Lorentz PS150 Series Operating instructions

v140627
Manual for Installation and Operation
Manuel d’installation et de fonctionnement
Manual de Instalación y Operación
PS150 - PS4000 Series
Solar Submersible Pump Systems
Systèmes de Pompes Solaires Immergées
Sistemas de Bombas Solares Sumergibles
PS-CS-F Series / PS150 Boost
Solar Surface Pump Systems
Systèmes de Pompes Solaires de Surface
Sistemas de Bombas Solares de Superficie
EN
FR
ES

ENGLISH
150318

2
Introduction
Thank you for purchasing a LORENTZ pump system. LORENTZ has set a new standard for quality, efficiency and
durability in solar pumping.
Before you begin: All pump systems are equipped with nameplates, which contain all important data. Check the model
numbers of all the components of your system, verify that they are the items that you ordered and ensure that the packaging
is undamaged and complete. To allow best system performance and to avoid damage read and follow the installation
instructions carefully.
How to use this guide: This manual is for system installation only, follow it closely for a safe and durable installation.
The system layout must be planned beforehand. We advise using the LORENTZ COMPASS software for correct pump system
sizing.
SITES: We highly recommend registering the installation at SITES in LORENTZ partnerNET. SITES provides an easy overview
of all installed pump systems, including serial numbers and installation details. This will be essential information should
problems occur and will simplify trouble shooting and warranty topics to great extent.

2
3
Installation Overview
This installation overview is provided to familiarize you with the typical steps that are taken when installing a solar water
pumping system. Your particular installation may require the steps to be done in a different order. You should read the whole
manual before making your first installation.
WARNING – This installation overview does not substitute the detailed instructions given in this
manual. Read and follow the manual carefully to ensure reliable operation and long life of the
product and to avoid danger to health and life.
1. PV and Controller Installation
Please follow manufacturer instructions for PV installation.
Every PV installation must be equipped with a PV discon-
nect switch. Suitable switches are available from LORENTZ.
Please refer to “DC Disconnect Switch” on page 17 for
more information on the requirements the PV disconnect
must meet.
Install the controller close to the PV array in a shaded
location to minimize cable length on the input side.
For detailed information refer to “7.6 Mounting, Space and
Ventilation Requirements” on page 20.
2. Electrical Installation
1. Pump wiring: The ECDrive must be connected to
the terminals L1, L2, L3 and GROUND. Observe rotation
direction.
For detailed information refer to “7.7.1.2 Pump Wiring” on
page 27.
2. Accessories wiring: Connect a well probe to terminals
1 and 2 (required), remote control switches to terminals 3,
4 and 5 (depending on type), flow meters to terminals 8
and 9 (with DataModule only), pressure sensors to termi-
nals 10 and 11 (with DataModule only).
For detailed information refer to “7.7.1.3 Pump Accessories
Wiring” on page 28.
3. DC input wiring: Connect the positive terminal of the
PV array to +, the negative terminal to −. Observe max.
input voltage. For battery systems install a jumper between
terminals 6 and 7.
For detailed information refer to “7.7.1.4 Input Wiring for
Solar-direct Systems” on page 29.
4. Grounding: A protective earth connection must be
wired to either GND or , depending on the type of
controller.
For detailed information refer to “7.7.1.6 Grounding” on
page 31.
3. Pump Installation
Submersible pumps: Lower the pump into the water
source with caution, use a safety rope.
For detailed information refer to “8.3 Submersible Pumps”
on page 38.
Surface pumps: Install the surface pump on an adequate
foundation with sufficient pipe sizing to ensure efficient op-
eration. Fill the pump with clean water prior to starting it.
Depending on your pump system, refer to “8.4 CS-F Sur-
face Pumps” on page 43 or “8.3 Submersible Pumps”
on page 38 for detailed information.

4 Contents
Contents 5
1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Receipt, Storage and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Product Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Naming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Operating Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
6 Pump System Sizing & Layout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6.1 Pump System Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 System Layout: Submersible Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 System Layout: Surface Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4 System Layout: Surface Boost Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Controller Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3 Controller Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Technical Data of the Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.5 Controller Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.6 Mounting, Space and Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.7 Wiring the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.7.1 Controllers without pre-wired Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.7.1.1 Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.7.1.2 Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.7.1.3 Pump Accessories Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.7.1.4 Input Wiring for Solar-direct Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.7.1.5 Input Wiring for Battery-based Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.7.1.6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.7.2 Controllers with pre-wired Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.8 Jumper Settings (PS150 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8 Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
8.1 General Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1.1 Pipe Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1.2 Cable Splicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Pump System Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.3 Submersible Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3.1 Wiring the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3.2 Installation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.3.3 Installation Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3.5 Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3.5.1 Safety Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3.5.2 Plastic Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3.5.3 Stilling Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Contents 5
8.4 CS-F Surface Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4.1 Placement and Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.4.2 Pump Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4.3 Installation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.4.4 Suction Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4.5 Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4.5.1 Filling Pump with Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4.5.2 Rotary Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4.5.3 Final Check-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5 Boost Surface Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.1 Placement and Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.2 Pump Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5.3 Installation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.5.4 Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5.5 Plumbing Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.5.6 Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9 Pump Accessories Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
9.1 Well Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Float Switch (Full Tank Shut-off). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3 SunSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.4 Water Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.5 Pressure Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.6 Level Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.7 Sacrificial Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.8 Surge Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.9 PV Disconnect with Lightning Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10 Operating the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
10.1 LED Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.2 Starting the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.3 Time Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.4 Parameter Setting (with DataModule only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
11 LORENTZ CONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
11.1 DataModule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.2 PumpScanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3 PS Communicator & pumpMANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
12.1 Pump does not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12.2 Pump attempts a Restart every 120 Seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12.3 Pump Overload (Pump ON LED is red). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6Declaration of Conformity
1 Declaration of Conformity
We, BERNT LORENTZ GmbH & Co. KG Germany, declare
under our sole responsibility that the products
PS150 Boost, PS150 C, PS150 HR, PS200 HR, PS600
HR, PS600 C, PS600 CS-F, PS1200 HR, PS1200 C,
PS1800 HR, PS1800 C, PS 1800 CS-F, PS4000 HR,
PS4000 C, PS4000 CS-F
to which the declaration relates, are in conformity with the
Council Directives on the approximation of the laws of the
EC Member States relating to:
Machinery (2006/42/EC)
Electromagnetic compatibility (2004/108/EC)
Electrical equipment designed for use with certain
voltage limits (2006/95/EC)
Henstedt-Ulzburg, Germany
1 January 2014
Bernt Lorentz, CEO
2 Receipt, Storage and Handling
Check upon receipt that the packaging is undamaged and
complete. If any abnormity is found, contact your supplier.
LORENTZ pumps are supplied from the factory in proper
packing in which they should remain until they are to be
installed at the site. Handle the pump with care and avoid
unnecessary impacts and shocks.
Prolonged intermediate storage in an environment of high
humidity and fluctuating temperatures must be avoided.
Moisture condensation may damage metal parts. Non-com-
pliance can void the warranty. It is recommended storing
the parts in a closed and dry room.
The motor, the pump end and controller can be stored (not
used) in the range of –20 °C to +65 °C (–4 °F to +149 °F).
The components should not be exposed to direct sunlight.

MF <HU-1>
Product Specification 7
3 Product Specification
3.1 General
LORENTZ solar submersible and surface pump systems
are designed to efficiently deliver high volumes of water
running exclusively on solar power. They are typically used
in irrigation projects and for wide area drinking water
applications where they reliably meet the most demanding
requirements, economically, without pollution and without a
grid connection or diesel generator.
A typical solar pumping system is composed of a PV gen-
erator array, a pump and a solar pump controller. Based on
the design philosophy that it is more efficient to store water
rather than electricity, there is no energy storing device such
as a storage battery in a typical solar pumping system.
The PV generator, an aggregation of PV modules connected
in series and in parallel, absorbs solar irradiation and con-
verts it into electrical energy, providing power for the whole
system. The pump controller controls and adjusts the system
operation and adjusts the output frequency in real-time
according to the variation of sunlight intensity to realize the
maximum power point tracking (MPPT).
Each LORENTZ pump system consists of a pump end,
pump motor and a controller. This modular concept keeps
all electronics above ground even for submersible pumps,
simplifying servicing and lowering cost of ownership.
3.2 Features
LORENTZ pumps have the following features:
Engineered in Germany using high quality non
corrodible materials
IP65/ NEMA 3A corrosion resistant controller housing
Pump control based on power available
ECDRIVE DC Brushless motors, specifically designed for
solar operation with up to 92% efficiency
Controllers with DataModule (-D name tag):
Monitoring and management including on-board record-
ing of up to 5 years of performance data, smart device
access via PumpScanner Android™ App and integration
to LORENTZ pumpMANAGER remote management
service optionally available.

8Product Specification
Pump model definition for surface pumps:
For CS-F1 to CS-F20 pumps
CS - F 4 - 3
stages
rated flow (m³/h)
vertical multistage pump
centrifugal surface
For CS-F32 to CS-F85 pumps
CS - F 32 - 60 - 2
number of small impellers
stages x 10
rated flow (m³/h)
vertical multistage pump
centrifugal surface
For boost pumps
Boost - 330
rated flow (GPH)
positive displacement vane
type surface pump
3.3 Naming
Pump model definition for submersible pumps:
For centrifugal pumps
C- SJ 60 - 2 - 2
number of small impellers
stages
rated flow (m³/h)
submersible
centrifugal
For helical rotor pumps
HR - 23 H/HH/L - 1
temperature class
high lift / very high lift /
long rotor
rated flow (cm³/revolution)
helical rotor pump

4 Operating Conditions
Ambient requirements: PS pump systems can be oper-
ated up to 3000 meters above sea level and at an ambient
temperature of up to 50 °C. The PS controller is designed
for use in environments classified as pollution degree 3 in
accordance with IEC-664-1: Conductive pollution occurs,
or dry non-conductive pollution, which becomes conductive
due to condensation, is to be expected.
Fluid: LORENTZ PS Helical Rotor (HR) and Centrifugal
pumps can be used for drinking water supply, livestock
watering and irrigation applications not containing solid or
long fibred particles larger than sand grains, with a max.
grain size of 2 mm. The max. permitted sand content is 50
ppm, a higher sand content will reduce the pump life con-
siderably due to wear. The max. salt content is 300-500 ppm
at max. 30°C / 85°F. Defects due to pumping other liquids
are not covered by the warranty.
LORENTZ PS BOOST pumps can be used for clean water ap-
plications only. The water must not contain any abrasive par-
ticles. It is highly recommended to install an intake strainer
to protect the pump from any dirt ingress. Please refer to
“8.5.4 Filtering” on page 51 for further information.
Fluid temperature: Depending on the type of your
LORENTZ pump system, different requirements for fluid
temperatures apply:
PS centrifugal submersible - The maximum fluid temper-
ature for centrifugal submersible pumps is +50°C.
PS centrifugal surface - The maximum fluid temperature
for centrifugal surface pumps is +70°C.
PS boost surface - The maximum fluid temperature for
boost pumps is +80°C.
PS helical rotor (HR) submersible - Designing and
building helical rotor pumps for a narrow range of fluid
temperature is important to ensure the best possible effi-
ciency. LORENTZ PS helical rotor pumps are available in five
different temperature classes:
Temp. class 0: 0 – +10 °C
Temp. class 1: +10 – +20 °C
Temp. class 2: +20 – +30 °C
Temp. class 3: +30 – +40 °C
Temp. class 4: +40 – +50 °C
The pumps have a tolerance range of ±2 °C regarding
the respective temperature ranges, except for the lowest
allowed temperature of 0 °C.
The temperature class is part of the pump units’ name tag,
please refer to chapter”3.3 Naming” on page 8. The
pump system shall only be operated within the temperature
range specified upon ordering.
CAUTION – PS200 HR pump ends and
pump units must always be ordered with
the next higher temperature class, to avoid
starting problems in weak irradiation
conditions.
CAUTION – Operating the pump outside of
the specified temperature range can lead
to reduced efficiency and/or damage the
pump and can void the warranty.
MF <HU-1>
Operating Conditions 9

5 Safety Instructions
Safe operation of this product depends on its correct trans-
portation, installation, operation and maintenance. Failure to
follow these instructions can be dangerous to life or health
and/or void the warranty.
READ AND FOLLOW
ALL INSTRUCTIONS!
Explanation of warning symbols
WARNING – Disregard can lead to injury,
death or damage the system.
CAUTION – Recommended to avoid
damage, premature ageing of the pump or
similar negative consequences.
When installing and using this electrical equipment, basic
safety precautions should always be followed, including the
following:
WARNING – To reduce the risk of injury, do
not permit children to use this product
unless they are closely supervised at all
times.
WARNING – The appliance is not to be
used by persons (including children) with
reduced physical, sensory or mental
capabilities, or lack of experience and
knowledge, unless they are instructed and
closely supervised.
WARNING – To reduce the risk of electric
shock, replace damaged cords
immediately.
WARNING – It must be assured that all
grounding connections are properly made
and that the resistances meet local codes
or requirements.
The manual contains basic instructions which must be
observed during installation, operation and maintenance.
Before installation and start-up, the manual should be
carefully read by the person in charge of the installation. The
manual should also be read by all other technical personnel/
operators and should be available at the installation site at
all times.
Personnel qualifications and training – All per-
sonnel for the operation, maintenance, inspection and
installation must be fully qualified to perform that type
of job. Responsibility, competence and the supervision of
such personnel must be strictly regulated by the operator.
Should the available personnel be lacking the necessary
qualification, they must be trained and instructed accord-
ingly. If necessary, the operator may request the manu-
facturer/supplier to provide such training. Furthermore
the operator/user must make sure that the personnel fully
understand the contents of the manual.
Dangers of ignoring the safety symbols – Ignoring
the safety directions and symbols may pose a danger
to humans as well as to the environment and the
equipment itself. Non-observance may void the warranty.
Non-observance of safety directions and symbols may
for example entail the following: Failure of important
functions of the equipment/plant; failure of prescribed
methods for maintenance and repair; danger to persons
through electrical, mechanical and chemical effects; dan-
ger to the environment because of leakage of hazardous
material; danger of damage to equipment and buildings.
Safety-oriented operation – The safety directions
contained in the manual, existing national regulations for
the prevention of accidents as well as internal guidelines
and safety-regulations for the operator and user must be
observed at all times.
10 Safety Instructions

General safety directions for the operator/user –
If hot or cold equipment parts pose a danger then they
must be protected by the operator/user against contact
with people. Protective covers for moving parts (e.g.
couplings) must not be removed when the equipment
is running. Leaks (e.g. at the shaft seal) of hazardous
pumping media (e.g. explosive, toxic, hot liquids) must be
disposed of in such a way that any danger to personnel
and the environment is removed. All government and lo-
cal regulations must be observed at all times. Any danger
to persons from electrical energy must be eliminated by
using good installation practices and working to local
regulations (e.g. VDE in Germany).
Safety directions for maintenance, inspection
and assembly work – It is the user’s responsibility to
make sure that all maintenance, inspection and assembly
work is performed exclusively by authorized and qualified
experts sufficiently informed through careful study of the
operating instructions. The accident prevention regula-
tions must be observed. All work on the equipment must
be done when it is not operational and ideally electrically
isolated. Ensure all power sources and accessories (e.g.
float switch) are disconnected when working on the
system. Follow all appropriate electrical codes. There are
no user-serviceable parts inside the motor or the con-
troller. The sequence for shutting the equipment down is
described in the manual and must be strictly observed.
Pumps or pump units handling hazardous liquids must
be decontaminated. Immediately upon completion of
the work, all safety and protective equipment must be
restored and activated. Before restarting the equipment,
all points contained in chapter “Initial start-up” must be
observed.
Unauthorized changes and manufacturing of
spare parts – Any conversion of or changes to the
equipment may only be undertaken after consulting
the manufacturer. Original spare parts and accessories
authorized by the manufacturer guarantee operational
safety. Using non-authorized parts may void any liability
on part of the manufacturer. There are no user-servicea-
ble parts inside the motor or the controller.
Unauthorized operation – The operational safety of
the equipment delivered is only guaranteed if the equip-
ment is used in accordance with the directions contained
in this manual. Limits stated in the data sheets may not
be exceeded under any circumstances.
RETAIN THESE
INSTRUCTIONS
FOR FUTURE USE!
10 Safety Instructions
Safety Instructions 11

6 Pump System Sizing & Layout Diagrams
6.1 Pump System Sizing
To professionally size and install a water pumping system,
depending on the pump type and application various
variables need to be taken into consideration:
Static head - Vertical height from the dynamic water level
to the highest point of water delivery.
Suction head - Vertical height from the water level to the
pump inlet where the water level is below the pump inlet.
Pressure losses - Loss of water pressure due to pipe
length and friction caused by pipe material and additional
pipe line elements like elbows, valves.
For solar water pumping additionally local irradiation
levels are necessary to calculate the available power during
each day and the effect on water output.
To easily manage and consider the different variables,
LORENTZ strongly advises to size pump systems with
LORENTZ COMPASS, the solar pump planning software.
COMPASS is the LORENTZ tool for designing,
planning and specifying solar pump systems. It
is available for download to all LORENTZ partners on
partnerNET.
COMPASS is a PC-based tool to simply specify solar
pumping systems in real time. It is based on NASA weather
data and uses precise algorithms for even the most complex
calculations.
By selecting the location from a list of more than 250,000
cities, entering the total dynamic head (TDH) and the
necessary amount of water per day the software will
automatically show suitable pump systems and the
necessary size of the PV generator.
For more complex situations COMPASS offers features from
suction head calculation to pipe type specific pressure loss
calculation.
NOTE - Always ensure the values used for
sizing with COMPASS match the conditions
on site. Incorrect parameters can lead to a
wrong sizing report.
Figure 1: COMPASS sizing
12 Pump System Sizing & Layout Diagrams

6.2 System Layout: Submersible Pumps
CAUTION - This graphic is an exemplary
pump system layout diagram and for ease
of understanding only. For system
installation and wiring read and follow the
detailed instructions given in this manual.
PV generator PV module
for SunSwitch
PV disconnect PS controller float switch
water meter
pressure sensor
surge protector
safety rope
stilling tube
submersible pump
grounding rod
splicing kit
well probe
12 Pump System Sizing & Layout Diagrams
Pump System Sizing & Layout Diagrams 13

PV generator PV module
for SunSwitch
PV disconnect PS controller float switch
pressure sensor
water meter
surface pump
valve
strainer
filler
gate valve
filter cage
nonreturn valve
well probe
or float switch
grounding rod
surge protector
6.3 System Layout: Surface Pumps
CAUTION - This graphic is an exemplary
pump system layout diagram and for ease
of understanding only. For system
installation and wiring read and follow the
detailed instructions given in this manual.
14 Pump System Sizing & Layout Diagrams

water meter
6.4 System Layout: Surface Boost Pumps
CAUTION - The displayed pump system
layout diagrams are exemplary and for
ease of understanding only. For system
installation and wiring read and follow the
detailed instructions given in this manual.
grounding rod
PV generatorPV disconnectPS controllersurge protectorwater tap
PS Boost installation kit
PS Boost pump
underground tank
pressure tank
PS Boost inline filter
float switch
14 Pump System Sizing & Layout Diagrams
Pump System Sizing & Layout Diagrams 15

7 Controller Installation
7.1 General
WARNING – All electrical connections must
be performed by qualified experts only.
WARNING – Do not dismantle the
controller while still connected to the
power supply! Before any installation,
maintenance or inspection activities wait
at least five minutes after the power
supply has been disconnected from the
controller!
CAUTION – Installing a SunSwitch is
mandatory for all PS1800 CS-F and all
PS4000 pump systems. Operating without
a SunSwitch can lead to increased wear or
damage to the pump. Such damage is
excluded from the warranty.
CAUTION – Never let the pump run dry.
Dry running will damage the pump and
void the warranty. LORENTZ requires a dry
run protection for every pump system.
For more information on mandatory accessories and their
installation, please refer to “7.7.1.3 Pump Accessories Wir-
ing” on page 28 and “9 Pump Accessories Installation”
on page 54.
Treat the controller as industrial waste when processing the
discarded controller. It is possible that some components
could produce toxic and harmful gas.
16 Controller Installation

DC Disconnect Switch
Every solar pump system must be equipped with a properly
sized DC disconnect switch. The switch must be installed
between the PV generator and controller. It must meet the
following requirements:
 minimum rating according to “Table 1: Minimum DC
disconnect rating” on page 17
 continuous current rating according to maximum
current of the connected PV generator or higher
 the switch must be rated for DC current, not AC
A PV disconnect switch matching all requirements above
can be purchased from LORENTZ.
CAUTION – The use of a properly sized
disconnect switch is an important safety
measure and obligatory for a professional
installation of a solar pump system.
Table 1: Minimum DC disconnect rating
Controller Min. DC disconnect switch rating
PS150 50V DC
PS200 100V DC
PS600 150V DC
PS1200 200V DC
PS1800 200V DC
PS4000 375V DC
Electrical Conduit
Electrical conduit is recommended. We recommend the use
of an electrical conduit (pipe) to protect outdoor wiring
from the weather, from human activities and from damage
caused by animals. If you do not use a conduit, use a strong,
high-quality outdoor cable. Where cables enter the junction
box, install sealed strain-relief cable glands.
Wire sizes
For signal cables, the min. wire size should be 1.5 mm²
(16AWG). For power cables, the min. wire size should be 2.5
mm² (14AWG). Compare your wire sizes to the LORENTZ
COMPASS sizing reports. Cables should be shielded to meet
the EMC requirements.
16 Controller Installation
Controller Installation 17

7.2 Controller Types
Depending on the pump system, the controller will either be
in transparent plastic or aluminium housing.
Controllers in transparent housing have all indicator lights
directly on board. The power on/off switch is located at the
bottom of the housing, next to the cable glands.
The controllers in aluminium housing have indicator lights
and a power on/off switch on the front.
Both controller types function in the same way and are to be
wired according to the instructions in this manual.
NOTE – The on/off switch only affects the
pump operation, it does not work as a
power disconnect switch.
Figure 2: Controller Types
PS150 to PS200 (not UL) PS150-UL to PS200-UL
PS600 to PS1800
PS4000
Prewired plugs: If ordered, the controller will have
prewired plugs. In this case, no wiring is needed inside the
controller. Refer to “7.7.2 Controllers with pre-wired Plugs”
on page 32.
Datamodule: The datamodule is an optional internal
component. It allows easy configuration of the pump
system using the LORENTZ PumpScanner smartphone appli-
cation. If combined with a PS Communicator it also allows
remote pump monitoring and management with LORENTZ
pumpMANAGER. For more information on the DataModule
refer to chapter “11 LORENTZ CONNECTED” on page 65.
For setup of the controller using PumpScanner please refer
to the PumpScanner documentation available on partner-
NET. For more information on pumpMANAGER please go to
www.lorentz.de/connected.
18 Controller Installation