

    PDS33 Series Chapter 7 Regular maintenance Controller and Pump • Controller Periodically checking of Status display, error code display and fault record, long term verification of cooling fan and cleaning of heat sink are needed. • Pump The pump’s motor is permanently sealed, no need to maintain. Pump head is a...

  • Page 52: Chapter 8 Backup Ac Power

    PDS33 Series Chapter 8 Backup AC power In order to ensure continuous water supply, solar water pump system can be manually switched to standby AC power supply when the light is insufficient or wet days. When switching, the need to ensure that the DC and AC power supply reliable mutual lock.
  • Page 53 PDS33 Series If the pump motor rated voltage is three-phase AC 220-240V, then the single-phase AC 220V standby power supply L/N power line, need to be connected to the main terminal R/T of the controller - 52 -...
  • Page 54 PDS33Series System Report System and Components Date of Purchase Distributor (Contact details) System Controller Serial Number Motor Serial Number or Power Pump Type Submersible Surface Solar Power Solar Module Manufacturers Type Peak Voltage(Vmp） Open Circuit Voltage(Voc) Quantity Connection Series Parallel - 53 -...
  • Page 55 PDS33Series Installation Installation Date Installer (contact details) Submersible Pump Surface Pump Well Depth m/ft Head m/ft (self suction) Pump Depth m/ft Suction lift m/ft Vertical Height (well m/ft mouth to the tower top) MAX. Suction m/ft lift Static Water Level m/ft Dynamic Water Level m/ft...
  • Page 56 PDS33Series - 55 -...

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