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PS200PS600PS1200
INSTRUCTIONS FORINSTALLATIONOPERATIONSERVICE
For more information please contact your installer or:
Dankoff Solar Products, IncSanta Fe, NM 87507
Tel. 505-473-3800Fax 505-473-3830
Tel. ++49.4193.7548-0Fax ++49.4193.7548-29
release 05/01/10
SOLAR WATERPUMP SYSTEMS
2
1 WARNINGS .......................................................................................................................................................... 4
2 SYSTEM REPORT FORM ..................................................................................................................................... 5
3 INTRODUCTION ................................................................................................................................................... 8
PHOTO GALLERY ......................................................................................................................................................... 9
4 INSTALLING THE SOLAR ARRAY....................................................................................................................... 11
4.1 Location of the Solar Array ............................................................................................................................ 114.2 Solar Array Assembly Methods ..................................................................................................................... 114.3 Solar Array Mounting Rack ............................................................................................................................ 114.4 Orienting the Solar Array to Solar South ....................................................................................................... 124.5 Setting the Solar Array Tilt Angle ................................................................................................................... 13
5 ELECTRICAL INSTALLATION ............................................................................................................................. 14
5.1 Controller, Junction Box, and Conduit .......................................................................................................... 145.2 Grounding and Lightning Protection ............................................................................................................ 165.3 Solar Array Wiring .......................................................................................................................................... 185.4 Solar Array Disconnect Switch in the Junction Box ...................................................................................... 195.5 Junction Box (Controller Input) Wiring .......................................................................................................... 205.6 Maximum RPM Setting .................................................................................................................................. 215.7 Submersible Pump Cable and Splice .......................................................................................................... 225.8 Wiring Order for Correct Rotation ................................................................................................................. 235.9 Low-Water Probe for Dry-Run Protection ..................................................................................................... 245.10 Automatic Control For Full-Tank Shutoff ....................................................................................................... 255.11 Battery-Based Systems ................................................................................................................................ 275.12 Pressurizing Systems .................................................................................................................................. 28
6 PREPARING TO INSTALL THE PUMP ................................................................................................................ 30
6.1 WARNINGS about Handling Helical Rotor Pumps ...................................................................................... 306.2 Drop Pipe ...................................................................................................................................................... 316.2 Safety Rope and Binding .............................................................................................................................. 326.4 Installation in a Surface Water Source ......................................................................................................... 336.5 Deep Well Setting — How Deep? ................................................................................................................ 346.6 Coping with Dirty Water Conditions ............................................................................................................. 346.7 Utilizing a Low-Production Water Source ..................................................................................................... 356.8 Installing the Pump Under a Windmill or Hand Pump Cylinder .................................................................. 35
7 IN-WELL ASSEMBLY AND INSTALLATION ........................................................................................................ 36
7.1 Rubber Spacers (Models -07, -10, -14, -20 only) ......................................................................................... 367.2 Machine Installation ...................................................................................................................................... 377.3 Hand Installation ........................................................................................................................................... 377.4 Sanitizing the Well ........................................................................................................................................ 38
8 OPERATING THE PUMP ..................................................................................................................................... 39
9 TROUBLE SHOOTING ........................................................................................................................................ 41
9.1 If The Pump Doesn’t Run ............................................................................................................................. 419.2 Inspect The System ...................................................................................................................................... 429.3 Electrical Testing ........................................................................................................................................... 439.3.1 Table of AC running current for PS200 and PS600 systems ................................................................................................................ 449.3.2 Table of AC running current for PS1200 systems .................................................................................................................................. 449.4 If The Pump Runs But Flow Is Less Than Normal ...................................................................................... 469.5 Problem Report Form ................................................................................................................................... 479.6 Electrical Testing Illustrated ......................................................................................................................... 50
Contents
3
Contents continued
CAUTIONrecommended to avoid disfunc-tion or premature ageing of thepump etc.
WARNINGdisregard might lead to injury ordamage the installation
QUESTION AND ANSWERgives explanation
ADVICE
Symbols
10 MAINTENANCE .................................................................................................................................................. 54
10.1 Controller and Pump .................................................................................................................................... 5410.2 Solar Array ..................................................................................................................................................... 5410.3 Electrical Wiring ............................................................................................................................................ 54
11 MANUFAC-TURER’S WARRANTY ...................................................................................................................... 55
12 STANDARDS, ENVIRONMENTAL AND TEMPERA-TURE SPECIFI-CATIONS ..................................................... 55
13 REFERENCE SECTION ....................................................................................................................................... 56
13.1 Principles of Operation ................................................................................................................................. 5613.2 Water Pipe Sizing Chart ................................................................................................................................ 5813.3 Wellhead Assemblies for Drilled Wells ....................................................................................................... 5913.4 Water Storage for Solar Water Pumps ......................................................................................................... 6013.5 Monitoring a Solar Pump System ................................................................................................................. 6113.6 Freeze Protection for Solar Water Pumps .................................................................................................... 6113.7 Selecting and Using Meters for Electrical Testing ....................................................................................... 6213.8 Measuring Solar Energy Intensity ................................................................................................................. 6213.9 Glossary of Solar Electricity and Water Pumping ........................................................................................ 6313.10 Calculating Pumping Efficiency and Power Requirement ........................................................................... 6713.11 System Wiring Diagram for Solar-direct (non-battery) System .................................................................... 68
4
Open circuit (no-load) voltage above 100V forPS200-, above 150V for PS600- and above200V for PS1200 controllers will destroy thecontroller. This may occur if the solar array iswired incorrectly. (See Solar Array Wiring,Section 5.3.)
Do not attempt to run the Motor without thePSXXX controller.
Do not attempt to use the controller for anypurpose other than LORENTZ PS-PumpSystems.
To be installed, connected and serviced byqualified personnel only. Ensure all powersources are disconnected when makingconnections. Follow all appropriate electricalcodes. There are no user serviceable partsinside the motor or the controller.
Solar pumps run at low flow rates, and havecloser tolerances than conventional pumps.Extreme sand or silt concentration (greaterthan 2% by volume) may cause the pump tostop, or the pipe to fill with sand. Do not usethe pumps to clean out a dirty well. (SeeSection 6.6. for advice about dirty water.)
Helical rotor pumps are sensitive to heat.Protect the pump from sunshine or othersource of heat, or it may lock temporarily. Ifthe water source is, or will be warmer than72° (22°C), a special model may be required.(See Section 6.4.)
Undersized wire will cause failure to start.(See Section 5.7.)
Install proper system grounding for safetyand lightning protection (See Section 5.2)
Do not touch the controller input or pumpwires together to test for a spark.
Do not run the pump dry. Exception: to testdirection of rotation, for maximum 15 seconds(See Section 5.8)
Test the direction of motor rotation beforeinstalling the pump (counter-clockwise lookingdown). If direction is reversed, exchange theconnection of any two of the three powerwires to the pump. (See Section 5.8)
When pump is stopped by a shadow or byaction of float switch, it will restart after a 120seconds.
The low water probe must be submersed, orthe pump will stop for 20 minutes. If the probeis not to be used, connect the probe terminalstogether in the junction box. (See section 5.5and 5.9)
Helical rotor models (without a C in the model#) are not self-draining. If drainage is requiredfor freeze-protection, install a weep hole ordraining device below freeze level. SeeSection 13.6 Do not remove the check valvein attempt to make it self-drain.
1 WARNINGS
Failure to followthese instruc-tions will voidthe warranty.
Install this system in accordance with localregulations and accepted codes of profes-sional practice.
This manual is the property of the LORENTZPump owner.
Please give it to the owner or maintenancepersonnel when you are finished!
Request copies from your pump supplier ordownload from www.Lorentz.de
This manual is for controller modelsPS1200, PS600, PS200 as illustrated on thecover. For earlier models (before July 2003)refer to Version 1 and 2
Copyright © 2002-2004 by BERNT LORENTZGMBH & CO KG and DANKOFF SOLARPRODUCTS, INC. All rights reserved
5
2 SYSTEM REPORT FORM
System and Components
System Voltage V
Date of Purchase
Purchased from
Battery System? yes no
if not: Quantity of Solar Modules (panels)
Solar Module Brand
Module Model #
Controller Model PS1200
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 specifictemperature range. Last digit of Pump End Model # indicates temperature class.If a special temperature range was not specified, the last digit of model number (X) will be 1.
Class 0 32 °F to 54 °F 0 °C to 12 °C
Class 1 46 °F to 72 °F 8 °C to 22 °C Class 1 is the standard class.
Class 2 64 °F to 90 °F 18 °C to 32 °C
Class 3 82 °F to 108 °F 28 °C to 42 °C
Class 4 100 °F to 126 °F 38 °C to 52 °C
See Section 12for more abouttemperaturespecifications.
6
Installation Report
Installation Date
by
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 mm2 / inch
Type
Length m / ft
Additional Pipe Length (to tank)
Size mm2 / inch
Type
Length m / ft
Submersible Pump Cable
Wire size mm2 / AWG
Total Length (controller to pump) m / ft
MAX RPM CONTROL
(See Section 5.6) Factory setting is Maximum.
If this setting was reduced, enter setting here:
System Report Form continued
yes no
7
System Report Form continued
Performance Report
When the pump is operating, record this data. This will help you to assess its performance anddiagnose 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 takenat full vertical lift, note here
8
Thank you for purchasing a LORENTZPUMP. We set a new standard for quality andeconomy in solar pumping. It incorporatesthe best solar pump technologies that werevery expensive until its introduction in 2002.
Before you begin Check the model numbersof all the components of your system, andverify that they are the items that you ordered.Also check against the PUMP specificationsand performance charts (end of this manual)to be sure the system is appropriate for yourapplication. If you expect to pump water thatis very cold or very warm, check the “tempera-ture range” specifications (Section 12). If youthink you may have the wrong pump for yourapplication, call your supplier immediately.
Please fill in the SYSTEM REPORT. This willbe essential information if any problemsoccur.
This manual covers two types of systems,battery and solar-direct. If you purchasedthe Pump to connect to a battery system, youcan skip the sections about the solar arrayand solar-direct systems.
REFERENCE SECTION (Section 13) ManysInstallers are new to solar pumping, so weprovide helpful information—principles ofoperation, instructions for wellhead assem-bly, water storage, control and monitoring ofwater supply, pipe sizing, freeze protection,and a glossary of technical terms.
3 INTRODUCTION
9
PHOTO GALLERY
A MODEL INSTALLATIONA PS600 300Wp solar-direct systemColorado, USA
This system was installed by students in asolar water pumping class.
- The array is set at summer tilt angle.
- The controller is mounted on the northside of the pole, directly under the array.This shades it from the hot mid-day sun.
- Mounting and ground-bonding details areshown in Section 5.1.
- Electrical conduit runs from the PUMPjunction box to the wellhead to protect thepump wires. The water pipe is all underground.
Courtesy of Dankoff Solar Products, NM, USA
This PV array wasassembled andwired on theground, then liftedwith a crane.Courtesy of Dankoff SolarProducts,NM, USA
PS600 HR04-300Wp system in
Colorado, USA,installed by
students in a solarpumping class.
The drop pipe is0.75"
polyethylene.Hand installationrequires caution
and is not alwaysrecommended
(see Section 7.3)Courtesy of Dankoff Solar
Products NM, USA
PV array assembly. The mounting pole is shortenough to facilitate assembly without mechanicalassistance.Courtesy of Dankoff Solar Products, NM, USA
Setting an arraypole in con-
crete.Courtesy of Dankoff Solar
Products, NM, USA
10
A tracking solar array
The mounting pipe was extended to 11 feet (3m), by welding it to a larger pipe. Wire is typeUSE (outdoor rated). The wire is looped tohelp it to shed water and to flex. Wires enterthe conduit through a “weather head”.Courtesy of Dankoff Solar Products, NM, USA
Owners of a domestic water system watch asthe pump fills their polyethylene storage tank.The tank was buried later.Photo courtesy of Dankoff Solar Products, NM, USA
11
4 INSTALLING THE SOLAR ARRAY
Sunlight is the “fuel” that drives a solar pump.Full solar exposure of the solar array is criticalfor full performance of a solar-direct system.
Choose a location for the solar array that hasunrestricted sun exposure through the dayand through the year. The array can be placedseveral hundred feet (100 m) or more from thewellhead. There will be no loss of perform-ance if the electrical wire is sized properly, butnaturally, the cost of wire will increase signifi-cantly. The System Sizing Table specifieswire size requirements for both normal andextended wire lengths.
CAUTION Shading a smallportion of a PV array may causethe pump to stop completely.
Each PV module (panel) containsa series of solar cells (typically
36 or 72 cells). Every cell that is shaded actslike a resistor, reducing the output of theENTIRE ARRAY. Shading just a few cells willreduce the power disproportionately, and maystop the pump. Consider this when decidingwhere to install the array.
To determine where shadows may be cast atany time of the year, you can survey the sitewith a Solar Pathfinder®. This device isespecially useful in forested areas or wher-ever there are obstructions nearby. It isavailable directly from Solar Pathfinder (USA)tel. (317) 501-2529, fax (931) 590-5400,www.solarpathfinder.com.
Place the bottom edge of the array at least 2feet (.6 m) above ground to clear rain spatter,growing vegetation and snow. Keep in mindthat trees and perennial plants will grow tallerin the coming years.
There are two ways to install the solar array.
1. Assemble the array on the ground, wiringand all, then lift the entire assembly onto thepole or roof. A system of 300 watts or moremay require the assistance of a backhoe,boom truck or crane to lift it over the pole.
2. Assemble the array piece-by-piece on thepole. If the pole is higher than about 6 feet(2m), it is best to construct a temporaryplatform, like a scaffold assembly commonlyused in building construction). A scaffoldsystem can be rented from a local supplier.
4.3 Solar Array MountingRackWARNING Your mountingstructure must be engineeredfor wind resistance and safety.Follow the rack (or tracker)manufacturer’s instructions
that are packed with your rack.Solar Tracking A solar tracker is a specialpole-mounted solar array rack that tiltsautomatically to follow the daily path of thesun. In clear summer weather, it can in-crease your daily water yield by 40-50%. (It ismuch less effective in winter and in cloudyweather.)
4.1 Location of the Solar Array 4.2 Solar Array AssemblyMethods
12
8 9
1011 1
2
43
6
7 5
6
© 1996 by John VeltmanSouth
North
AM PM
West East
Jun
Aug
Sep
Oct
NovDec
MayApr
MarFeb
Jan
Jul
40o50o
30o
Sun Compass Instructions1. Draw an arrow from Month dot to intersec-tion of your Standard Time and LatitudeNorthern (50° N to 70° N)The gray line is an example: August, 2 PM at40° N lat.
2. Stand and face your shadow.
3. Hold this page horizontally.
4.Point the arrow that you drew to center ofyour shadow.
5. Sun Compass now points to the fourdirections.
SUN COMPASS
4.4 Orienting the Solar Array to Solar South
Sun Compass™ is available for the followinglatitudes:
1. U.S.A. (25° to 55°) – shown here
2. Northern (50° N to 70° N)
3. Equatorial (20° N to 20° S)
4. Southern (10° S to 40° S)
To obtain reproduction rights, contact: JohnVeltman PO Box 23533, Santa Fe, NM 87502USA
For the USA(lower 48 states)and other 25° to55° North latituderegions.
Find True Southquickly andaccurately usingonly your shadow.No magneticcompass needed!
For full performance, your solar array mustbe oriented within 10° of true (solar) south.Depending on your location, a compassreading may show an error of as much as 20°.To correct this discrepancy, apply the mag-netic declination for your region. Manyregional maps indicate the magnetic declina-tion. If you don’t have a compass but can seeyour shadow and know the time of day, usethe Sun Compass™.
13
Solar Array TiltAngles byLatitude
0-25° latitudes: Apply a minimum tilt angle of10°, or dust and debris will accumulate.
4.5 Setting the Solar Array Tilt Angle
CAUTION People often forget to makeseasonal adjustments.Ideal angles (from horizontal) are:Summer optimum = latitude - 15°Winter optimum = latitude + 15°
Maximum performance is obtained from asolar pump when its photovoltaic array is tilted(elevated) to face the sun. The solar arrayracks that are supplied with the PumpSystems are adjustable to the desired tiltangle. It is the responsibility of the installer toperform this adjustment.
Some systems include a solar tracker, andothers with a fixed (non-tracking) rack. Bothtypes of array have a manual tilt-angleadjustment. (The tracker follows the dailypath of the sun, but not the seasonal tiltvariation.)
The optimum tilt angle is determined by thelocation (latitude). It also varies with the timeof the year. This data is presented in the tablebelow.
Should the tilt angle be adjusted periodicallythrough the year? This depends on theseasonal water-use pattern, and also onhuman factors. There are three options tochose from.
Select one of these options for seasonalmanagement:1. Year-round compromise (no seasonaladjustment) Set the angle equal to the latitudeof the location and “forget it”. This is practicalbecause people often forget to adjust thearray. The performance displayed in theSystem Sizing Table is based on this fixedcompromise setting of the tilt-angle.
2. Seasonally adjusted It is sufficient toperform the adjustment only twice per year, atthe spring and autumn equinoxes, to thesummer and winter angles indicated below.For central USA, this will increase the dailywater production by about 8% in summer, 5%in winter compared to option 1.
3. Seasonal use only If the pump is to beused no more than half of the year, set thearray to the appropriate seasonal angleshown below, and “forget it”.
If you use the pump all year but do not wantseasonal adjustment to be required, set theangle to year-round compromise (equal tolatitude).
noitacoL)selpmaxe( edutitaL
remmuStliT
retniWtliT
dnuoR-raeYesimorpmoC
eliT
nrehtuoSadanaC °05 °53 °56 °05
drihTreppUASUfo °54 °03 °06 °54
drihTelddiMASUfo °04 °52 °55 °04
drihTrewoLASUfo °53 °02 °05 °53
lartneCocixeM °02 °5 °53 °02
14
5 ELECTRICAL INSTALLATION5.1 Controller, Junction Box, and Conduit
WARNING To beinstalled, con-nected andserviced byqualified person-nel only. Ensureall powersources aredisconnectedwhen makingconnections tothe controller.Follow allappropriateelectrical codes.There are nouser serviceableparts inside themotor or thecontroller.
CAUTION Loose connections are the mostcommon cause of system failures.Pull on each connection to confirm that it issecure.
Location Place the controller close to thesolar array, not the pump. This will reduce therisk of lightning damage.
Explanation — The controller’s input circuitryis more sensitive to surges than its output. Itis safest to minimize the length of the inputwiring.
Protection from solar heat Electronicdevices are most reliable when they areprotected from heat. Mount the controller inthe shade of the mid-day sun. An ideallocation is directly under the solar array, onthe north side of the mounting pole. If shadeis not available, cut a piece of sheet metaland bolt it behind the top of the controller.Bend it over the controller to provide shade.This is especially important in extremely hotlocations. Extreme heat may trigger a thermalswitch in the controller and cause it to turn off.
Location of controller Mount the controllervertically to keep out rainwater. It is preferableto mount it ON THE NORTH SIDE of a pole orother structure, to help reduce solar heating.This may also allow easiest access withouthitting your head on the lower (south) edge ofthe array.
Junction Box (optionally) A pre-wiredjunction box is available for your system. Thejunction box terminals will handle pump wiresas large as #6 (13 sq. mm). If large wirescannot be accommodated easily in the box,you can join them to smaller wires in thejunction box. #12 (4 sq. mm) or larger isacceptable for this very short length. Do NOTremove terminal screws. If the key to thejunction box gets lost, it can be opened with ascrewdriver.
Mounting the controller and junction boxto a pole See photos on the following page.The controller can be mounted onto the solararray support pole using materials availablefrom your local electric supply store. The bestmounting hardware is “slotted strut” (Unistrut®
or equivalent) with matching conduit clamps tofit around the mounting pole. This makes avery strong assembly that is easy to adjust. InNorth America, these materials are commonlyavailable from electric suppliers.
Electrical conduit is recommended We urgeyou to use electrical conduit (pipe) to protectoutdoor wiring from the weather, from humanactivities, and from chewing animals. Seephotos on the following pages. If you don’tuse conduit, use strong, high-quality outdoorcable. Where cables enter the junction box,install sealed strain-relief cable clamps.
Keep the controller and junction box sealedUnused holes must be sealed to keep outanimals, insects, water and dirt. Each hole issupplied with a rubber plug that can be keptin place for this purpose.
Battery system Batteries must be in a coollocation for best longevity, and in a protectiveenclosure for cleanliness and safety. Placethe controller near the batteries but NOT inthe same enclosure. They must be safelyisolated from the battery terminals and fromcorrosive gasses.
15
Typical assembly of controller and junctionbox on the solar array mounting pole. Boxesare secured using slotted strut and conduitclamps.
Mount thecontroller on thenorth side of thepole to reducesolar heating.
Bare ground wires bond the PV modules tothe controller enclosure, and continue down tothe ground rod. Flat braid is flexible andeliminates the need for terminal lugs.
slotted strut (Unistrut® or equivalent), cut tothe width of the box.
conduit clamp to fit slotted strut
hose clamp
Conduit holes3 holes for 3/4" conduit (28mm)
1 hole for 1 1/4" conduit (45mm)
Holes are in a removable plate that can bereversed.
Rubber plugs are included for unused holes.
Controller, Junction Box, and Conduit continued
16
5.2 Grounding and Lightning Protection
Surges induced by lightning are one of themost common causes of electronic controllerfailures in solar water pumps. Damagingsurges can be induced from lightning thatstrikes a long distance from the system, oreven between clouds. The risk of damage isgreatly reduced if these instructions arefollowed.
Location of the pump controller Place thecontroller close to the solar array, not thepump. This will reduce the risk of lightningdamage. Explanation: The controller’s inputcircuitry is more sensitive to surges than itsoutput. It is safest to minimize the length ofthe input wiring.
Construct a discharge path to ground Aproperly made discharge path to ground(earth) will discharge static electricity thataccumulates in the above-ground structure.This helps prevent the attraction of lightning. Ifa lightning strike occurs at close proximity, awell-grounded conductive structure can divertthe surge AROUND the electrical circuitry,greatly reducing the potential for damage.The controller has built-in surge protectors,but they help ONLY if the system is effectivelygrounded.
Earth connection – Create an effectivedischarge path It helps to picture this as a“drain field” for electrons. Here are sugges-tions for grounding, in order of their efficacy:
1. The best possible ground rod is a steel wellcasing located near the array. Drill and tap ahole to make a strong bolted connection tothe casing with good metallic contact. Bolt ona brass terminal lug. After the connection ismade, seal the connection with siliconesealant or other waterproof compound toprevent corrosion. Protect the ground wire(s)from physical damage so they aren’t stressedby being stepped on, etc.
2. Install a copper plate or other specializedgrounding devices designed for the purpose.Some systems use salts to improve theconductivity of the surrounding soil.
3. Install one or more copper-plated groundrods at least 8 feet (2.5m) long, preferably inmoist earth. Where the ground gets very dry(poorly conductive), install more than one rod,spaced at least 10 feet (3m) apart.
4. If the soil is rocky and doesn’t allow groundrods to be driven, bury BARE copper wire in atrench at least 100 feet (30m) long. If a trenchis to be dug for burial of water pipes, groundwire can be run along the bottom of thetrench. The wire size must be minimum #6 (16sq. mm) or double #8 (10 sq. mm). Connectone end to the array structure and controller.Or, cut the ground wire shorter and spread itin more than one direction.
Dry or rocky locations To achieve goodgrounding at a dry or rocky site, consult alocal contractor who specializes in lightningprotection. It is best to plan the procedure inadvance, and to coordinate the effort withother earth-excavating procedures that needto be done. Reference: www.lightning.org
Bond (interconnect) all the metal structuralcomponents and electrical enclosuresInterconnect the PV module (solar panel)frames, the mounting rack, and the groundterminals of the disconnect switch and thecontroller, using wire of minimum size #8(6mm2), and run the wire to an earth connec-tion.
Ground connections at the controller Thecontroller and junction box have redundantground terminals inside. They are all con-nected in common with the metal enclosuresof both the controller and the junction box.Ground connections can be made to any ofthese points.
Ground connections to aluminum Thisapplies to connections at the solar arrayframework, and at the controller’s enclosurebox. Connections to aluminum must be madeusing terminal lugs that have an aluminum-to-copper rating (labeled “AL/CU”) and stainlesssteel fasteners. This will reduce the potentialfor corrosion.
WARNINGFailure to installand connect aneffective ground-ing system willgreatly increasethe risk oflightning dam-age and will voidyour warranty.We suggest youwire the ground-ing system FIRSTso it is notoverlooked. Theconcrete footer ofa ground-mounted array willNOT provideadequate electri-cal grounding.
17
CAUTIONGround thecable shield atthe controllerend only, not atthe float switch.
WARNINGIsolate solarpump wiringfrom electricfence systems.Do not connectthe pump systemto the sameground rod as anelectric fence. Donot run power orfloat switch cablesclose to anelectric fence.
DO NOT GROUND the positive or the nega-tive of the power circuit. The best lightningprotection results from grounding the metal-lic structure only, and leaving the powersystem ungrounded. This is called a “floating”system.
Explanation: With a floating system and agood structural ground, lightning inducedsurges tend to reach ground through thestructure, instead of the power circuit. Whenhigh voltage is induced in the power circuit,the voltage in negative and the positive sidestend to be nearly equal, thus the voltageBETWEEN the two is not so high, and notusually destructive. This method has beenfavored for many decades by most engineersin the remote power and telecommunicationsfields.
Exception for battery systems: You canconnect the pump to a battery-based homepower system that has a negative ground. Ifthe wiring distance to the pump exceeds 100feet (particularly in a high lightning area), DC-rated surge protection devices are recom-mended.
Legal exception: If the local electricalauthority requires grounding of the powercircuit, ground the PV ARRAY NEGATIVEwire. This may increase the risk of lightningdamage.
Solar array wiring Bind the array wires closetogether, or use multi-wire cable. Avoidforming loops. This helps induced voltages ineach side of the circuit to equalize and canceleach other out.
Wire twisting for long runs Twisting wirestogether tends to equalize the voltage inducedby lightning. It reduces the voltage differentialbetween the wires. This reduces the probabil-ity of damage. This method is employed intelephone cable, and in many other applica-tions. Some power cables are made withtwisted conductors. To twist wires yourself,you can alternate the direction of the twistabout every 30 feet (10 m). This makes thejob much easier.
Float switch cable A long run of control cableto a float switch in the storage tank can pickup damaging surges from nearby lightning.The best protection is to use shielded,twisted-pair cable . Shielded cable has ametallic foil or braid surrounding the twowires. Ground the cable shield as illustratedin Section 5.10.
Low water probe cable A long horizontal runof wire to the low-water probe at the pumpcan pick up damaging surges from nearbylightning. Wire twisting is helpful. The bestprotection is to use shielded, twisted-paircable, same as recommended for a remotefloat switch. This product is suitable for directburial, but not for submersion in the well. Atthe wellhead, make a transition to submers-ible probe wires.
Additional lightning protection The controllerhas built-in surge protection devices. How-ever, additional grounding measures orsurge protection devices are recommendedunder any of the following conditions:
1. Isolated location on high ground in asevere lightning area
2. Dry, rocky, or otherwise poorly conductivesoil
3. Long wire run (more than 100 feet / 30m)from the controller to the wellhead, or to thefloat switch.
Additional lightning protection devices (surgearrestors) can be obtained from your pumpsupplier. The device(s) for the controller’s PVinput, float switch and probe connections,must be rated for DC. The device(s) for thecontroller’s AC output to the motor must berated for 3-phase AC. In each case, theclamping (bypass) voltage should be 90V orhigher, but not much higher.
In extreme cases, it is best to employ theservice of a local lightning protection contrac-tor.
Reference www.lightning.org
Grounding and Lightning Protection continued
18
WARNING: Thephotovoltaicarray generateshazardousvoltages. A 48Volt (nominal)array cangenerate nearly100 volts whendisconnectedfrom load. Ashort circuit orloose connec-tion will producean arc that cancause seriousburns. All wiringmust be done byqualified person-nel, in compli-ance with local,state, andnational electri-cal codes.
5.3 Solar Array Wiring
2 types of PV module junction systems
TOP Quick-connect system using “MC”connectors.BOTTOM Junction box with screw terminalsand conduit holes
The solar array can produce hazardousvoltage even under low light exposure. Toprevent shock hazard while wiring the array,leave one or more wires disconnected orcover it with opaque material.
Solar-direct (non-battery) systems use avariety of array configurations. Some use 12V(nominal) modules, and some use 24Vmodules. Modules are connected in seriesfor 24 - 36 - 48V and up to 96V (for PS1200Systems), and sometimes also in parallel toincrease the current. Refer to the SystemWiring Diagram for your system, attached atthe end of this manual. Be sure the modules(panels) match the description on yourSystem Wiring Diagram.
Solar module connections The terminals inthe module junction boxes can be confusing.Refer to the module manufacturer’s instruc-tions that are packed with the modules. Makestrong connections that will hold for manyyears. Most array failures are caused byloose, corroded, or shorted connections.
Type of wire Use either electrical conduit oroutdoor UV-resistant wire. The solar array hasa life expectancy beyond twenty years. Don’tdegrade it with inferior materials! Use mini-mum wire size #12 (4 sq. mm) for the connec-tions between modules and for short dis-tances to the controller. Some appropriatetypes of wire are: USE, UF, SE and SOOW.
Solar tracker wiring If you are installing asolar tracker, pay careful attention to the wiresection that leads from the moving rack downto the stationary mounting pipe. Use a highlyflexible wiring assembly. Form a drip loop toshed water and to minimize stress. SEETRACKER PHOTO and caption in the PHOTOGALLERY. Secure the assembly mechanicallyat each end so the insulation and the connec-tions are not stressed by the tracker’s motion.Swing the tracker fully in each direction, atvarious seasonal tilt angles, to verify that thecable will not rub or restrict the trackingmotion.
MC connectors Some PV modules havethese quick connectors. If the connector is notappropriate at some junctions, you can cut thewire and make a conventional connection.
19
5.4 Solar Array Disconnect Switch in the Junction Box
CAUTION Looseconnections are acomon cause offailure. Pull eachconnection toconfirm.
CAUTION If youare not using alow-water probe,connect a smallwire betweenterminals 1 and 2.
Note: Overload protection (fuses or circuitbreaker) is NOT required in the solar arraycircuit.
Explanation:
1. Short circuit current from the solar arraycan never reach the ampacity (maximum safeamps capacity) of the recommended wire.
2. The PS- controller has internal overloadprotection.
Disconnect Scwitch
The disconnect switch satisfies NationalElectrical Code requirements for a safetydisconnect between the solar array and thecontroller. During installation and mainte-nance, switch off the disconnect switch toprevent shock and arc burn hazard.
20
5.5 Junction Box (Controller Input) Wiring
WARNING TEST THE VOLTAGE beforeconnecting power to the controller. Voltage(open circuit) must not exceed 100V forPS200-, 150V for PS600 and 200V forPS1200 systems. (Even in cloudy weather,the open circuit voltage will be near maxi-mum.)WARNING Do not apply a direct connectionor an amp meter between + and – when thecontroller is connected. A short circuithere will cause a strong discharge.WARNING SOLAR-DIRECT systems only —Do not connect any electrical load to thesolar array if it is not part of the LORENTZPump system. Connection of a batterycharger, active solar tracker controller, electricfence charger, or other load simultaneouslywith LORENTZ PS systems may “confuse”the controller and prevent proper operation.
CAUTION If youare not using alow-water probe,connect a smallwire betweenterminals 1 and 2.
System Diagram For solar-direct systems,refer to the System Diagram at the end of thismanual.
Ground connections The two groundterminals in the junction box are bondedtogether and are also bonded to the metallicenclosures of both the junction box and thecontroller. See Section 5.2
POWER IN Ensure that the solar arrayDISCONNECT SWITCH (or battery fuse orcircuit breaker)- is OFF. Connect the powerfrom the solar array to the input terminals inthe junction box. Observe polarity. If yourwires are not clearly marked +/–, test themusing a DC voltmeter or multitester.
PUMP See Section 5.8.
Low Water Probe See Section 5.9
Float Switch See Section 5.10, AutomaticControl for Full-Tank Shutoff. A connection ismade at the factory between terminals 4 and5. If you are NOT using a float switch, leavethis connection in place.
21
5.6 Maximum RPM Setting
All PSXXX controller offer the option ofreducing the maximum speed of the pump.
This RPM control reduces the maximumspeed (RPM limit) to as low as about 30%. Itwill NOT reduce the starting or low-lightperformance. The pump uses less powerwhen it pumps less water.
Reasons to reduce the maximum RPM1. To prevent over-pumping a limited watersource (see Section 6.7)
2. To improve energy and water-sourcemanagement in a battery system where slowpumping is adequate to meet the demand
3. To limit the back-pressure (and preventpossible pump overload) when pumping into adirect-pumped irrigation system, a filtrationsystem, or an undersized pipeline
How to reset the Maximum RPM setting
CAUTION If youperform thisadjustment,record thesetting on theSystem ReportForm (Section 2).If flow testing isdone in the future,the result maylead to a wrongconclusion if thisadjustment is notaccounted for.
1. Remove the bottom end of the PS-XXXcontroller enclosure (the end with the conduitopenings)
2. Locate the adjustment knob shown in thephoto below (circled)
3. In most cases, the knob will be at thestandard factory setting full clockwise asindicated by “setting #1” illustrated below.Turn it counter-clockwise to the desiredsetting. The exact positions may vary fromthis illustration. Follow the ink marks on thecontroller.
Terminals inside the PS-XXX controller.“Max. RPM setting” is at right.
Maximum RPM Setting Knob
12
Original Factory Setting (#1)
22
5.7 Submersible Pump Cable and Splice
Selection of cable Use only an approvedtype of submersible well pump cable, thesame type that is used for conventional ACpumps. It is available from your pumpsupplier or installer, or a local water wellsupply distributor. You need 4-conductorcable. It is often called “3-wire-with-ground”because it has 3 power wires plus a groundwire. To determine the minimum required wiresize, refer to the Systems Sizing Table.
Submersible Splice A splice kit includescrimp connectors to join the copper wires,adhesive heat-shrink tubing, and instructions.If the drop cable is too large to fit in the crimpconnector, cut off some of the wire strands.Use a crimping tool, and observe that thewires are held very securely.
motor leader cable
wires spliced with adhesive heat-shrink tubing
drop cable
23
5.8 Wiring Order for Correct Rotation
WARNING If thepump wires arein the wrongorder, the motorwill run inreverse and thepump will notfunction. Dam-age may result.Check thedirection BE-FORE installingthe pump. Theproper directionis COUNTER-CLOCKWISEwhen viewedfrom above.
The power wires on the pump are black withwhite lettering to indicate L1, L2 and L3.WRITE DOWN the colors that you splice toL1/ L2 / L3 so you can match them with theL1/ L2 / L3 terminals in the pump controller.
If your pump cable has the standard RED,BLACK and YELLOW colors, use thissequence:
The power wires on the pump may also bebroun-black-grey for Motors delivered Q22005. Then use broun as L1, black as L2and grey as L3Testing the pump for direction Helical rotorpumps will produce water flow only if they arerotating in the right direction. If you place it ina water tank or a bucket, you will observe flowif the rotation is correct. (Submerge at least75% to observe full flow).
Alternative, dry test If you don’t have a watervessel to test the pump in, you can test it dryby watching the pump shaft and running it foronly a few seconds. The metal label on thepump has an arrow to indicate the properdirection of rotation. If the pump is new fromthe factory, it is lubricated so it can run dry forabout 90 seconds without risk. If the pump isnot new, it can be run dry safely for about 15seconds. Either way, this is more than enoughtime to observe the direction of the shaft.
If you did not write down the color match (orthe wind blew your note away) connect thethree power wires to the controller in ANYrandom order. Apply power. Observe thepump shaft rotation, then turn the power off. If
WARNING Whentesting fordirection, do notrun the pumpdry for morethan 15 seconds.
the direction is wrong, exchange ANY TWO ofthe power wires at the controller. In any case,when you are finished connecting the pumpto the controller, test it to assure the properdirection.
Did you install the pump in the well withoutchecking the wiring order or the direction?OR – Is it running but not pumping?HELICAL ROTOR pump (model numberdoes NOT contain “C) Turn the pump on.Observe if air is rising from the pipe. If it isn’t,reverse any two motor wires and observeagain. If you cannot observe air rise, chosewhichever direction is quieter (less vibration).There is risk of dry-run damage if it runs toolong in reverse. If the pump is new from thefactory, it is lubricated so it can run dry forabout 90 seconds without risk. If the pumphas been used, it must not be run for morethan about 15 seconds. In many cases, apump that is reversed will turn off due tooverload.
CENTRIFUGAL pump (model with C in thename) In reverse, it will produce no flow (orvery little). This will NOT damage the pump. Ifthe flow is not normal, reverse any two motorwires.
Question The motor shaft is hard to turn byhand, and moves in a bumpy manner. Is thisnormal?
Answer YES. This is caused by permanentmagnets in the motor. It is especially hard toturn when it is connected to the controller, or ifthe pump wires are connected together.
DER KCALB WOLLEY NEERG
1L 2L 3L dnuorG
24
5.9 Low-Water Probe for Dry-Run Protection
WARNINGRunning com-pletely dry willdamage thepump and voidthe warranty.The purpose ofthe probe systemis to sense theloss of water andturn the pump offbefore it can rundry.
Installation The probe is packed with twostainless steel hose clamps. For a pump thatis to be installed in a vertical position, clamp itto the pipe just above the pump outlet, asshown in the photo. Splice the two probewires using the splice kit components that arepacked with the probe. The assembly proce-dure is the same as the main pump splice.
If you are NOT using the well probe, it mustbe bypassed. Connect a short wire betweenthe probe terminals in the junction box(terminals 1 and 2). Do this only if you feelcertain about the reliability of the watersource. Wire size: #18 AWG ( 1mm²) orlarger.
Principle of operation The probe contains amechanical float with a magnet inside. Whenthe probe is submerged, the float rises, andthe magnet actuates a switch. The switchcloses (makes contact) to indicate the pres-ence of water. The switch is sealed, so thecontacts never touch the water.
If the water level drops below the probe, thefloat drops, and the switch opens (breakscontact). The controller will stop the pump andthe “Low-Water OFF” light will indicate. Whenthe water level recovers and switch closesagain, the controller will delay the restart for20 minutes. This gives time for the water levelto recover. To force a quick restart, turn thecontroller off, then on again.
NOTE Pumps made before October 2003may have a different type of probe, withwet electrodes. Either type can be usedwith the PS-XXX series controllers.The Low Water-OFF light flashes slowly forthe remainder of the day, even if the waterrecovers and the pump restarts automati-cally. This tells you that the water source ranlow at least once since the power wasdisrupted (or sun went down). To turn thelight off, reset the controller by turning it off/on.
CAUTION Thelow-water probemust be posi-tioned vertically,within 10°. If thepump is NOT tobe installedvertically, find analternative way tomount or suspendthe probe, so thatit is higher thanthe pump, and ina vertical position.
CAUTION Do not use apressure switch with a “lowwater cutout” or “loss ofprime” feature as a method ofdry-run protection. A helicalrotor pump will maintainpressure as it runs dry, so thismethod will not work reliably.For pressure switch information,see Section 5.12, PressurizingSystems.
Potential problems with the low-waterprobe in surface water The probe has amoving float. It is highly resistant to depositsand debris. However, it may stick under someextreme conditions, especially from algae orwater creatures (snails, etc.) that may bepresent in surface water. Possible solutionsare:
1. Hang the probe independently of the pumpand pipe (clamped to a weight, but not to thedrop pipe). This way, it can be pulled up forinspection or cleaning without the need to pullthe pump. (This may not be feasible if the wellcasing is smaller than 6".)
2. Pull the probe out periodically (with thepump if necessary) for testing and inspection.The pump should stop at the moment theprobe leaves the water.
3. Wrap the probe in a protective screen(fiberglass window screen, for example).
Substitute a different type of float switch. Youcan use any switch that makes contact on rise(normally open).
Low-water probeinstalled in the
standard position,for a pump that is
positioned vertically
25
5.10 Automatic Control For Full-Tank Shutoff
We recommend the use of a float switch orother 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, andeliminates unnecessary pump wear. PS-XXXcontrollers allow the use of small signalcable to a remote float switch, even if the tankis a long distance away.
Float switch requirements1. A switch must be used, not wet electrodes.
2. The preferred system requires a floatswitch to MAKE contact on rise to turn thepump OFF. This is called “normally open”(N.O.). It may be commercially labeled as a“pump down” switch, but here it works inreverse, to allow pumping up.
sealedcable clamp
cableweight
pump off
pump on
pumpingrange
QUESTION Why do we use areverse-action (N.O.) floatswitch? (a pump-down switchfor a pump-up application)
ANSWER If the cable con-nection is broken, the pumpwill continue to operate. Thewater supply will not bedisrupted (but of course, thetank will overflow). This is thegeneral preference in theindustry. If you prefer thepump to stop if the connectionis broken, use a normallyclosed (N.C.) float switchinstead.
Wiring to the controller(junction box) Thecontroller (and junctionbox) offers two options forconnection of a remoteswitch. These allow theuse of either a “normallyopen” (N.O.) or a “nor-mally closed” (N.C.)switch. “Normal” refers tothe status of the contactswhen the switch is DOWNand calling for water.
Float switch cable require-ments1. Two wires are needed.
2. Minimum wire size #18AWG ( 1mm²). This is goodfor a distance as far as 2000feet (600 m).
3. The cable must be suitablefor its environment.
4. If it must run a longdistance, use twisted-pairshielded cable to reduce thechance of damage from lightning-inducedsurge. (See Section 5.2 Grounding andLightning Protection).
Grounding shielded float switch cable Ifyou use shielded cable, connect the shield toground AT THE CONTROLLER ONLY. DONOT ground the shield at the float switch. Thiswill reduce surges induced by nearby light-ning.
Wiring a “normally open switch” Connect the switch to terminals 3 and 4 (NO andcommon) and connect terminals 4 and 5 together, as illustrated.Closing (connecting) the switch circuit turns the pump OFF
Wiring a “normally closed/reverse action switch” Connect the switch to termins 4and 5. Closing (connecting) the switch turns the pump ON
26
If you are not using a float switch, terminals4 and 5 must be connected. Terminal 3remains disconnected.
Operation of the float switch system Whenthe water level is high, the float switch willstop the pump. The FULL-TANK OFF indica-tor on the controller will light up. When thewater level drops, the float switch will signalthe controller. The indicator light will go out,and the pump will restart if sufficient power isavailable.
Overriding the float switch You may want tooverride the float switch to allow overflow forirrigation purposes or to test or observe yoursystem. For a N.O. switch circuit, install aswitch to DISCONNECT ONE of the floatswitch wires. FOR A N.C. switch circuit, installa switch to CONNECT the two float switchwires together.
WIRELESS ALTERNATIVE, using a floatvalve and pressure switch It may befeasible to use a FLOAT VALVE in the watertank (instead of a float switch) for remoteshutoff. This eliminates the need for a cable tothe tank when the tank is a long distance fromthe pump system. When the tank fills, thevalve shuts, causing pressure to rise at thepump. A pressure switch is installed at thewellhead (or at anywhere along the pipe). Thepressure switch is wired to the pump control-ler, and adjusted to respond to the rise andfall of pressure. The assembly is similar tothat of a normal pressurizing system. Referto Section 5.12.
CAUTIONS for the wireless alternative1. The pump system must be capable ofproducing at least 25 PSI (60 feet, 18m)more than the full lift pressure. (A conven-tional pressure switch may not functionreliably at a lower pressure differential.)
2. If the lift from the pressure switch up to thetank is to exceed 100 vertical feet (30m), theoff-pressure may exceed the pressure ratingsfor normal components, which is typically 150PSI (10 bar).
3. Pressure switch adjustments are critical. Besure to observe carefully to verify the perform-ance.
4. Install a pressure gauge near the pressureswitch, to help you make adjustments.
5. Install a small pressure tank near thepressure switch. Without it, rapid start/stopcycling is likely to occur which is very undesir-able. Any captive-air pressure tank of 2gallons (8 ltr) or larger is sufficient.
6. Adjust the pressure tank pre-charge to apressure slightly lower than the workingpressure in the pipe. On level ground, theworking pressure may be nearly zero. In thatcase, open the water-end of the pressure tankto the atmosphere and let out all the pre-charge air. (The air bladder must not collapseall the way.)
7. WARNING Install an appropriate pressurerelief valve for safety (see Section 5.12).
8. Be sure the tank has a safe way to overflowif the float valve leaks, wire breaks, etc.
9. To prevent slow action of the float valve,and lots of on/off cycling, we recommend aquick-acting float valve. Source: Tek Supply,www.teksupply.com (800) 835-7877, Item#WR-1300, or search “Hudson Valve”.
MANUAL REMOTE CONTROL SWITCH Thefloat switch circuit can be used with a manualswitch to turn the pump on and off from adistance. Use any simple on/off switchavailable from an electronic supply, electricalsupply, or hardware store (it only carries 12volts, very low current). Wire it according tothe illustration above, for a normally closedfloat switch.
Automatic Control For Full-Tank Shutoff continued
27
5.11 Battery-Based Systems
PS-XXX pump systems can be operatedfrom batteries.
Install a jumper wire between terminals 6and 7 to set the controller to battery mode.
This will de-activate the MPP-Trackingfunction and activate the Low Voltage Discon-nect.
Overload protection Install a fuse or circuitbreaker near the power source. For either 24or 48V , use a 25 amp circuit breaker ( PS200or PS600 Systems) or a time-delay (slowblow) fuse. The purpose of this protection isfor safety in case of a wiring fault, and toprovide a means of disconnect when install-ing or maintaining the system. PS-XXXcontrollers have electronic over-currentprotection against motor overload.
Wire Sizing for the DC circuit Wire must besized for no more than 5% voltage drop at 20amps (starting).
Refer to a wire sizing chart specifically for 24Vor 48V, or follow these examples:
24V SYSTEM:#10 wire to maximum distance of 30 ft.
CAUTION ThePS-XXX control-ler is NOT abattery chargecontroller. Acharge controllerprevents batteryovercharge. It is anormal part ofany renewableenergy batterycharging system.Be sure thecharge controlleris appropriate tothe type ofbatteries used.(Sealed batteriesuse lower voltagesettings thanliquid-filledbatteries.)
Metric: 6 sq. mm to max. 10m
48V SYSTEM:#12 wire to maximum distance of 22 ft.Metric: 4 sq. mm to max. 13m
GREATER LENGTHS For each 150% in-crease, use next larger wire size.
ON/OFF switching You can switch either theprimary power to the controller, or the remote(float switch) control circuit. For an explana-tion, see Section 5.12 (Pressurizing Sys-tems) “Pressure switch connection”.
Low-voltage disconnect function. Lead-acidbatteries can be permanently damaged byover-discharge when the voltage falls below acritical point. To prevent this, the PS battery-system controller will turn off at low voltage,and turn back on only after the battery hasrecovered significantly. The set points are:
24V SYSTEM: OFF at 22V ON at 24V48V SYSTEM: OFF at 44V ON at 48V
A controller in disconnect mode can be resetmanually by turning off/on, but it will quicklydisconnect again if the battery is not gaining asubstantial recharge.
28
LORENTZ PS-XXX Pump Systems areexcellent for automatic water pressurizingwhen powered by a battery system. If you areraising water vertically AND pressurizing, thepump must handle to total head. Note therelationship: 2.31 ft. = 1 PSI (1 Bar = 10vertical meters.) Example: A pump that lifts100 vertical feet (30m) and pressurizes to 60PSI (4 bar) must pump the equivalent of 240feet (70m). Be sure your pump was chosencorrectly for your application. The installationis similar to that of a conventional AC pump.
A typical pressurizing control assembly isillustrated in the following photo. These arestandard components, same as used forconventional AC water pressure systems. Theparts (from left to right) are:
1. check valve (prevents back-flow)
2. pressure gauge 0-100 PSI (0-7 bar)
3. pressure relief valve 75 PSI (5.3 bar)
4. tank tee (a bronze casting that holds all thecomponents)
5. pressure switch (turns the pump on/offaccording to pressure set-points, adjustable)
6. hose outlet (to drain the system or tosupply water when outlet is shut off)
7. ball valve (to shut off the supply to theoutlets)
The components can be purchased from localsuppliers, or as a kit from your pump sup-plier
WARNING APRESSURERELIEF VALVEIS REQUIRED. Ifthe pressureswitch fails, thiswill preventextreme pres-sure frombursting the tankor piping andcausing a flood.Install the valvenear the pressuretank, before theshutoff valve. Usea 1/2" (or larger)valve set about25-75% higherthan the cut-outpressure. Run apipe or hose fromits outlet to adrain or to theoutdoors wherewater dischargewill not causedamage.
5.12 Pressurizing Systems
Pressure tank A pressure tank is required.We recommend a captive-air pressure tankof 40 GALLONS (150 liters) OR MORE, toassure a steady supply of water pressure asthe pump cycles on and off and the waterdemand varies. A large tank is always best.Size and cost are the only practical limita-tions. More than one tank can be used toincrease the total capacity.
How to pre-charge a captive-air pressuretank for PS-XXX Pump SystemsFor the system to function properly, the airbladder in the tank must be pre-charged withair according to these instructions.
1. Make note of the cut-in setting of thepressure switch (either by observation orknowing the factory setting).
2. Turn off the pump and exhaust the waterfrom the tank if necessary, so the waterpressure is 0.
3. Find the air fitting on top of the tank.Measure the air pressure in the tank using atire gauge.
4. Adjust the pressure to about 3 PSI (.2 bar)LESS THAN THE CUT-IN PRESSURE.
Pressure switch PS-XXX Pumps Systemscan use an ordinary pressure switch sold forconventional AC pumps. Do not use apressure switch with “low water cutout” or“loss of prime” feature (with a shutoff lever
ball valve
WATER INfrom pump
pressure switch
To PressureTank
pressure gauge
check valvetank tee
hose outlet
WATER OUTto distributionsystem
29
on the side). It is intended to prevent dry runof centrifugal pumps. The helical rotor pumptypes will maintain pressure even as it runsdry, so this device will not work reliably. It willalso shutoff if the pressure falls due to highwater demand.
Pressure switch connection There are twoways to connect the pressure switch:
1. primary power switching The switch isused to disconnect the DC power source.Wire the switch between the power sourcedistribution point and the controller, as youwould with a conventional pump.
2. remote switching This method uses the“remote float switch” terminals. Small wire
(minimum #18 AWG) can be run to thepressure switch from a long distance. Seeillustration below. Advantage: the controllerstays on all the time. If the water source runslow (even if it recovers) the “Source Low”indicator light will stay on to notify the user.Power draw of the controller in OFF mode isonly about 1 watt.
Pressure switch connected to the controller(junction box) for “remote switching”
Pressurizing Systems continued
30
6 PREPARING TO INSTALL THE PUMP6.1 WARNINGS about Handling Helical Rotor Pumps
CAUTION (helical rotor mod-els) BEFORE INSTALLATION,KEEP THE PUMP OUT OF THESUN. If the pump gets hot, therubber stator will expand and
may lock the rotor. No damage will result fromthis, but you may be unable to test thedirection of rotation. If the pump gets hot,allow it to cool in water for 20 minutes beforetesting.
WARNING (helical rotor mod-els) DO NOT APPLY MACHINEGREASE TO THE PUMP.Ordinary machine grease willdamage the stator (NBR
rubber) and void the warranty. Helical rotorpumps are lubricated at the factory with aclear, non-toxic grease. Its only purpose istemporary, to allow the pump to be run dry fora short time to test the direction of rotation.There is no normal reason to reapply lubricantbut if you do, use VASELINE (petroleum jelly,white petrolatum) or non-toxic silicone greaseapproved for water valves and seals.
WARNING for SIPHON APPLI-CATIONS If a pump system hasa vertical lift LESS THAN 33FEET (10m) up from the surfaceof the water source, and then thewater flows downhill to a lower
point, a siphon effect may cause suction onthe pump. This will cause an upward thrust onthe motor shaft, resulting in damage to themotor. Prevent this by installing an air vent ora vacuum breaker at the high point on thepipe.
31
6.2 Drop Pipe
PS-XXX Pump Systems can be installedusing the same pipe components that areused for conventional submersible pumps.Use pipe with a sufficient pressure rating,with coupling components that are designedto handle the weight of the entire assembly.
Torque arrestor It is NOT REQUIRED. (soft-start motor system.)
Size of pipe A long line of undersized pipewill reduce the performance of the system.Proper selection of pipe size is based on themaximum flow rate and the total length ofpipe from the pump to the pipe outlet or tank.Refer to the pump specifications at the end ofthis manual to determine the peak flow ratefor the system you are installing. For sizing ofa long pipe line, refer to Section 13.2 WaterPipe Sizing Chart. It is often wise to makeburied pipelines extra-large, in case a largerpump is desired in the future.
Reduced drop pipe size should be consid-ered in the following situations:
1. Sandy water conditions – especially with asolar-direct system. The flow will be very slowon cloudy days. This may cause sediment toaccumulate in the drop pipe. Smaller pipe willincrease the flow velocity and helps exhaustthe sediment. (See Section 6.6 “Coping withDirty Water Conditions”.)
2. Hand installation – to reduce the weight,especially for removal when the pipe is filledwith water.
Balance these advantages against theincreased friction loss in smaller pipe. You canuse a pipe size that is smaller than the pumpoutlet by using a reducer bushing. Horizontalpipes can be larger.
PS-XXX Pump Systems have a stainlesssteel outlet fitting. It is compatible with iron,steel, galvanized, bronze, brass, or anyplastic pipe components.
WARNING Donot use a ropewinch to installor remove apump in a drilledwell casing. Donot use a vehicleto install orremove a pump.See Section 7.3.
CAUTION Do not assemble iron,steel, or galvanized pipecomponents in metallic contactwith brass or copper. This willcause rapid electro-chemicalcorrosion.
CAUTION If polyethylene (blackflexible) pipe is to be used, seeSection 7.3.
CAUTION Screwing a metalpipe component into a plasticreducer bushing may causethe bushing to crack, sooneror later. If you use a plastic
reducer bushing, reinforce it with a hoseclamp (all-stainless steel) as shown in thephoto. Tighten the clamp first, then hand-tighten the metal pipe component.
Hose clamp reinforcing aplastic reducer bushing
32
6.2 Safety Rope and Binding
Safety rope can prevent loss of the pump. Ifthe drop pipe breaks, the rope will preventstrain on the electrical cable and can be usedto pull the pump out. Use 1/4" (6mm) waterwell safety rope. It can be purchased fromyour pump supplier or from a local pumpsupplier. Polypropylene marine rope is alsogood. DO NOT use nylon.
Secure the safety rope at the wellheadPrepare to tie the rope inside the well casing.If your well cap does not have a place to tiethe rope, drill a hole in the casing and installan eye-bolt. Prepare this detail BEFORE youinstall the pump. (See Section 13.3 WellheadAssembly for Drilled Wells.)
Bind the drop pipe/cable/wires/rope withtape Lay out the pipe, submersible cable,probe wires and rope on the ground. Do nottwist them together. Bind everything to thepipe about every 10 feet (3-4m) using vinyltape. Use either standard (UL-listed) electricaltape (about 6 to 8 turns) or “pipe wrap tape”,which is wider and requires fewer turns. Pipewrap tape is available from plumbing andelectric supply stores. Remember that thepipe will stretch, and the cable will not. Leavea slight excess length of cable between eachwrap as illustrated.
WARNING Do not use nyloncable ties in water. Nylonabsorbs water and gets weakafter a few years. To bind thepump cable to the drop pipe, usevinyl electrical tape or pipe-wraptape.
WARNING when using flexiblePOLYETHYLENE (PE) pipe,allow for pipe stretch. Make thecable, probe wires and ropelonger than the pipe, to preventtension when the pipe stretches.
>> cable & wires – 1.5% longer than pipe
>> rope – 1 % longer than pipe
Distribute the excess length along the lengthof the pipe (as illustrated) and leave a littlemore excess length around the splice.
If the water is highly mineralized or has highbiological activity, you may choose to hangthe low-water probe separately from the pipe,cable and rope, so it can be pulled up sepa-rately for inspection or service. See Section5.9 Low Water Probe.
WARNING Safetyrope for wellpump installa-tion is foremergencypump removal. Itmust not be aprimary meansof support. Makeit slightly longerthan the droppipe so it doesnot bear anyweight.
WARNING Donot use nylonrope in water.Nylon absorbswater andweakens after afew years. Failurecan causedamage or loss ofyour equipment.Usepolypropylenerope made forwater well ormarine applica-tions
WARNINGPlastic rope willweaken fromlong exposure tosunlight. Secureit INSIDE the wellcasing to avoidexposure. If sunexposure cannotbe avoided, usestainless steelwire rope.
mot
orpu
mp
end
Bind the submersible cable,low-water probe wires and
safety rope to the pipe.
Pipe wrap tape or electricaltape located at about every
10 feet (3 m) over the lengthof the pipe
submersible cable splice
low water probe(not shown)
Tie safety rope here
33
6.4 Installation in a Surface Water Source
CAUTION Highwater tempera-ture can causefailure to start.Low temperaturecan reduce liftand flow capac-ity. This canoccur in surfacewater duringweather ex-tremes, due totemporaryexpansion orcontraction of therubber stator. Theproduct specifica-tions say: Opti-mum water temp.is 46°F to 72°F(8°C to 22°C).Other ranges areavailable byspecial order.These perform-ance problemsare temporaryand will NOTdamage thepump. If you areuncertain aboutusing the pumpyou received,contact yoursupplier beforeyou install it.
CAUTION Thepump must befully submerged.A helical rotorpump mayoverheat and stop(temporarily) if thepump end is notfully submerged.
This refers to a surface well, spring, pond,lake, river or tank.
Positioning the pump The pumpmay be placed in an inclined orhorizontal position if desired. Toreduce the intake of sediment,do not place the intake veryclose to the bottom.
Models 03, 03H, 04 and04H have a small “venthole” near the top of thepump (photo). If the hole isnot submersed, it will suck airand prevent the pump fromperforming fully. The purpose ofthis hole is to allow water to fillan internal gap, to conduct heataway from the rubber stator.
River or stream Secure thepump from logs and debris thatmay float downstream. Usestainless steel wire rope or chaininstead of plastic safety rope(plastic rope will weaken insunlight). Consider digging ashallow well near the stream. This will allowfiltration of the water through the earth, andwill protect the pump from floating debris orhuman tampering.
Position of the low-water probe CAUTIONThe low-water probe must be positionedvertically, within 10°. Normally, it is to beinstalled on the pipe above the pump outlet,as shown in Section 5.9. This will only work ifthe pump is installed vertically. If the pump iswill NOT be vertical, find an alternative way tomount or suspend the probe, so that it ishigher than the pump, and in a verticalposition.
Is a flow sleeve required? NO, not within thenormal temperature range. The PS-Pumpshigh-efficiency motor generates very littleheat. A conventional submersible pumprequires a flow sleeve to assist motorcooling when installed in open water (notconfined by a narrow casing). It is a piece of4-6" pipe that surrounds the pump to in-crease flow around the motor.
Depth of submersion PS-Pumps may besubmersed as deep as necessary to ensurereliable water supply. The lift load on thepump is determined by the vertical head ofwater starting at the SURFACE of the water inthe source. Increasing the submergence ofthe pump (placing it lower in the source) willNOT cause it to work harder or to pump lesswater. Avoid placing the pump close to thebottom where it will pick up sediment.
Filtration at the pump intake PS-Pumps willtolerate small amounts of sand, but you mayneed to filter out larger debris that is normallyfound in a pond or stream. You can constructa simple coarse screen to protect the pumpand to reduce the nuisance of debris in yourwater system. One method is to wrap thepump with about 6-8 layers of loosely-wovenfabric or screen, of a material that will notdecay or rust. Some suggestions arefiberglass window screen, agricultural shadecloth, or weed-barrier fabric (available fromnursery and landscaping suppliers). Bind thefabric or screen with all-stainless hoseclamps, rubber, or polypropylene rope. Do notuse nylon; it softens with submersion in water.An improved method is to construct a sealedpump enclosure from 4-6" plastic pipe, withmany holes or slots to let water in. Then, wrapthe screen around that enclosure. This willdistribute the flow through a much larger areaof screen. After cutting holes or slots in theplastic pipe, wipe the inside carefully toremove plastic shavings and dust.
WARNING for SIPHON APPLI-CATIONS If a pump system hasa vertical lift of less than 33 feetup from the surface of the watersource, and then the water flowsdownhill to a lower point, a
siphon effect may cause suction at the pumpoutlet. This will cause an upward thrust on themotor shaft, resulting in damage to the motor.Prevent this by installing an air vent or avacuum breaker at the high point on the pipe.
>
34
6.5 Deep Well Setting — HowDeep?
PS-Pumps may be submersed as deep asnecessary to ensure reliable water supply.The lift load on the pump is determined bythe vertical head of water starting at theSURFACE of the water in the source. Increas-ing the submergence of the pump (placing itlower in the well) will NOT cause it to workharder or to pump less water, nor will itincrease the stress or wear on the pump.
There are reasons NOT to set the pump nearthe bottom of the well, if it isn’t necessary:
1. A deep setting will increase the sizerequirements, costs and weight of pipe andcable.
2. A deep setting may increase the chance ofsand or sediment being drawn into the pump.
To make an informed decision, it is helpful tohave accurate data for your water source. Inmost places, drillers are required to report thedetails and the performance of wells that theydrill. If you do not have the driller’s wellrecord, you may be able to obtain a copy fromyour regional government office that overseesground water resources and issues drillingpermits. In USA, it is a state office, typicallycalled Department of Natural Resources orState Engineer’s Office. However, the datamay be missing or inaccurate, and conditionscan change over the years. In critical cases, itis wise to have the well re-tested by a waterwell contractor.
6.6 Coping with Dirty WaterConditions
PS-Pumps have good resistance to quanti-ties of sand and fine sediment that cannormally occur in a well. However, anyamount of abrasive material will reduce thelife of this pump, like any other pump.Extreme sediment can cause the pump tostick. Sediment can also settle inside thedrop pipe each time the pump stops, andblock the flow. For water sources that containhigh amounts of sand, clay, or other solids,consider the following suggestions.
To avoid pumping dirty water
1. Have your well purged, developed, orotherwise improved by a water well contractorbefore installing the pump.
2. Temporarily install a more powerful pumpto draw at a high flow rate until the waterlooks clean.
3. Set the pump as high as possible in thewell. If the pump can be placed higher thanthe perforations in the well casing, it willprobably avoid all but the finest suspendedsilt.
4. After lowering the pump in a well, wait atleast 15 minutes for sediment or debris tosettle down.
5. If the water source is at the surface, dig ashallow well next to the water source to obtainclean water.
6. If the water source is at the surface, use afabric screen to protect the pump (see Section6.4).
If dirty water cannot be avoided
1. Use a reduced size of drop pipe. This willmaximize the velocity of water flow in order toexhaust sand particles. Refer to Section 13.2Water Pipe Sizing Chart. Select the smallestsize pipe that does not impose excessivefriction loss. Use a reducer bushing on thepump if necessary, to adapt it to a smallerpipe size (see the caution about plasticbushings in Section 6.2).
2. Monitor the situation regularly by observingthe volume of water pumped and/or thecurrent draw of the pump (AC amps – seeSection 9.3 and 13.7). As a pump wears, itsflow rate (and current draw) will decreasegradually. Replace the pump end whenreduced performance is observed, or beforeyour season of greatest water demand.Increased current draw may indicate debrisstuck in the pump and/or pipe.
Question Whateffect does hard,mineralized,alkaline or saltywater have?
Answer Gener-ally, none.Dissolved miner-als and salts arenot abrasive.
35
6.7 Utilizing a Low-ProductionWater Source
6.8 Installing the Pump Under aWindmill or Hand PumpCylinder
PS-Pumps can make the best of a limitedwater source, even if the pumping rate canexceed the recovery rate. You want to drawthe most water possible, without running dry.PS-Pumps can handle this in two ways.
The low-water probe The low-water probeallows the pump to work to its full potentialuntil the water level drops (see Section 5.9).This is a good strategy because you get allthe water you can while the sun shines.Place the pump near the bottom of the well toutilize the storage of water in the well. Whenthe pump is stopped by the low-water probe,it re-starts after a 20 minute delay. The LowWater OFF light will slowly flash even afterthe water recovers and the pump restarts, toindicate that the level got low at some timeduring the day. See Section 5.9, Low WaterProbe. It may be feasible to hang the probeindependently and use it to locate the waterlevel at any moment. See Section 6.3, SafetyRope and Binding.
Reduce the Maximum RPM setting If thewell has little storage capacity, the supply mayrecover before the 20-minute restart delay. Inthis case, reduce the “Maximum RPM” settingin the controller. See Section 5.6.
WARNING Do not use a valveas a means of reducing theflow. With a helical rotor pump,excessive pressure may result.Use the Maximum RPM settinginstead.
PS-Pumps can be combined with a classicwater-pumping windmill or hand pump, toutilize both energy sources automatically. Thefollowing system is often used with a conven-tional AC pump, so a generator can be usedfor backup. The AC pump is placed immedi-ately below the cylinder, and connected to thecylinder’s threaded intake. When power isapplied to the AC pump, it pushes water upthrough the cylinder, pushing its valves open.When the windmill draws water, it sucks it upthrough the AC pump with little resistance.(The centrifugal pump end of the standard ACpump allows water to flow through it when it isstopped.) When both pumps operate, eachone is relieved of its load, more or less.
This system can be employed with PS-Pumps. A centrifugal model (one with a “C” inthe model number) will allow water to flowfreely through it and does NOT require anyspecial precautions. For helical rotor models,the following warning applies.
To use a helical rotor pump under a cylinder,you must build a bypass assembly with a Tfitting and a foot valve (a check valve withintake screen). When the cylinder’s flowexceeds that of the solar pump, water issucked in through the foot valve. When thesolar pump’s flow exceeds that of thecylinder, the foot valve closes and allows thesolar pump to work normally and push upthrough the cylinder.
Question How is a pump damagedfrom “dry run”?
Answer If the pump runs completelydry, parts will overheat and bedamaged. However, if water is onlytrickling into the pump, it will usuallyprovide enough lubrication andcooling to prevent damage.
WARNINGhelical rotormodels (thosewithout a “C” inthe modelnumber) willNOT allow waterto flow freelywhen stopped. Abypass footvalve must beused. If it is notused, the result-ing suction cancause an uplifton the rotorwhich will causedamage andvoid the war-ranty.
Bypass foot valve assembly with offsetelbows to fit a drilled well casing
windmill or handpump cylinder
footvalve
PUMP
To make this system for a casing6" (150 mm) or smaller, an offsetusing 45° elbows must becarefully constructed, as illus-trated. Copper fittings must beused for the bypass assemblydue to the limited space in thewell casing. Do not use any ironfittings in this assembly.
36
7 IN-WELL ASSEMBLY ANDINSTALLATION
SEE REFERENCE SECTION At the end ofthis manual (Section 13) you will find instruc-tions for wellhead assembly, water storage,control and monitoring of water supply, pipesizing, freeze protection, and more.
7.1 Rubber Spacers (Models -07, -10, -14, -20 only)
This applies ONLY to models HR-07, 10, 14and 20 (HR-07, 14 and 20 pump ends)
Helical rotor pumps vibrate due to the eccen-tric rotation of the helical rotor. This is normal.Rubber spacers reduce the vibration that maybe transferred to the well casing. Models –03and –04 vibrate very slightly so they are notsupplied with rubber spacers.
Clearance for drilled well casings Rubberspacers fit a 6" (150 mm) inside-diameter orlarger well casing.
Cut the rubber spacer legs to fit smallercasing If you are installing the pump in a wellcasing smaller than 6", cut the spacer legs.Grooves indicate where to cut for a 4" (100mm) casing. Use a fine-tooth saw to cut therubber.
CAUTION Thethreads in thecheck valverequire anadhesive seal-ant. They are nottapered pipethread. Normally,there is no reasonto remove thecheck valve. Ifyou do remove it,use a hardeningadhesive sealantor epoxy gluewhen you replaceit. See CAUTIONin Section 9.1.
These helical rotor models doNOT have rubber spacers:
HR-03 HR-04 HR-04H
These modelshave rubberspacers:
(HR-07)
(HR-10) (HR-14) (HR-20)
37
7.2 Machine Installation
Water well pumps can be installed by hand inshallow water sources and in remote areasthat are not accessible to a pump servicetruck. Hand installation is generally performedusing rolled flexible POLYETHYLENE (PE)drop pipe rather than rigid pipe. In NorthAmerica, most professional pump contractorsdo NOT have the equipment to pull flexiblepipe. Their equipment is designed for rigidpipe in 21-foot pieces. Do not use flexible pipeunless you are committed to safely handlingits total weight (full of water) IN THE FUTUREwhen the pump must be removed. Forinstallations that are deeper than about 50feet (15m), please consider the followingwarnings and cautions.
We do not encourage hand installation exceptin shallow-water situations. Installation andremoval should never be performed by handwithout an adequate number of workers. Ifyou have any doubts about the feasibility,safety and economy of installation AND futureremoval, hire a professional pump servicecontractor.
Before considering installation or removal byhand, estimate the weight of the system andconsider the number of people necessary toinstall the pump AND to remove it in the future(with water in the pipe). To estimate the totalweight, add the following:
1. Cable weight — #10 submersible cable (3-wire + ground) weighs approximately 25 lbs.per 100 ft. (40 kg per 100m). Each larger size(smaller AWG#) weighs approximately 30%more.
2. Water in the pipe (lbs.) = pipe insidediameter (inches)2 X 0.34 X length (feet).Example: Water in 100 feet of 1" pipe weighsabout 34 lbs.
3. The pump weighs approximately 25 lbs.(11.5 kg.).
7.3 Hand Installation
If you are professionally equipped to installconventional AC submersible pumps, you canuse the same equipment and methods forour pumps. PS-Pumps have no special piperequirements. You can use any suitable rigidor flexible pipe. The only exception is toconsider reducing the pipe size in cases ofhigh sand concentration (to increase flowvelocity). See Section 6.2 Drop Pipe, andSection 13.2 Water Pipe Sizing Chart.
WARNING Handinstallation andremoval ispotentiallyhazardous.
WARNING DONOT USE AVEHICLE toinstall or removea pump. Duringremoval, thepump can catchon joints or edgesin the well casing.Damage or loss ofthe pump canoccur before thevehicle operatorcan react.
CAUTIONS for polyethylenepipe (PE, rolled pipe)1. Do not exceed the pressurerating of the pipe. The mostcommon PE pipe is type SIDR-
15. It has a pressure rating of 100 PSI (7 bar).This is equal to 230 feet (70m) of total verticallift. Types SDR-9 and SIDR-7 have a pressurerating of 200 PSI (14 bar), equal to 460 feet(140m). They is available from local suppliersin some areas, or from your Solar pumpsupplier. Special compression connectors aremade for this pipe.
2. Use only pipe connectors that are designedfor the pipe you choose. Do not use galva-nized steel adapters. They will rust through.
3. Do not use any sealing compound in PEpipe connections.
4. If you use insert connectors with hoseclamps, use TWO clamps at each adapter.Tighten them with a wrench. Use “all stain-less” hose clamps. Automotive clamps havecarbon steel screws that will rust and fail.
5. Have extra hose clamps on hand in caseyou damage or lose one.
6. Have an extra coupling on hand in caseyou bend the pipe too sharply (kink it) andmake a weak spot.
7. PE pipe will stretch about 1%. Make theelectrical cable and safety rope about 1.5%longer than the pipe so when the pipestretches, the cable and splice will not bestressed.
8. If you plan to bury PE pipe in the ground,contact the pipe manufacturer for additionalinstructions.
WARNING DONOT USE AROPE WINCH toinstall or removea pump in adrilled wellcasing(borehole).If you use a winchto pull the pumpby pulling thesafety rope, theelectrical cablecan slip down thepipe and/or thepipe can collapse.If the pipe orcable jams andgets wedged inthe casing, youcan lose yourequipment andeven permanentlyblock the well!Some installersuse a winch witha reel of about 3feet (1m) diam-eter or larger, topull flexible pipe.This is ideal if youhave the equip-ment and experi-ence to do the jobsafely.
38
Sanitizing a well will kill bacteria that mayhave been introduced during the pumpinstallation. This can be done with chlorinebleach or chlorine pellets poured down thewell just before or just after a pump isinstalled. Once you introduce these chemi-cals make sure that the pump is working toprevent that it sits for a longer time in theaggressive environment.
Consult a local supplier orenvironmental health authorityfor a recommended procedure.Do not use an excessive con-centration.
WARNING PS-Pumps may be damaged bysoaking in a high concentration of chlorinesolution. Avoid prolonged contact.
7.4 Sanitizing the Well
39
8 OPERATING THE PUMP
This explains the function of the switch andthe indicator lights on the pump controller. SWITCH
POWER ON/OFFWhen switched off/on during operation, it resets allsystem logic.
Indicator lights
SYSTEM (green)The controller is switched on and the power sourceis present. In low-power conditions, the light mayshow even if there is not enough power to run thepump.
PUMP ON (green)Motor is turning. Sequence of flashing indicatespump speed. See below sequence
PUMP OVERLOAD (green changes to red)
SOURCE LOW (red)The water source dropped below the level of thelow-water probe. After the water level recovers, thepump will restart, but this light will slowly flash untilthe sun goes down, power is interrupted, or thePOWER switch is reset. This indicates that thewater source ran low at least once since theprevious off/on cycle.
TANK FULL (red)Pump is turned off by action of the remote floatswitch (or pressure switch or manual switch,whichever is wired to the “remote float switch”terminals.
BATTERY LOW (tank light flashes)Battery systems only – battery voltage fell to 44 /22V, and has not yet recovered to 48/24V.
RPM indication: Pump speed can be read off by theflashing sequence of the Pump ON LED.
LED ON > 900One flash > 1200Two flash > 1600Three flash > 2000Four flash > 2400Five flash > 2800
40
Starting the pump Be sure there is not aclosed valve or other obstruction in the waterline. Switch on the array disconnect switch inthe junction box, and toggle the power switchon the controller. It is normal to leave theswitches on at all times, unless you desire tohave the system off.
A solar-direct pump should start under thefollowing conditions
1. clear sunshine at an angle of about 20°or more from the surface of the solararray
2. cloudy conditions, if the sunshine isbright enough to cast some shadow
3. low-water probe submersed in the watersource (or bypassed in the controller) –Water-Low light OFF
4. full-tank float switch is not responding to afull tank – Tank-Full light OFF
5. battery system only – voltage is higherthan the low-voltage disconnect point (22Vor 44V)
When sunshine is insufficient Whensunshine on the array is present, but too weakfor the pump to run, it will attempt to startabout every 90 seconds. During each attempt,you will see the PUMP ON light come on.
When pump runs slowly (PUMP ON) underweak sun conditions
1. PS-Pump models that have “C” in themodel number -– These use a centrifugalpump end. In weak sun, the pump mayspin without lifting water all the way to theoutlet. This is normal.
2. PS-Pump models that do NOT have “C” inthe model number – These use a helicalrotor (positive displacement) pump end. Ifthe pump is turning, even slowly, water willbe delivered at a slow rate.
When pump stops from a sudden shadow onthe solar array
If a shadow suddenly passes over the array,like if you walk in front if it, the controller willlose track of the input voltage. It may makerapid on/off noises and a high-pitched noise,then stop. This does NOT indicate a problem.The pump will attempt to restart after thenormal delay.
Time delays1. After pump stops due to insufficient
sunshine – 120 SECONDS
2. After full-tank float switch resets – 2 to 3SECONDS
3. After low-water probe regains contact withwater in the source -– 20 MINUTES butthe indicator light will slowly falsh for therest of the solar day, or until power isdisrupted or the controller is turned off/on.
4. Battery systems – after low voltagedisconnect point is reached, delay to stoppump – a few SECONDS. After voltagerecovers, delay to re-connect – a fewSECONDS
To force a quick start To test or observe thesystem, you can bypass the normal timedelays. Switch the POWER switch off then onagain. The pump should start immediately ifsufficient power is present.
Pump vibration Most PS-Pump models usea HELICAL ROTOR pump end (those that doNOT have a “C” in the model number. A slightvibration is normal with these pumps. If noiseis disturbing, try changing the position of thepump. PS-Pump models that have a “C” inthe model number use a CENTRIFUGALpump end similar to conventional pumps.They should produce no significant vibration.
PUMP OVERLOAD (PUMP ON light showsred instead of green) The system has shutoff due to an overload. This can happen if themotor or pump is blocked or very difficult toturn and is drawing excessive current (hardto turn). Overload detection requires at least250 Watt output of the solar array. This canbe caused by a high concentration of solidsin the pump, high water temperature, exces-sive pressure due to high lift or a restrictionin the pipe, or a combination of these factors.The controller will make 3 start attemptsbefore shutting down the system. TheSystem ON LED will be OFF and the redOVERLOAD LED ON. The system will notreset until the ON / OFF switch is turned OFFand ON again. See Troubleshooting, Section9.3 “HIGHER CURRENT”.
Operating the Pump continued
41
9 TROUBLE SHOOTING
Please read this section before calling forhelp.If you call for help, please refer to the modeland serial numbers. (See SYSTEM REPORT,page 3.)
IF THE CONTROLLER MUST BE REMOVEDFOR REPAIR OR REPLACEMENT Removethe wires and flexible conduit from thecontroller and remove the CONTROLLERONLY.
LEAVE THE JUNCTION BOX IN PLACE.
9.1 If The Pump Doesn’t RunMost problems are caused by wrong connec-tions (in a new installation) or failed connec-tions, especially where a wire is not secureand falls out of a terminal. The System ONlight will indicate that system is switched onand connected to the controller. It indicatesthat VOLTAGE is present but (in a solar-directsystem) there may not be sufficient power tostart the pump. It should attempt to start atintervals of 120 seconds.
Pump attempts to start every 120 secondsbut doesn’t runThe controller makes a slight noise as it triesto start the pump. The pump will start to turnor just vibrate a little.
1. There may be insufficient power reachingthe controller. A solar-direct (non-battery)system should start if there is enough sunto cast a slight shadow. A battery systemshould start if the supply voltage is greaterthan 22V (24V system) or 44V (48Vsystem).
2. If the pump was recently connected (orreconnected) to the controller, it may berunning in reverse direction due to wiringerror. See Section 5.8.
3. If the motor shaft only vibrates and will notturn, it may be getting power on only twoof the three motor wires. This will happenif there is a broken connection or if youaccidentally exchanged one of the powerwires with the ground wire. See Section9.3, testing the motor circuit and thecontroller output.
4. The pump or pipe may be packed withmud, clay, sand or debris.
5. Helical rotor models: The rubber statormay be expanded from heat, due to sunexposure or pumping water that is warmerthan 72°F (22°C). This may stop the
pump temporarily, but will not causedamage. (See Section 12, TemperatureSpecifications.)
6. Helical rotor models: The pump may haverun dry. Remove the pump stator (outerbody) from the motor, to reveal the rotor. Ifthere is some rubber stuck to the rotor,the pump end must be replaced.
7. Helical rotor models: The check valve onthe pump may be faulty or stuck, allowingdownward leakage when the pump is off.This can prevent the pump from starting.
PUMP OVERLOAD (PUMP ON light showsred instead of green) The system has shutoff due to an overload. This can happen if themotor or pump is blocked or very difficult toturn and is drawing excessive current (hardto turn). Overload detection requires at least250 Watt output of the solar array. This canbe caused by a high concentration of solidsin the pump, high water temperature, exces-sive pressure due to high lift or a restrictionin the pipe, or a combination of these factors.The controller will make 3 start attemptsbefore shutting down the system. TheSystem ON LED will be OFF and the redOVERLOAD LED ON. The system will notreset until the ON / OFF switch is turned OFFand ON again. See Troubleshooting, Section9.3 “HIGHER CURRENT”.
CAUTION DONOT REMOVETHE CHECKVALVE from thepump. If you wantto look for dirtstuck inside thepump, it ispreferable tounbolt the pumpbody and pull itfrom the pump. IFYOU MUSTREMOVE THECHECK VALVE,use a hardeningadhesive sealanton the screwthreads when youreplace it. Epoxyglue is good. Thethreads are nottapered. They willleak if a harden-ing sealant is notused. Teflon tapewill make a goodseal, but it maynot prevent thejoint from un-screwing.
42
Many problems can be located by simpleinspection. No electrical experience isrequired for this.
Inspect the solar array1. Is it facing the sun? (See solar array
orientation, Sections 4.4 and 4.5)
2. Is there a partial shadow on the array? Ifonly 10% of the array is shadowed, it canstop the pump!
Inspect all wires and connections1. Look carefully for improper wiring (espe-
cially in a new installation).
2. Make a visual inspection of the conditionof the wires and connections. Wires areoften chewed by animals if they are notenclosed in conduit (pipe).
3. Pull wires with your hands to check forfailed connections.
Inspect the controller and junction box1. Remove the screws from the bottom plate
of the controller. Move the plate downward(or the controller upward) to reveal theterminal block where the wires connect.(See Section 5.5.)
2. First, check for a burnt smell. This willindicate a failure of the electronics. Lookfor burnt wires, bits of black debris, andany other signs of lightning damage.
3. Open the junction box. Is the Power INswitch turned ON? Pull on the wires to seeif any of them have come loose.
4. Inspect the grounding wires and connec-tions! Most controller failures are causedby an induced surge from nearby lightningwhere the system is NOT effectivelygrounded. Ground connections must beproperly made and free of corrosion. (SeeSection 5.2.)
Check the low-water probe system (SeeSection 5.9)
If the controller indicates “SOURCE LOW”when the pump is in the water, inspect thelow-water probe system. The probe ismounted on, or near the pump. If inspection isnot feasible, you can bypass the probe or testit electrically. See Section 9.3 below.
1. If the probe is NOT being used, there mustbe a wire between terminals 1 and 2.
2. The probe is a cylindrical plastic devicemounted on or near the pump. It containsa small float on a vertical shaft. The float
must be able to move up to indicate that itis submerged, and down to indicate that itis dry.
3. The probe must be positioned vertically(within about 10°).
4. The probe or a probe wire may be broken.Inspect the wires for damage.
5. Does the pump run when the probe isOUT of the water? This can happen if thefloat in the probe is stuck. In surfacewater, this can happen from algae, asnail, or other debris (see Section 5.9).
6. If the pump was purchased before August2003, it may have a wet-electrode probe.In case of trouble, it can be replaced witha new (mechanical float) probe, with nochanges to wiring or controller.
Check the full-tank float switch (SeeSection 5.10)
If the controller indicates “TANK FULL” whenthe storage tank is not full, inspect the floatswitch system. If your system has a floatswitch, it will be mounted in the tank. Ifinspection is not feasible, you can bypassthe switch or test it electrically. See Section9.3 below.
1. If a float switch is NOT being used, theremust be a wire between terminals 4 and5.
2. Inspect the float switch. Is it stuck in theUP position?
3. There are two types of float switch,normally-open and normally-closed.Check to see that the wiring is correct forthe type that is used. (See Section 5.10)
Force a quick startIf you restore a connection or bypass theprobe or float switch, there is no need to waitfor the normal time delay. Switch the on/offswitch (or the power source) off then onagain. The pump should start immediately ifsufficient power is present.
9.2 Inspect The System
43
A “multimeter” is required and a clamp-onammeter is helpful. For advice, see Section13.7, Selecting and Using Meters for Electri-cal Testing.
Record your test results on the ProblemReport Form, Section 9.5.“ Test #” REFERS TO TABLES AND PHOTOSIN SECTION 9.6If you see a false reading of the SOURCELOW or TANK FULL light, go to Test # 9 / 10/ 11Test the solar array circuit1. OPEN-CIRCUIT VOLTAGE Section 9.6
cf. Test #1 This is “idle” voltage. It isnormally high because no current is beingdrawn (it’s doing no work).
2. SHORT CIRCUIT CURRENT cf. Test #2or spark test — This is helpful if the pumpis trying to start or does not seem to getfull power. DISCONNECT THE ARRAYfrom the controller before making this test.(A short circuit at the array will only causecurrent slightly higher than normal.) If youdon’t have a DC amp meter, a spark thatcan jump 1/4" (6 mm) indicates a goodprobability that the array is workingproperly.
3. VOLTAGE UNDER LOAD (with pumprunning) cf. Test #3
4. CURRENT UNDER LOAD cf. Test #4Was power was connected to the controllerwith reverse polarity?
No lights will show on the controller. Thiswill not cause damage. cf. Test #1
Test the motor circuit (resistance test withPOWER OFF), cf. Test #7Make this test if there is proper voltage at thecontroller input but the motor does not run. Itwill confirm the condition of the entire motorcircuit, including the motor, pump cable andsplice.
Test the running current of the motorcircuit (AC amps), cf. Test #6/6AThis is one of the most useful trouble shootingtechniques because it indicates the force(torque) that the motor is applying to thepump. For greatest ease, use a clamp-onammeter, available from local electricalequipment suppliers. It allows you to measurecurrent without breaking connections (cf. Test#6A).
Table of AC RUNNING CURRENT Forhelical rotor pumps, normal running currentindicated on this table. The current staysnearly constant as voltage and speed vary.Your measurements may vary by as much as10%, and more if temperature is out of thenormal range. Comparing your reading withthis table. This will indicate whether the workload on the motor is normal for the lift it isproducing. Make note of your measurement.Future changes may indicate pump wear, orchange in the level of the water source.
HIGHER CURRENT (especially PUMP OVER-LOAD light) may indicate:1. The pump may be handling excessive
sediment (sand, clay).
9.3 Electrical Testing
44
9.3.2 Table of AC running current for PS1200 systems
9.3.1 Table of AC running current for PS200 and PS600 systems
tfiLpmuP
852
5105
3257
03001
83521
64051
35571
16002
67052
19003
701503
221004
731054
251005
761055
081006
591056
012007
mtf
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45
2. The total dynamic head (vertical lift pluspipe friction) may be higher than you thinkit is.
3. There may be an obstruction to the waterflow — sediment in the pipe, ice in thepipe, a crushed pipe or a partially closedvalve. (Is there a float valve at the tank?)
4. Helical rotor models: Water may bewarmer than 72°F (22°C). This causes therubber stator to expand and tightenagainst the rotor (temporarily, non-damaging). See Section 12 for tempera-ture limits.
5. Helical rotor models: Pump may have rundry. Remove the pump stator (outer body)from the motor, to reveal the rotor. If thereis some rubber stuck to the rotor, thepump end must be replaced.
To reset the OVERLOAD shutoff (red light),switch the pump controller OFF and ON.
LOWER CURRENT may indicate:1. In a deep well, the level of water in the
source may be far above the pump intake,so the actual lift is less than you think. Thisis not a problem.
2. The pump head may be worn, thus easierto turn than normal (especially if there isabrasive sediment).
3. There may be a leak in the pipe system,reducing the pressure load.
4. Helical rotor models: Water may be colderthan 46°F (8°C). This causes the rubberstator to contract, away from the rotor. Thepump spins easier and produces less flowunder pressure.
Test the low-water probe circuitIf the controller indicates “SOURCE LOW”when the pump is in the water, the low-waterprobe system may be at fault. (See Section5.9.) The controller applies 5VDC to theprobe terminals. When the water level isabove the probe, the switch in the probemakes contact. That causes the appliedvoltage to drop toward zero. The systems“sees water” and allows the pump to run. Ifthe voltage is greater than 3V, dry shutoff istriggered. Test #9The low-water probe has an internal 1Kresistor in series with the switch. When closed(in water), the normal resistance is around1000 .
To bypass the low-water probe (and activatethe pump), connect a small wire between theprobe terminals (Test #1 and Test #2) in thejunction box. Restart the controller. If thepump runs, there is a fault at the probe or inthe probe wiring. The wires may be shorted(touching each other) or open (broken) or themoving part on the probe may be stuck withdebris, or the probe may be out of its normal,vertical position.
Test the full-tank float switchIf the controller indicates “TANK FULL” whenthe tank is not full, the float switch or pressureswitch system may be at fault. (See Section5.10 or 5.12)
1. If the remote switch circuit is NOT beingused, there must be a wire betweenterminals 4 and 5.
2. There are two types of float switch,“normally open” and “normally closed”.Check to see that the wiring is correct forthe type that is used.
3. Most float switches are “normally open”.Disconnect a wire from terminal 3 or 4,and the pump should run. Connect a wirebetween terminal 3 and 4, and the pumpshould stop. See also Test #10
4. Most pressure switches (and some floatswitches) are “normally closed”. Connecta wire between terminals 4 and 5, andthe pump should run. See also Test #11
If the pump responds to the bypass testsabove but not to the float switch, the wiresmay be shorted (touching each other) oropen (broken), or the switch may be stuck
Electrical Testing continued
46
with debris, or out of its correct position.
1. Is the solar array receiving shadow-freelight? (It only takes a small shadow to stopit.) Is it oriented properly toward the south,and tilted at the proper angle? SeeSection 0.
2. Be sure you have the right pump for thetotal lift that is required, out of the well +up the hill. In the case of a pressurizingsystem, the pressure head is equivalent toadditional lift (1 PSI = 2.31 feet) (1 bar =10 m).
3. Be sure all wire and pipe runs are sizedadequately for the distance. Refer to wiresizing in the pump sizing table, and to thepipe sizing chart in this manual, referencesection.
4. Inspect and test the solar array circuit andthe controller output, as above. Writedown your measurements.
5. There may be a leak in the pipe from thepump. Open a pipe connection andobserve the water level. Look again laterto see if it has leaked down. There shouldbe little or no leakage over a period ofhours.
6. Measure the pump current and compare itwith the table in the previous section.Test #6
7. There is a “max. RPM” adjustment in thecontroller. It may have been set to reducethe flow as low as 50%. See Section 5.6.
Has the flow decreased over time?1. Is the AC motor current lower than
normal? The pump end (pumping
mechanism) may be worn from too muchabrasive particles (sand or clay) in thewater.
2. Is the AC motor current higher thannormal? Doesn’t start easily in low light?This is likely to be related to dirt in thepump and/or pipe.
3. Look in the water tank or pipes to see ifsediment has been accumulating.
4. Run the pump in a bucket to observe.
5. Remove the pipe from the pump outlet(check valve) and see if sand or silt isblocking the flow.
6. If the check valve itself is clogged with dirt,see CAUTION, Section 9.1.
7. To help prevent dirt problems, see Section6.6 Coping With Dirty Water Conditions.
8. After years of use, it may be necessary toreplace the pump end. Call your pumpssupplier for advice.
9.4 If The Pump Runs But Flow Is Less Than Normal
47
If you need help, this form will expeditethe trouble shooting process. Please fill itin to the best of your knowledge.
9.5 Problem Report Form
Date
Contact InfoDealer
Installer
System Owner
Person responsible for troube shooting
How to contact
Pump System IDSolar-direct or battery system? Solar-direct battery
Pump or System Model #
Pump Model # Serial #
Controller Model # Serial #
If Battery System
Voltage V
Is it pressurized? yes no
Well/Water Source Data
Well depth
Static water level
Drawdown level
Recovery rate of well
Depth of pump setting
Additional vertical liftfrom top of well
Total head
Installation Date
Drop pipe, length & size
Pipe from well headto tank, length & size
Pump cable size & length
Wiring from solar array tocontroller, size & length
Page 1/3 of Problem Report Form
48
Page 2/3 of Problem Report Form
Problem Report Form continued
Describe the Problem
If pump won’t start, include sequence andduration of the indicator lights.
Low-water probe: Is the low-water probe installed?If not, there must be a wire between junction box terminals 1 and 2.(See Section 5.9.)
Did you test the pump before installation in the well?
Did the system work properly before this problem?
Has there been a thunderstorm recently?
Has the RPM control in the controller been reduced from maximum?
SOLAR-DIRECT systems only:There must be NO OTHER electrical load or device connected to thesame solar array. This may include an active (electric) solar tracker (LORENTZ active trackers can work together with our pumps) or anelectric fence charger. Disconnect it and try it again.
yes no
yes no
yes no
yes no
yes no
ELECTRICAL MEASUREMENTS
Test # refers to the photos in Section 9.6
Weather conditions during measurement
Time of day
Solar array (or battery) volts with PUMP OFF V DC Test #1
Solar array (or battery) volts during pumping V DC Test #3
Solar array (or battery) current during pumping A DC Test #4/4A
Pump Speed, count the number of flashes Test #5
49
Page 3/3 of Problem Report Form
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.
Measure AC amps through any one motor wire. A ACNormal range for working pump is 1 - 9 A(a normal AC clamp-on meter will work)cf. Test #6/6A
DC Volts on 3 motor phases — YES, set the meter to DC and test as above. Around than 1/10V is good. Around 1/2V is bad.Note here only if bad V DC
MOTOR CIRCUIT RESISTANCE (Test #7)
This will test the integrity of the motor and the wiring to it. This is done with NO POWERapplied. If you are not familiar with measuring resistance, please refer to your meter’sinstruction manual. You will need to use the lowest ohms range on your meter. Hold the probestightly to the wires and scratch then a little to ensure good contact. Hold tight until the meterdisplay shows the LOWEST reading that you can get. Holding the probes with your fingers willnot alter the reading.
DISCONNECT the motor wires (L1 / L2 / L3) from the junction box.Measure the resistance between each pair on the motor cable
L1-L2 L1-L3 L2-L3
The resistance must be in the range of 0.1 to 1.5 ohms — ALL EQUAL.
Problem Report Form continued
Resistance of each pump wire to ground – There shouldbe NO continuity. A meter reading should be much higherthan 100K ohms. DO NOT TOUCH the wires or probes withyour fingers when reading this high range, or your own bodycontinuity will reduce the reading, cf. Test #8
If you see false indications of the lights for SOURCE LOW orTANK LOW, cf. Test #9/10/11
Water TemperatureIs the water warmer than 72 oF (22 oC)? This can cause ahelical rotor to tighten due to expansion of the rubber stator.
oF / oC
Notes
50
These tests are extremely helpful when tryingto assess the performance of a system, orlocate a fault. These procedures will help youto fill out the Problem Report (Section 9.5).
Obtaining and using a multimeter Referto Section 13.7, and to your meter’s instruc-tion manual. Measuring current (amps) iseasiest if you have a clamp-on ammeter, asshown in photos 2A, 4A and 6A.
Probe input Some meters give a choice ofprobe sockets. The negative (black) probeALWAYS goes in the “COM” (common)socket. The + (red) probe input varies, and isspecified below.
9.6 Electrical Testing Illustrated
WARNINGThese tests posepotential shockand burn hazards.Follow appropri-ate safety precau-tions.
WARNING Tomeasure voltage,put the + probe inthe VOLTS socketon the meter. If itis in an AMPSsocket, attemptinga voltage readingwill cause a shortcircuit andpotential damage.
Range If your meter is “auto-ranging”, thisdoes not apply. Otherwise, use the rangethan the reading you expect. For example, inTest #1, “normal” voltage is around 80. Theproper range may be 100V or 200V, depend-ing on your meter design.
Access Open the junction box for access tothe terminals. The appearance of your wiringmay vary.
Part 1 – Testing the Solar Array (DC)REFER TO THE NUMBERED PHOTOS ON THE FOLLOWING PAGEThis test refers to a 48V solar array with a PS600 pump set. Your system voltagemay vary from that
*) Test 4 or 4A – The current is determinedby both the array AND the load (currentdraw of the pump system). If the pump isnot under full load (like in a bucket), thecurrent may be as little as 1 amp.
BATTERY SYSTEMS Perform tests #1, 3 and 4 (4A), as above. Normal resultfor #1 should equal the battery voltage,typically 44-58V Normal result for #3 isslightly lower, not more than 2V lower.
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51
Electrical Testing Illustrated continued
Test 1 + 2 Test 2a
Test 4 Test 4a
Test 3 Same as Test 1, but disconnect switched ON
PV discconnectswitch OFF
PV discconnectswitch ON
PV disconnectswitch ON
and pump running
Remove one array wire and re-make theconnection THROUGH your meter. Probeconnections must be secure. A clampingdevice is helpful (split bolt is shown as anexample).
PV disconnectswitch ON
and pump running
DC clamp-on meter must be zero-set first
52
Part 2 – Testing the pump circuit (AC and resistance)REFER TO THE NUMBERED PHOTOS ON THE FOLLOWING PAGE
Electrical Testing Illustrated continued
Part 3 – Testing the low-water probe circuit
Part 4 – Testing the full-tank float switch (or pressure switch) circuit
*) Resistance: Hold the probes tightly to the wire and scratch them to ensure good contact.Hold them still until the meter display shows the LOWEST reading that you can get. Holdingthe probes with your fingers will not alter the reading.
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Electrical Testing Illustrated continued
Test 5 Test 6
Test 6A Test 7
Other testsSee Section 9.2:
Check the low-water probe andcheck the full-tankfloat switch
Analog (mechani-cal) meterrequires zero-adjustment. Forthis test, you cantouch probes withyour fingers.
Remove any onepump wire and re-make the connectionTHROUGH yourmeter. Probeconnections must besecure. A clampingdevice is helpful
Test 10 Test 11If a normally open (N.O.)float switch is used, it iswired this way.To measure switchcircuit resistance,DISCONNECT the wiresfrom terminals 3 & 4,similar to Photo #7.
If a normally closed (N.C.)float switch OR pressureswitch is used, it is wiredthis way.To measure switch circuitresistance, DISCONNECTthe wires from terminals 4 &5, similar to Photo #7.
Speed indication of Pump.By counting the ammount of flashes of thePump ON LEDthe RPM of the pump can be read off 900 RPM Pump ON LED is ON1200 RPM Pump ON LED flashes once1600 RPM Pump ON LED flashes twice2000 RPM 3 X flashing2400 RPM 4 X flashing2800 RPM 5 X flashing
54
10 MAINTENANCE10.1 Controller and Pump
10.2 Solar Array
10.3 Electrical WiringController and junction box The controlleris electronic with no moving or wearing parts.It requires no maintenance. There are rubbergasket seals at the top and bottom, andrubber plugs to seal unused conduit holes.Inspect them to insure that the controller issealed from moisture, insects, etc. Check thatmounting and conduit hardware is tight.
Motor The motor is water-lubricated andrequires no maintenance. It is permanentlysealed and has no brushes or other frequentlywearing parts.
Pump end The pump mechanism (pumpend) is lubricated only by water and requiresno maintenance. It may wear after someyears, especially if there are abrasive solids inthe water. If sand accumulates in the storagetank or pipes as a result of normal pumping, itis best to take periodic measurement of thepump’s performance. If the flow rate is lessthan normal, see Section 9.4. A worn pumpend can be replaced in the field, after thepump is pulled from the water source.
Power wiring Inspect wires and connec-tions carefully. Any wires that are hangingloose should be secured to prevent them fromswinging in the wind. Exposed wiring must besunlight resistant and in good condition. Inthe case of a tracking array, look carefully forany wire damage due to rubbing, bending, orpulling as the tracker swings. If wiring wasnot performed to professional standards,improve it to prevent faults in the future.
Grounding Inspect the grounding systemcarefully. All connections must be tight andfree of corrosion. Poor grounding can lead todamage from lightning-induced surges. SeeSection 5.2.
Solar array mounting bolts Bolts tend toloosen as the array structure flexes in highwinds. Check tightness. All bolts should allhave lock washers to keep them tight.
Sun exposure Cut away any vegetation thatwill grow enough to block solar illumination.Shading even a small corner of the solar arraymay stop the pump, or greatly reduce its flow.
Solar array cleaning If there is dirt, mineraldeposits, bird droppings or other debris stuckto the solar array surface, clean it with water,vinegar or glass cleaner.
Solar Array Tilt Inspect the tilt of the array.The optimum tilt angle varies with the season.Some people adjust the tilt twice per year.Other people set it at a single setting as apermanent compromise. Section 4.5 fordetails.
Solar Tracker If the system uses a solartracker, lubricate the bearings, check mount-ing bolts and mechanism. Refer to trackermanufacturer’s instructions.
55
11 MANUFAC-TURER’SWARRANTY
HR-xx Pumps, ECDRIVES and PS-xxxcontrollers are warranted by the manufac-turer to be free from defects in materialand workmanship for two (2) years fromdate of purchase.Failure to provide correct installation, opera-tion, or care for the product, in accordancewith the instruction manual, will void thewarranty. Product liability, except wheremandated by law, is limited to repair orreplacement, at the discretion of the manu-facturer or importer.
Neither manufacturer nor importer is respon-sible for the labor or other charges necessi-tated by the removal, transportation, orreinstallation of any defective product.
Warranty does not cover damage due tofailure to install the device properly, mishan-dling or abuse, failure to protect circuitry fromweather exposure, failure to protect fromoverheating due to sun exposure or othersources of heat, failure to protect from saltspray or other corrosive factors such aselectrolytic action, failure to seal out insects,spiders or rodents, lightning, flood or otheracts of nature, or failure of or inappropriateapplication of peripheral devices includinglightning or surge protectors.
Pump Rotor / Stator and Vanes of PS-Boost,ETAPUMP and PS-XXX Motor / Pump areconsidered to be normal wearing parts, andare not covere under warranty.
Warranty does not cover damage due tosand or abrasive particles in the water, orincompatibility of pump materials withcorrosive substances or hydrocarbon orpetroleum impurities, or from running thepump with an insufficient supply of water.
No specific claim of merchantability shall beassumed or implied beyond what is printed onthe manufacturer’s or importer’s printedliterature. No liability shall exist from circum-stances arising from the inability to use theproduct, or its inappropriateness for anyspecific purpose. It is the user’s responsibilityto determine the suitability of the product forany particular use.
12 STANDARDS,ENVIRONMENTALAND TEMPERA-TURE SPECIFI-CATIONS
In all cases, it shall be the responsibility ofthe customer to ensure a safe installation incompliance with local, state and nationalelectrical codes.
PS-xxx controllers are built to DIN-VDEregulations and carry the CE stamp indicat-ing that the European Union electromagneticinterference standards (Dt. EMV) have beenfulfilled. Printed circuit boards are conformal-coated against moisture. The enclosure isthick anodized aluminum, gasket-sealed andraintight for any outdoor environment (enclo-sure class IP55). The controller is suited totropical conditions according to IEC 68-2-30.The controller is not submersible.
Temperature RangesPumps: Helical rotor pumps (all without C inthe model number): For pumps in the stand-ard temperature class, the optimum range ofwater temperature is 46°F to 72°F (8°C to22°C).
Controller: Ambient air temperature -22°F to113°F (-30°C to 45°C). The controller hasover-temperature protection.
Storage TemperaturePump and controller can be stored (not used)in the range of 0°F to 120°F (-20° C to 50 °C).
56
Solar array Photovoltaic (PV) cells produceelectricity directly from sunlight (not fromheat). Light causes electrons to jump from thetop layer of the cell, into “holes” in the layerunderneath. When a circuit is made betweentop and bottom layers, electric current flows.Each cell produces about 1/2 volt. As sunlightvaries, the current (amps) varies while thevoltage stays nearly constant.
PV cells are connected in series for thedesired voltage, and sealed under glass tomake a “PV module”.The assembly ofmodules is called a “PV array”. There are nomoving or wearing parts in PV modules. Theglass used in high quality PV modules istempered, and is extremely strong. It istested to federal standards that includeresistance to a 1" ice ball traveling at 100mile per hour.
Some PS-Pump systems use a “passive” oractive solar tracker, which tilts the array tofollow the sun through the day. Daily outputcan be increased by that feature up to 50%.
Our ETATRACK systems reduce system cost
Brushless motor system PS-Pumps use a“brushless DC motor system”. This consists ofa special 3-phase AC motor (synchronous,permanent magnet), and a controller thatchanges the solar DC power to 3-phase AC.AC creates a rotating magnetic field thatcauses the shaft to spin. The motor’s speed isdetermined by the frequency of the AC power.The controller varies the frequency (and thevoltage) to bring the motor up to speed slowly.It then adjusts the motor speed according tothe power available from the sun.
Older-technology solar pumps have a tradi-tional DC motor that uses “brushes” (smallblocks of carbon-graphite) to conduct currentto the spinning part of the motor. Not only dothe brushes wear out in a few years, but it isnecessary to have air in the motor and aperfect seal to keep water out. The brushlessmotor is filled with, and lubricated by water. Itis similar mechanically to conventional ACsubmersible motors.
Controller The PS-controller starts the pumpslowly and adjusts its speed according to thepumping load and the power available fromthe solar array. Power output from the array isoptimally matched to the load by maximumpower point tracker (MPPT) and linear currentbooster (LCB) functions, to produce maxi-mum power transfer throughout all condi-tions. The LCB function is analogous to anautomatic transmission in an automobile. Itstarts the pump in “low gear” (it lowers the
13 REFERENCE SECTION13.1 Principles of Operation
array voltage and boosts the current). Underlow sun conditions, it stays in “low gear” toresist stalling. As sunlight increases, itadvances continuously toward “high gear”(higher voltage). The MPPT system refinesthe LCB function by tracking changes in thearray voltage. Array voltage varies primarilywith temperature (it is higher at low tempera-tures). When the pump stalls in low sunlight,the controller switches the pump off.
The controller converts the DC power from thesolar array to 3-phase AC power to run themotor. Due to the special natuerl of this ACvoltage which is made with PWM technologyit cannot be measured with a multimeter.Motor speed (RPM) is proportional to the ACfrequency. The frequency starts low (about 20Hz), and increases gradually to a maximumof 3400 RPM (70 Hz).
The float switch circuit operates at 12VDC,carrying maximum current of 4.7mA. Thecontroller has terminals for either normallyopen (N.O.) or normally closed (N.C.) switch-ing.
The low-water probe circuit applies 5VDC to aprobe. The water conducts a small amount ofcurrent between the two electrodes of theprobe. If the probe is out of the water, thecontroller stops the pump. When the waterlevel recovers, there is a 20 minute delaybefore restart.
Pump end – centrifugal models Pumpswith a MODEL NUMBER CONTAINING “C”use a multi-stage centrifugal pump end,similar to that of conventional well pumps –this is for high volume at 75 feet (23m) orless.
Pump end – helical rotor models Pumpswith a MODEL NUMBER THAT DOES NOTCONTAIN “C” have a helical rotor pump end(also called “progressive cavity” pump). Therotor fits closely into a rubber stator that has ahelical groove of a different pitch. The mis-match between the rotor and stator formssealed cavities that trap water. As the rotorturns, the cavities progress toward the outlet.
57
Positive displacement action The helicalrotor pump differs from centrifugal pumps inthat it maintains high efficiency and liftcapacity even at low rotational speeds andlow flow rates. This allows the pump to workwith a small, inexpensive solar array, and tofunction in low sunlight conditions.
The helical rotor pump has only one movingpart. It produces a smooth flow and requiresno valves to function. It is far more reliablethan diaphragm and piston-type solarpumps.
Self-cleaning action The rotor sweeps thefull surface of the rubber stator with everyturn. It is impossible for deposits to accumu-late. Solid particles tend to roll away from thecontact area, making the pump extremelyresistant to abrasion. Particles that aretrapped against the rubber are tolerated bythe flexibility of rubber.
Some history Helical rotor pumps havebeen used in the oil industry for over 60years. They are used to pump concrete! Theyhave been used for solar pumping since the1980’s, but were very expensive until theLORENTZ helical rotor pump was intro-duced.
Close-up of thesame rotor. This
is a test specimenthat pumped
extremely sandywater for 500
hours in the testlab. The surface
is almost like new,and the pump
performs to fullspecifications.
Motor withhelicalrotorattached,statorhousingremoved.
Principles of Operation continued
HELICAL ROTOR MODELS ONLY
Sealed cavities trap water andprogress toward the outlet
helical rotor
rubber stator
58
13.2 Water Pipe Sizing Chart
Don’t cheat yourself with undersized pipe!Use this chart to determine the additionalhead imposed on your pump due to pipefriction, based on flow rate, pipe size and pipelength. Consider the TOTAL pipe length fromthe pump to the pipe outlet to the tank.
Pipe fittings impose additional frictionloss. A sharp 90° pipe elbow adds frictionapproximately equal to 6 feet (2m) of pipeof the same size.
FLOW PIPE DIAMETER (inches; nominal, actual)
RATE 1/2* 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 5 6GPM LPM 0.662 0.82 1.05 1.38 1.61 2.07 2.47 3.07 4.03 5.05 6.06
1 3.8 1.13 0.14 0.05 0.02 2 7.6 4.16 0.35 0.14 0.05 0.023 11.4 8.55 2.2 0.32 0.09 0.054 15 14.8 3.7 0.53 0.16 0.09 0.025 19 22.2 5.8 0.81 0.25 0.12 0.056 23 31.0 7.9 1.0 0.35 0.18 0.07 0.027 27 10.6 1.5 0.46 0.23 0.08 0.038 30 13.4 1.9 0.58 0.30 0.09 0.059 34 16.9 2.4 0.72 0.37 0.12 0.06
10 38 20.3 2.9 0.88 0.46 0.16 0.07 0.0211 42 24.3 3.5 1.04 0.53 0.18 0.08 0.0312 45 28.6 4.1 1.2 0.65 0.21 0.09 0.0414 53 5.5 1.6 0.85 0.28 0.12 0.0516 61 7.0 2.1 1.1 0.37 0.14 0.0618 68 8.7 2.6 1.3 0.46 0.18 0.0720 76 10.6 3.2 1.6 0.55 0.21 0.08 0.0222 83 13.4 3.8 2.0 0.67 0.25 0.09 0.0324 91 14.9 4.4 2.3 0.79 0.30 0.12 0.0426 99 5.2 2.7 0.90 0.35 0.14 0.0528 106 5.9 3.1 1.0 0.42 0.16 0.0530 114 6.7 3.5 1.2 0.46 0.18 0.0635 133 8.9 4.6 1.6 0.62 0.23 0.0740 152 1.4 5.9 2.0 0.79 0.30 0.09 0.0245 171 14.2 7.4 2.5 0.97 0.37 0.12 0.0450 190 17.3 9.0 3.0 1.2 0.46 0.14 0.0555 208 10.7 3.6 1.4 0.55 0.16 0.0660 227 12.5 4.2 1.7 0.65 0.18 0.07 0.0265 246 14.6 4.9 1.9 0.74 0.22 0.08 0.0370 265 16.7 5.6 2.2 0.85 0.25 0.09 0.0475 284 19.0 6.4 2.5 0.97 0.28 0.10 0.0580 303 7.2 2.8 1.1 0.32 0.12 0.0685 322 8.1 3.2 1.2 0.37 0.14 0.0790 341 9.0 3.5 1.4 0.39 0.15 0.0895 360 9.9 3.9 1.5 0.44 0.16 0.09100 379 10.9 4.3 1.7 0.49 0.18 0.12150 569 23.1 9.1 3.5 1.0 0.37 0.16200 758 15.5 6.0 1.8 0.62 0.28
This Chart appliesonly to PVC pipe,Schedule 40 (160PSI), and topolyethylene (PE)pipe with SIDRdesignation (mostcommon 100 PSIblack flexiblepipe)Friction Loss in Plastic Pipe with Standard Inside Diameter (SIDR)
Head Loss from friction in vertical m/ft per 100 m/ft of pipe
SHADED VAL-UES are veloci-ties over 5 ft persecond andshould beselected withcaution
*) 1/2 data applies topolyethylene pipe only.PVC has smaller ID of0.612”
59
13.3 Wellhead Assemblies for Drilled Wells
To support the drop pipe and seal thewellhead, choose one of these methods:
Well Seal SystemThese methods are NOT specific to solarpumps. The components are available fromconventional water well suppliers.
The well seal is a plate that fits on top of thewell casing. It provides a seal againstcontamination, and it supports the weight ofthe in-well assembly. In a freezing climate, thewellhead must be located in a heated buildingor in a covered well pit, or the pipe must bemade to drain when the pump stops (seeSection 13.6 Freeze Protection).
Use metal pipes above ground, for strength.A tee and a plug is used instead of an elbow,because the plug allows direct observation ofwater level and flow. It also provides a placeto attach a lifting device.
Pitless Adapter SystemThe pitless adapter is a fitting that allows yourburied pipe to pass through the well casingunderground, without the need to build acovered pit. It provides protection againstfreezing, flooding, animals and humanactivities that can damage exposed piping.
After the pitless adapter is installed, the pumpcan be installed and removed from above,with no further need to dig. The inside halfslides apart vertically by means of a dovetailjoint and an O-ring. A piece of threaded pipeis used as a temporary tool for installation orremoval. Thread it into the socket on theinside half of the adapter.
If the well casing is 4" (inside diameter) thepitless adapter must be designed not toreduce the clearance inside the casing (itclamps around the outside of the casing).
Two pumps in one well If you have a wellcasing of 6" or larger, you may be able toinstall two pumps in the well, by using twopitless adapters.
Check ValveA check valve (non-return valve) preventsstored water from escaping down the well incase of a leak in your drop pipe. It may alsohelp the pump to start easier if it feeds into avery long pipeline. If you use a weep hole forfreeze protection, omit this check valve toallow the pipe to drain.
plug
check valve
eye bolt
safetyrope
metalpipe
section
wellseal
wellchasing
electric cable
electricalconduit
wellchasing
well cap
electric cable
temporary pullerpipe
eye bolt
check valveoptional
pitlessadapter
drop pipe
60
13.4 Water Storage for Solar Water Pumps
Storage Tank Capacity Generally, storagecapacity should equal 3 to 10 days of averagewater consumption, or more. This depends onthe climate and usage patterns. For domesticuse in a cloudy climate, 10 days is minimal. Ina sunny climate, this allows for a generoussafety margin. For deep irrigation of trees(where the soil holds moisture for a week) 3days’ storage may be adequate. For irrigatinga garden, 5 days may be adequate. Youcannot store too much water!
Storage Tank Plumbing This illustrationshows many options. They are not all re-quired, but are illustrated for purposes ofdiscussion.
We suggest that you place your normal pointof discharge higher than the bottom of yourwater tank, in order to hold a reserve so thatthe tank does not run completely dry.
You can lose your water supply under any ofthese conditions:
1. a period of low sunshine and/or excessivewater demand
2. an electrical or mechanical failure in thesystem
3. a leak in the tank or piping
4. an accidental discharge of stored water
Place a second outlet valve at the bottomlevel of your storage tank, to use the reservesupply in case of emergency.
Pipe sizing The pipe from the pump to thetank may need to be larger than the pumpoutlet, depending on the flow and the lengthof pipe. A single pipe may be used for both filland discharge. In that case, size the pipe forthe maximum discharge that you want toaccomplish. You may oversize the pipe ifthere is a chance that you may install asecond pump, or larger pump in the future.Sizing the pipe larger than necessary will NOTinfluence the performance of the system. SeeSection 13.2, Water Pipe Sizing Chart.
If you plan to use gravity-flow to supply waterfrom the storage tank, be sure the dischargepipe is large enough to allow sufficient flow tomeet the maximum water demand withoutexcessive friction loss.
Pressure of delivery Every 2.3 feet verticalfeet of drop produces 1 PSI of pressure,minus any friction loss (10m produces 1 bar).The volume of water stored in the tank doesnot effect the pressure delivered.
Water Purification Check local healthauthorities and/or plumbing codes to ensureyou will comply with requirements for using astorage tank that is open to the atmosphere,for potable water. Sanitation by means ofchlorination, ozone or infrared system may berequired or recommended.
Air VentRequired if top of tank issealed, particularly if thetank is buried
Inlet Pipe (optional)Feed well water in at this level if you want the pipe from the well todrain after the pump stops (see “Freeze Protection”). Your choice ofinlet here at top of tank will not significantly effect pump performance.
Overflow OutletIf float switch is used: this drains excess water safely away in case thefloat control system fails. If float switch is not used: this can sendwater to additional storage or irrigation.
Refresher Valve (optional)A slow leakage of water at this level will cause the pump to refresh thewater periodically during times of low demand.
Main Shutoff Valve (normally open)
Reserve Shutoff Valve
Drain / Cleanout Valve
To Water Distribution System
In-/Outlet PipeA single pipe can handle water going both into and out of the tank.Note the relatively large size of the main discharge pipe Thisfacilitates gravity flow with minimal pressure loss.
Monitoring Valve (optional)
Water Well
Water Meter (optional)
Check Valve(spring-loaded type)
Pressure Sensor forWireless Level Control
Wireless Level Controlfor Full-Tank Shutoff (optional)This eliminates float switch and cable. Ituses a pressure sensor on the pipe. SeeAutomatic Control for Full-Tank Shutoff
Float Switchon
off
cable topump controller
61
13.5 Monitoring a Solar Pump System
Monitoring the pump Will you be able toobserve the output of your pump at the pointof discharge? If not, you may not know if itmalfunctions. Consider installing a watermeter, or additional valves so that the flow canbe directly observed. (See illustration inSection 13.4)
13.6 Freeze Protection for Solar Water Pumps
In a cold climate, water can freeze in a pipeand block the water flow. This will cause anelectrical overload that will cause the pump tostop.
Pressure relief If there is any possibility of apipe freezing, install a pressure relief valve toprevent excess pressure in the pump line.Install it below frost line. Adjust the valve toopen if the pressure exceeds normal. This isespecially important for helical rotor pumps(model number not containing “C”) which candevelop very high pressure.
Burial of pipe The best way to preventfreezing is to bury all piping below frost line.The modern method of burial at the wellheadis to install a pitless adapter (see section 13.3,Wellhead Assemblies for Drilled Wells).
Weep hole If you have above-ground pipingthat must be drained for freeze protection,make a tiny “weep hole” in the drop pipe,below frost line. This will cause a constant(but very small) leakage of water back into thewell. When the pump stops, the pipe will drainback slowly. The pipe must be sloped withoutlow spots, so it drains completely. In plasticpipe, a weep hole can be made with a hotneedle or an extremely small drill bit, or aneedle valve can be installed and adjusted.
Weep hole – “high tech” version The mostreliable way to control dripping is to use a“drip emitter” made for drip irrigation systems.It will resist accumulation of debris and
WARNING Donot install thepump with itscheck valveremoved.
Question: Willthe pump drainback when itstops?
Answer: NO! Thepump has a checkvalve that stopswater fromdraining backdown when itstops. A helicalrotor pump willnot drain backeven if the checkvalve is removed.
mineral deposits far better than a simple holeor a needle valve. Emitters are available fromirrigation suppliers, nurseries, and manyhardware stores. They are rated in gallons(liters) per hour. The most common ones arein the range of 1-2 gallons (4-8 liters) perhour. Use a relatively fast one for bestreliability, especially if you get mineral depos-its. Drill a hole in the pipe to fit the emitter,and push the emitter into the hole.
Drip emitters are made for a pressure limit ofabout 40 PSI (2.8 bar). This limits the verticallift above the emitter to about 90 feet (28 m).In cases of relatively high lift, use a “pressurecompensated” emitter. It will maintain arelatively constant drip rate as the pressurevaries. This will reduce water loss when thepump is running.
Polyethylene pipe Flexible “poly pipe” (PE)has proven to tolerate repeated freezing.Connections may loosen from ice expansion,but the pipe is not damaged. Poly pipe isoften used in places where pipe may freezeaccidentally or occasionally. See Section 7.3for precautions regarding PE pipe. If you planto bury PE pipe, observe further precautionssupplied by the pipe manufacturer.
Monitoring the water level in your storagetank Will you be able to observe the level ofwater in your tank? If you cannot easily seeinto your storage tank, here are some meth-ods of tank monitoring.
1. dipstick in the air vent
2. float with a visible rod that protrudesthrough the top of the tank
3. clear sight-tube alongside the tank
4. precision pressure gauge (note: 1 PSI =2.3 feet)
62
13.7 Selecting and Using Meters for Electrical Testing
Most on-site trouble shooting requires a testinstrument called a multimeter which can beobtained from an electric supply, electronicsupply, automotive or hardware store. It willmeasure DC and AC volts, current (amps) andresistance (ohms, symbolized by &!). Here aresome criteria for selecting a meter for testing.
Digital or analog meter? A digital meter isbest. An autoranging digital meter is easiestto use, especially for a beginner. An analog(mechanical) meter is good if it is of highquality and at least 3" (75 mm) wide.
Resistance ranges The meter must read inthe 0-10 Ohm range to one decimal place.This includes all but the smallest andcheapest digital meters, and analog metersthat have at least three resistance ranges.
Ammeter ranges These are the options, withnotes about cost and benefits. $ costs areUS$, typical in USA.
1. Multimeter with milliamp range but no Amprange (under $35) – This will be useful forvoltage and resistance measurement, butnot for current. It is useful, but not ad-equate for all troubleshooting.
2. Multimeter with amp range to 10A or more,without clamp-on capability ($25-$150) –This will measure PV array current andpump running current. A wire must bedisconnected in order to measure current(current must flow through the meter).Inexpensive meters are delicate and notsuited to professional use.
3. DC/AC clamp-on ammeter ($50-$300) – aclamp-on meter allows measurement ofcurrent without disconnecting wires. Westrongly recommend this type of meter forsolar pumps and other electrical equip-ment. It makes the job much safer andeasier. Fluke Model 33 or 36 are theprofessional favorites. Cheaper ones areless reliable and should be checkedperiodically for accuracy.
Use two meters and clips for easier testing.It is often helpful to measure voltage andcurrent simultaneously. An inexpensive meteris adequate for voltage, because precision isnot necessary. Clip-wires or clip-on probesare very helpful if you don’t have three hands.
Resistance readings are always taken withNO POWER applied to the circuit. Always usethe LOWEST range that produces a reading
13.8 Measuring Solar EnergyIntensity
To accurately evaluate a solar-direct solarpump, it is necessary to measure sun inten-sity. For example, if the solar pump is produc-ing around 60% of the specified maximumflow, and you measure the sun intensity (inthe same plane as the array) as 60% of fullsun, you know the system is working properly.
The Daystar Meter is a hand-held instrumentthat measures sun intensity using a solar (PV)cell similar to those used to power your solarpump. It displays the solar potential in wattsper square meter (W/m2). The industry-standard for full sun intensity is 1000 W/m2,so a reading of 600 indicates 60% intensity.
The meter costs less than $150 (in USA).Order directly from the manufacturer:Daystar, Inc., 3240 Majestic Ridge, LasCruces, NM 88011 USA, tel. (505) [email protected] www.raydec.com/daystar
(RX1 is the lowest range). An “auto-ranging”meter will adjust its range automatically.
Zero adjustment Some meters have a zero-adjustment to insure accuracy. This applies toanalog meters when measuring resistance,and to clamp-on DC ammeters. Be sure to setthe zero if necessary!
WARNING Readthe instructionsthat come withyour meter, andfollow the safetywarnings.
WARNINGAttempting toread current(amps) betweenthe two poles ofa power circuitcauses a poten-tially dangerousshort circuit.Connect theprobes INSERIES with thecircuit – seeyour meter’sinstructionmanual. To readvoltage, the redprobe must NOTbe in the Ampssocket. This willcause a shortcircuit.
63
13.9 Glossary of Solar Electricity and Water Pumping
Courtesy ofDankoff SolarProducts, Inc.2810 Industrial Rd.Santa Fe, NM USA 87505(505) 473-3800www.dankoffsolar.com
Basic Electricity
AC - Alternating Current, the standard formof electrical current supplied by the utility gridand by most fuel-powered generators. Thepolarity (and therefore the direction of current)alternates. In U.S.A., standard voltages forsmall water pumps are 115V and 230V.Standards vary in different countries. Seeinverter.
DC - Direct Current, the type of powerproduced by photovoltaic panels and bystorage batteries. The current flows in onedirection and polarity is fixed, defined aspositive (+) and negative (-). Nominal systemvoltage may be anywhere from 12 to 180V.See voltage, nominal.
Current - The rate at which electricity flowsthrough a circuit, to transfer energy. Meas-ured in Amperes, commonly called Amps.Analogy: flow rate in a water pipe.
Efficiency - The percentage of power thatgets converted to useful work. Example: Anelectric pump that is 60% efficient converts60% of the input energy into work - pumpingwater. The remaining 40% becomes wasteheat.
Energy - The product of power and time,measured in Watt-Hours. 1000 Watt-Hours =1 Kilowatt-Hour (abbreviation: KWH). Varia-tion: the product of current and time isAmpere-Hours, also called Amp-Hours(abbreviation: AH). 1000 watt consumed for 1hour = 1 KWH. See power.
Converter - An electronic device for DCpower that steps up voltage and steps downcurrent proportionally (or vice-versa). Electri-cal analogy applied to AC: See transformer.Mechanical analogy: gears or belt drive.
Inverter - An electronic device that convertslow voltage DC to high voltage AC power. Insolar-electric systems, an inverter may takethe 12, 24, or 48 volts DC and convert it to115 or 230 volts AC, conventional householdpower.
Power - The rate at which work is done. It isthe product of Voltage times Current, meas-ured in Watts. 1000 Watts = 1 Kilowatt. Anelectric motor requires approximately 1Kilowatt per Horsepower (after typical effi-ciency losses). 1 Kilowatt for 1 Hour = 1Kilowatt-Hour (KWH).
Three-Phase AC - Three phase power is ACthat is carried by three wires. Power wavesare applied in a sequence. Three-phase is
used for large industrial motors, variable-speed motors, and brushless solar waterpump motors. Analogy: 3-cylinder engine.
Transformer - An electrical device that stepsup voltage and steps down current proportion-ally (or vice-versa). Transformers work withAC only. For DC, see converter. Mechanicalanalogy: gears or belt drive.
Utility Grid - Commercial electric powerdistribution system. Synonym: mains.
Voltage - The measurement of electricalpotential. Analogy: Pressure in a water pipe.
Voltage Drop - Loss of voltage (electricalpressure) caused by the resistance in wireand electrical devices. Proper wire sizing willminimize voltage drop, particularly over longdistances. Voltage drop is determined by 4factors: wire size, current (amps), voltage,and length of wire. It is determined byconsulting a wire sizing chart or formulaavailable in various reference tests. It isexpressed as a percentage. Water analogy:Friction Loss in pipe.
Voltage, Nominal - A way of naming a rangeof voltage to a standard. Example: A “12 VoltNominal” system may operate in the range of11 to 15 Volts. We call it “12 Volts” forsimplicity.
Solar Electricity
Charge Controller - A device that regulatesthe charge current to a battery in order toprevent overcharge. It prevents excessivevoltage and maximizes the longevity of abattery. It may also contain other controlfunctions (see Low Voltage Disconnect).
Deep Cycle Battery - Batteries that aredesigned to discharge as much as 80% oftheir capacity, hundreds of times. They differfrom engine-starting batteries by havingthicker plates and different metal alloys.
Low Voltage Disconnect - A control functionin a battery-based power system in which theload or loads are disconnected before thebattery gets over-discharged. Over-dischargewill damage a lead-acid battery. Typicalsettings for a 12V system are 10.5 or 11Vdisconnect and 12.5 or 13V reconnect.
Photovoltaic - The phenomenon of convert-ing light to electric power. Photo = light, Volt= electricity. Abbreviation: PV.
PV - The common abbreviation for photo-voltaic.
64
PV Array - A group of PV (photovoltaic)modules (also called panels) arranged toproduce the voltage and power desired.
PV Array-Direct - The use of electric powerdirectly from a photovoltaic array, withoutstorage batteries to store or stabilize it. Mostsolar water pumps work this way, utilizing atank to store water.
PV Cell - The individual photovoltaic device.Most PV modules are made with around 36 or72 silicon cells, each producing about 1/2 volt.
PV Module - An assembly of PV cells framedinto a weatherproof unit. Commonly called a“PV panel”. See PV array.
Solar Tracker - A mounting rack for a PVarray that automatically tilts to follow the dailypath of the sun through the sky. A “trackingarray” will produce more energy through thecourse of the day, than a “fixed array” (non-tracking) particularly during the long days ofsummer.
Voltage, Open Circuit - The voltage of a PVmodule or array with no load (when it isdisconnected). A “12 Volt Nominal” PVmodule will produce about 20 Volts opencircuit. Abbreviation: Voc.
Voltage, Peak Power Point - The voltage atwhich a photovoltaic module or array transfersthe greatest amount of power (watts). A “12Volt Nominal” PV module will typically have apeak power voltage of around 15-17 volts.The solar array for a PV array-direct solarpump should reach this voltage in full sunconditions, or a multiple of this voltage.Abbreviation: Vpp.
Pumps & Related Components
Booster Pump - A surface pump used toincrease pressure in a water line, or to pullfrom a storage tank and pressurize a watersystem. See surface pump.
Centrifugal Pump - A pumping mechanismthat spins water in order to push it out bymeans of centrifugal force. See also multi-stage.
Check Valve - A valve that allows water toflow one way but not the other.
Diaphragm Pump - A type of pump in whichwater is drawn in and forced out of one ormore chambers, by a flexible diaphragm.Check valves let water into and out of eachchamber.
Float Switch - An electrical switch that
responds to changes in water level. It may beused to prevent overflow of a tank by turning apump off, or to prevent a pump from runningdry when the source level is low.
Float Valve - A valve that responds tochanges in water level. It is used to preventoverflow of a tank by blocking the flow ofwater.
Foot Valve - A check valve placed in thewater source below a surface pump. Itprevents water from flowing back down thepipe and “losing prime”. See check valve andpriming.
Helical Rotor Pump - A pump with a helix-shaped rotor that fits closely into a rubberstator that has a helical groove. It formssealed cavities that trap water. As the rotorturns, the cavities move toward the outlet. Seepositive displacement pump. Synonyms:progressive cavity pump, screw pump.
Impeller - The device that spins inside of acentrifugal pump, in order to develop centrifu-gal force.
Jet Pump - A surface-mounted centrifugalpump that uses an “ejector” (venturi) device toaugment its suction capacity. In a “deep welljet pump”, the ejector is down in the well, toassist the pump in overcoming the limitationsof suction. (Some water is diverted backdown the well, causing an increase in energyuse.)
Multi-Stage Centrifugal - A centrifugalpump with more than one impeller andchamber, stacked in a sequence to producehigher pressure. Conventional AC deep wellsubmersible pumps and some solarsubmersibles work this way.
Positive Displacement Pump - Any mecha-nism that seals water in a chamber, thenforces it out by reducing the volume of thechamber. Examples: piston, diaphragm,helical rotor, vane. Used for low volume andhigh lift. Contrast with centrifugal. Synonyms:volumetric pump, force pump.
Priming - The process of hand-filling thesuction pipe and intake of a surface pump.Priming is generally necessary when a pumpmust be located above the water source. Aself-priming pump is able to draw some airsuction in order to prime itself, at least intheory. See foot valve.
Pulsation Damper - A device that absorbsand releases pulsations in flow produced by apiston or diaphragm pump. Consists of achamber with air trapped within it or a lengthof flexible tube.
Glossary of Solar Electricity and Water Pumping continued
65
Pump Jack - A deep well piston pump. Thepiston and cylinder is submerged in the wellwater and actuated by a rod inside the droppipe, powered by a motor at the surface. Thisis an old-fashioned system that is still used forextremely deep wells, including solar pumpsas deep as 1000 feet.
Self-Priming Pump - See priming.
Submersible Pump - A motor/pump combi-nation designed to be placed entirely belowthe water surface.
Surface Pump - A pump that is not sub-mersible. It must be placed no more thanabout 20 ft. above the surface of the water inthe well. See priming. (Exception: see jetpump)
Solar Pump Components
DC Motor, Brush-Type - The traditional DCmotor, in which small carbon blocks called“brushes” conduct current into the spinningportion of the motor. They are used in mostsolar surface pumps and in some low-powersolar submersibles. The motor chamber mustbe filled with air and perfectly sealed frommoisture. Brushes naturally wear down afteryears of use, and must be replaced periodi-cally.
DC Motor, Brushless - High-technologymotor used in more advanced solarsubmersibles. An electronic system is used toprecisely alternate the current, causing themotor to spin. See three-phase AC. A sub-mersible brushless motor is filled with waterand requires no maintenance.
DC Motor, Permanent Magnet - All DCsolar pumps use this type of motor in someform. Being a variable speed motor bynature, reduced voltage (in low sun) producesproportionally reduced speed, and causes noharm to the motor. Contrast: induction motor
Induction Motor (AC) - The type of electricmotor used in conventional single-phase ACwater pumps. It requires a high surge ofcurrent to start, and a stable voltage supply,making it relatively expensive to run from bysolar power. See Inverter.
Linear Current Booster (LCB) - An elec-tronic device which varies the voltage andcurrent of a PV array to match the needs of anarray-direct pump, especially a positivedisplacement pump. It allows the pump tostart and to run under low sun conditionswithout stalling. Electrical analogy: variable
transformer. Mechanical analogy: automatictransmission. Also called pump controller.See pump controller .
Maximum Power Point Tracking (MPPT) -An added refinement in some linear currentboosters, in which the input voltage tracks thevariations of the output voltage of the PVarray to draw the most possible solar powerunder varying conditions of temperature, solarintensity and load.
Pump Controller - An electronic device thatcontrols or processes the power to a pump. Itmay perform any of the following functions:stopping and starting the pump; protectionfrom overload; DC-to-AC conversion; voltageconversion; power matching (see linearcurrent booster). It may also have provisionsfor low-water shutoff and full-tank shutoffdevices, and status indicators.
Water Well Components
Borehole - Synonym for drilled well, espe-cially outside of North America.
Casing - Plastic or steel tube that is perma-nently inserted in the well after drilling. Itssize is specified according to its insidediameter.
Cable Splice - A joint in electrical cable. Asubmersible splice is protected by a water-tight seal.
Drop Pipe - The pipe that carries water froma pump in a well, up to the surface. It alsosupports the pump.
Perforations - Slits cut into the well casingto allow groundwater to enter. May be locatedat more than one level, to coincide with water-bearing strata in the earth.
Pitless Adapter - A special pipe fitting thatfits on a well casing, below ground. It lets thepipe pass horizontally through the casing sothat no pipe is exposed above ground where itcould freeze. The pump may be installed andremoved without further need to dig aroundthe casing. This is done by using a 1"threaded pipe as a handle.
Safety Rope - Rope used to secure thepump in case of pipe breakage.
Submersible Cable - Electrical cabledesigned for in-well submersion. Conductorsizing is specified in square millimeters, or (inNorth America) by American Wire Gauge(AWG) in which a higher number indicatessmaller wire. It is connected to a pump by acable splice.
Glossary of Solar Electricity and Water Pumping continued
66
Well Seal - Top plate of a well casing thatprovides a sanitary seal and support for thedrop pipe and pump. Alternative: See pitlessadapter
Water Well Characteristics
Driller’s Log - The document on which wellcharacteristics are recorded by the well driller.In most states, drillers are required to registerall water wells and to send a copy of the log toa state office. This supplies hydrological dataand well performance test results to the wellowner and the public. Synonym: well record.
Drawdown - Lowering of level of water in awell due to pumping.
Drawdown level - Depth to the watersurface in a well while it is being pumped.
Recovery Rate - Rate at which groundwaterrefills the casing after the level is drawn down.This is the term used to specify the productionrate of the well.
Static Water Level - Depth to the watersurface in a well under static conditions (notbeing pumped). May be subject to seasonalchanges or lowering due to depletion.
Wellhead - Top of the well.
Pump System Engineering
Friction Loss - The loss of pressure due toflow of water in pipe. This is determined by 4factors: pipe size (inside diameter), pipematerial, flow rate, and length of pipe. It isdetermined by consulting a friction loss chartavailable in an engineering reference book orfrom a pipe supplier. It is expressed in PSI orFeet (equivalent additional feet of pumping).Pipe fittings, especially 90° elbows, imposeadditional friction.
Head - See synonym: vertical lift.
Suction Lift - Applied to surface pumps:Vertical distance from the surface of the waterin the source, to a pump located above thesurface. This distance is limited by physics toaround 20 feet at sea level (subtract 1 ft. per1000 ft. altitude) and should be minimized forbest results.
Submergence - Applied to submersiblepumps: Distance below the static water level,at which a pump is set.
Total Dynamic Head - vertical lift + frictionloss in piping (see vertical lift and frictionloss).
Vertical Lift - The vertical distance thatwater is pumped. This determines thepressure that the pump pushes against. Totalvertical lift = vertical lift from surface of watersource up to the discharge in the tank + (in apressure system) discharge pressure.Synonym: static head. Note: Horizontaldistance does NOT add to the vertical lift,except in terms of pipe friction loss. NORdoes the volume (weight) of water containedin pipe or tank. Submergence of the pumpdoes NOT add to the vertical lift. See totaldynamic head.
Water Distribution
Cut-In Pressure and Cut-Out Pressure -See pressure switch.
Gravity Flow - The use of gravity to producepressure and water flow. A storage tank iselevated above the point of use, so that waterwill flow with no further pumping required. Abooster pump may be used to increasepressure. 2.31 vertical feet = 1 PSI. 10vertical meters = 1 bar. See pressure.
Head - Seevertical lift and total dynamichead. In water distribution, synonym: verticaldrop. See pressure.
Open Discharge - The filling of a watervessel that is not sealed to hold pressure.Examples: storage (holding) tank, pond, floodirrigation. Contrast: pressure tank.
Pressure - The amount of force applied bywater that is either forced by a pump, or bythe gravity. Measured in pounds per squareinch (PSI) or bar (atmospheres). PSI =vertical lift (or drop) in Feet / 2.31. Metric: 1Bar = vertical lift (or drop) of 10 verticalmeters.
Pressure Switch - An electrical switchactuated by the pressure in a pressure tank.When the pressure drops to a low set-point(cut-in) it turns a pump on. At a high point(cut-out) it turns the pump off.
Pressure Tank - A fully enclosed tank withan air space inside. As water is forced in, theair compresses. The stored water may bereleased after the pump has stopped. Mostpressure tanks contain a rubber bladder tocapture the air. If so, synonym: captive airtank.
Glossary of Solar Electricity and Water Pumping continued
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Pressure Tank Precharge - The pressureof compressed air stored in a captive airpressure tank. A reading should be takenwith an air pressure gauge (tire gauge) withwater pressure at zero. The air pressure isthen adjusted to about 3 PSI lower than thecut-in pressure (see Pressure Switch). Ifprecharge is not set properly, the tank will notwork to full capacity, and the pump will cycleon and off more frequently.
For permission to reproduce and distributeGlossary of Solar Electricity and WaterPumping, please contact Dankoff SolarProducts. Citation of the source and copyrightis required.
Copyright © 1997-2005 by Dankoff SolarProducts, Inc.All rights reserved
13.10 Calculating PumpingEfficiency and PowerRequirement
Glossary of Solar Electricity and WaterPumping continued
This formula lets you calculate the wire-to-water energy efficiency of any electric pump-ing system
% Efficiency = (Vert. Feet X GPM X 18.8) /WattsMetric: % Efficiency = ( Vert. meters XLPM X 16 ) / Watts
% is expressed as a whole number (“45”means 45%)
To estimate power requirement for anyproposed pumping job
Watts = ( Vert. feet X GPM X 18.8 ) /pump efficiency %Metric: Watts = (Vert. meters X LPM X 16)/ % pump efficiency
Average efficiency for AC electric pump isaround 35%, solar pumps range 40-60%.
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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 attachedhere, ask your pump supplier. The system here below is typical for either a PS200 ( 2 to 4modules in Series) or PS600 system ( 4 to 6 modules in Series)
13.11 System Wiring Diagram for Solar-direct (non-battery) System
PV Modules (Solar Panels)Before connecting the array to thecontroller measure the open-circuit voltage. It must be within arange of
PS200 : 35-90V DCPS600 : 75-135V DCPS1200: 110- 180V DC
To anygroundterminal atjunction boxor controller
If you are not using thelow-water probe, installa jumper wire betweenterminals 1 and 2
If you are not using afloat switch, install ajumper wire betweenterminals 4 and 5
EarthGround
PumpMotor
Low WaterProbe
SubmersibleCable Splice
For wire size, referto Pump SizingTable
Float Switch (optional)Float Switch Kit makes contact onrise to stop pump.Connect termins 3 (NO) and 4(COM) and connect terminals 4and 5 with jumper wire.
