Lorentz PS2 Troubleshooting Manual

Pump controller

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Version: V210126

Guide for troubleshooting for PS2 pump controller

Troubleshooting guide

for

PS2 pump controller

BERNT LORENTZ GmbH

Siebenstücken 24, 24558 Henstedt-Ulzburg, Germany,

Tel (+49) 0 4193 8806-700, www.lorentz.de

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All specifications and information are given with good intent, errors are possible and products may be subject to change without notice.

Pictures may differ from actual products depending on local market requirements and regulations.

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Summary of Contents for Lorentz PS2

Page 1 Version: V210126 Guide for troubleshooting for PS2 pump controller Troubleshooting guide PS2 pump controller BERNT LORENTZ GmbH Siebenstücken 24, 24558 Henstedt-Ulzburg, Germany, Tel (+49) 0 4193 8806-700, www.lorentz.de Page 1 / 31 All specifications and information are given with good intent, errors are possible and products may be subject to change without notice.
Page 2 How to check whether there is a short circuit on the controller board input? ........12 6.3. How to check the PV Generator ......................13 6.4. How to check the power supply in the PS2 controller ................15 6.5. How to check the MOSFETs in PS2 controller ..................18 6.6.
Page 3 Version: V210126 Guide for troubleshooting for PS2 pump controller 2. Safety instruction READ AND FOLLOW ALL INSTRUCTIONS! RETAIN THESE INSTRUCTIONS FOR FUTURE USE! • Personnel qualification and leakage of hazardous material; • Unauthorized changes and training – All personnel must danger of damage to equipment and buildings.
Page 4 PS2 pump system shows abnormal behavior, the first step would be using PumpScanner for Android® to check the actual status of the PS2 controller for any actual fault codes. Please see the picture below to get familiar with the different PCBs that are found inside a PS2 controller: Main-Board ∙...
Page 5 The first recommendation is to simplify the installed system before starting a troubleshooting focused on the controller. This means for example for the PS2 controller: Disconnect all the accessories from the controller and install a jumper instead to minimize external influences on the problem: •...
Page 6 Version: V210126 Guide for troubleshooting for PS2 pump controller products (as well as replacement boards) will not just avoid unnecessary site visits it will also speed up the troubleshooting process: The faulty component in a pump system can be identified much faster if a spare component is available for instant cross-checks.
Page 7 • Check the PV Generator → Chapter 6.3 on page 13 • Check the Power Supplies in the PS2 controller → Chapter 6.4 on page 15 • Check the MOSFETS on the Power-Board →Chapter 6.5 on page 18 Connection with PumpScanner Connect with PumpScanner and check the actual data section: •...
Page 8 Version: V210126 Guide for troubleshooting for PS2 pump controller 5. PumpScanner error codes The following table shows all errors which could be displayed in PumpScanner. Possible actions are listed which you can perform to troubleshoot. 5.1. Pump off reason: Description Explanation and Action The controller detected an open connection between terminal 1 and 2.
Page 9 Version: V210126 Guide for troubleshooting for PS2 pump controller and go into the “Operational Settings” section. Deactivate the “Pump OFF” checkbox in the section “Pump Speed” to run the pump system again. The Pump System stops because the measured irradiation value is below the set min.
Page 10 Version: V210126 Guide for troubleshooting for PS2 pump controller 5.2. Advanced information: Description Explanation and Action Analog Input 1 The sensor connected to Analog input 1 is delivering data out of the error specifications (current signal). Follow the step-by-step guide in chapter 0 on page 26 to identify whether the error is generated by the sensor or the controller.
Page 11 Version: V210126 Guide for troubleshooting for PS2 pump controller 6. How-to articles These how-to articles give a quick overview of how the testing procedures need to be done properly. 6.1. How to connect with the controller using PumpScanner PumpScanner is available on PartnerNET (www.lorentz.de/psdl). For further information read the Manual and User Guide of PumpScanner on PartnerNET (Support →...
Page 12 If the voltage of the PV Generator raises to the expected level, replace the Power-Board. If the voltage is still close to zero, the defective product is not the PS2 controller. Please check the PV Generator completely (wiring/each module Voc, Isc/…).
Page 13 6.3. How to check the PV Generator Open the PS2 housing to check the input voltage. This test will check the configuration of the PV Generator. There are holes in the terminal clamps, which can be used for test prods.
Page 14 Version: V210126 Guide for troubleshooting for PS2 pump controller This table shows the max. allowed voltage for each PS2 controller type as well as the min. voltage which is necessary to reach the max. speed: PS2 pump controller Min. voltage for max. speed Max.
Page 15 Version: V210126 Guide for troubleshooting for PS2 pump controller 6.4. How to check the power supply in the PS2 controller The PS2 controller uses three different voltage levels: • 15 V level on the Power-Board o Powered by the PV •...
Page 16 Version: V210126 Guide for troubleshooting for PS2 pump controller • Insert the red measuring tip (+) into the right pin (+) on the LED-Board as shown in the picture • Insert the black measuring tip (COM) into the fourth pin from the right hand...
Page 17 Version: V210126 Guide for troubleshooting for PS2 pump controller • Remove all additional cables which are connected to accessories • Bend the jumper cable up or remove the jumper cable to secure a proper contact between the terminal clamp and the test prods •...
Page 18 6.5. How to check the MOSFETs in PS2 controller Due to the design of the PS2 controller it is not possible to reach the MOSFETs directly with the test prods of your multimeter. The following test shows an easy way to check the MOSFETs.
Page 19 Version: V210126 Guide for troubleshooting for PS2 pump controller • Disconnect the ribbon cable which connects the Power-Board to the Main- Board • Configure your multimeter o Choose resistance – measurement o Insert the test prods into its provided sockets (black to COM &...
Page 20 Version: V210126 Guide for troubleshooting for PS2 pump controller • First step: check whether there is a short circuit between the (+) terminal and L1, L2 or L3 (check proper polarity). • Second step: o contact the measuring tip to the right MOSFET-leg (T7 –...
Page 21 Version: V210126 Guide for troubleshooting for PS2 pump controller 6.6. How to check Well Probe/Remote Switch input and the sensors The following test procedure identifies reasons why the pump stopped indicating Source Low and Remote Switch. If the pump off reason for the controller is “Source low”, you’ll just need to perform the test for the Source low sensor and source low input (T1 + T2).
Page 22 Version: V210126 Guide for troubleshooting for PS2 pump controller • Reconnect the PV Generator • Reconnect PumpScanner with the controller • Check whether the pump off reason still exists If the pump off reason still exists, you need to replace the IO-board. If the replacement has not resolved the failure, please replace the Main-Board as well because in this case the IO-board was not able to protect the Main-Board.
Page 23 Version: V210126 Guide for troubleshooting for PS2 pump controller • Connect the grabber clip to the Well probe cable/Remote Switch cable • Check whether the switch is open or closed If the connection between the sensor cables is an open loop, check whether this is a reasonable result (e.g.
Page 24 Version: V210126 Guide for troubleshooting for PS2 pump controller 6.7. How to check the Surge Protector (Sensors) A defective Surge Protector could cause a stopping pump controller. “Source low” or “Remote Switch” are plausible Pump-Off reasons. The following guide shows step-by-step how to check the Surge Protector in its two versions: •...
Page 25 Version: V210126 Guide for troubleshooting for PS2 pump controller Surge Protector version 1 • Check the resistance between the NO/NC and the opposite wire and the COM and the opposite wire • Both resistance values should be approx. 100Ω •...
Page 26 Version: V210126 Guide for troubleshooting for PS2 pump controller Surge Protector Version 2 • Similar to the previous version check the resistance between the negative - wire (black) and the opposite terminal then positive + wire (red) and its opposite terminal.
Page 27 The following guide will evaluate whether a wrong value is generated by the sensor or by the controller. For this test a proper 15 V/24 V power supply is needed. Secure that the PS2 controller supplies the power properly by performing the following steps: •...
Page 28 Version: V210126 Guide for troubleshooting for PS2 pump controller If a proper voltage is present, the validity of the sensor needs to be confirmed. The analog input of the controller uses 4-20 mA signals. Therefore, the current needs to be checked. The current is measured in series as shown in the following connection overview: •...
Page 29 After the current has been measured it needs to get converted into the “real” value (pressure). Identify the min. and max. value of the sensor using the datasheet. Since the PS2 controller uses 4 – 20 mA signals the value 4 mA is related to the min. value and the value 20 mA is related to the max.
Page 30 Version: V210126 Guide for troubleshooting for PS2 pump controller 6.9. How to check the resistance of the motor phases • Configure your multimeter o Choose resistance – measurement o Test prods into its provided sockets (black to COM & red to Ω)
Page 31 Version: V210126 Guide for troubleshooting for PS2 pump controller 6.10. How to check the isolation of the motor Different to the motor phase measurement it is important to use an isolation test device. This device can measure the resistance at a high voltage level.

This manual is also suitable for:

Ps2-150 Ps2-200 Ps2-600 Ps2-1800 Ps2-4000