Lorentz PS150 Series Operation manual

PS150 Centric INSTRUCTIONS FOR
INSTALLATION
OPERATION
SERVICE
Copyright©2004,2005byBERNTLORENTZKG, allrightsreserved.

2
1INTRODUCTION ..........................................................2
2WARNINGS .................................................................3
3DIMENSIONS ..............................................................3
4SYSTEMREPORTFORM ............................................4
5INSTALLATIONCONTROLLERPS150 .......................5
5.1 General Information ................................................5
5.2 Warnings to Installer ...............................................5
5. 3 Mechanical Installation...........................................5
5.2 Technical Data.........................................................5
5.4 Electrical Installation-Terminals .............................6
5.5 Monitoring ................................................................6
5.6 Wiring Order for Correct Rotation............................7
7 System Wiring ...........................................................8
7.1 System Wiring for 12 V Battery Installation .............8
7.2 System Wiring for 24 V Battery Installation .............8
7.3 System Wiring for 12-24 V Solar Direct Operation..9
7.4Battery HighRun Jumper..............................................9
7.5 Power Control for Solar Direct Operation ...............9
8TROUBLESHOOTING ................................................10
9WARRANTY...............................................................10
CAUTION
recommended to avoid disfunc-
tion or premature ageing of the
pump etc.
WARNING
disregard might lead to injury or
damage the installation
Symbols
Thank you for purchasing a LORENTZ PUMP.We set
a new standard for quality and economy in solar
pumping. It incorporates the best solar pump technolo-
gies that were very expensive until its introduction in
2002.
1 INTRODUCTION
PS150 is a highly efficient pump system which
provides city water pressure, anywhere. It is
economical for (drip-) irrigation, livestock, dugout
floating pump, water transfer to remote places and
many other applications. It is a submersible pump.
The pump end of PS150 is a positive displacement
type pump or a centrifugal one.
The PS150 brushless DC motors are specially made
for this system. The motor is using very advanced raw
earth magnet technology, hand made wiring for highest
copper density and does not need wearing brushes.
This results in an exceptional high efficiency with low
temperature dissipation.
PS150 can either be used in a battery system with
voltages of 12, 24V or alternatively it can be operated
as a solar direct system using the same Controller
PS150.
The solar battery is charged up during daylight hours
using the integrated charger of the PS150 controller.
The charger works effectively during reduced sunlight
conditions when direct pump operation is not possible.
The energy stored in the battery is available to operate
the pump at any time, day or night and during periods
of bad weather.
Extended bad weather periods with water demands of
up to 10m3per day will be reliably bridged due to the
high system efficiency even with low capacity batteries.
The pump is manufactured from non-corrosive
material (stainless steel).
Before you begin Check the model
numbers of all the components of your
system, and verify that they are the items
that you ordered. Also check against the
PUMP specifications and performance
charts (end of this manual) to be sure the
system is appropriate for your application. If you think
you may have the wrong pump for your application, call
your supplier immediately.
Please fill in the SYSTEM REPORT. This will be essen-
tial information if any problems occur.
CONTENTS

3
2 WARNINGS
Failure to follow
these instruc-
tions will void
the warranty.
PS150 pumps are different from other pumps.
It is a submersible pump.
Before beginning installation procedures, these
installation and operating instructions should be
studied carefully.
The installation and operation should also be in
accordance with local regulations and accepted
codes of good practice.
This INSTRUCTION MANUAL contains maintenance
information, and is the property of the pump owner
Please give this manual to the pump owner or mainte-
nance personnel when you are finished!
3 DIMENSIONS
L A B D S packaging shipping volume net weight gross weight
[mm] [mm] [mm] [mm] [mm] [m³] [kg] [kg]
C-SJ5-8 593 408 185 100 G 1 1/2" 650X160X150 0,016 12 12,5
Controller Type
PS150-C 320X240X160 0,0123 1,2 1,8
Pum
p
Unit ( Pu)
( motor + pump end)
Dimensions Shipping Dimensions

4
4 SYSTEM REPORT FORM
Before you start, indicate your systems datas.
System Voltage V
Date of Purchase
Purchased from
Quantity of Batteries
BatteryType
Quantity of Solar Modules (panels)
Solar Module Type
Pump Model
Pump Serial #
Controller Model
Controller Serial #
Installer: Record the following
Installation Date
Installed by
Cut-in Pressure bar / PSI
Cut-out Pressure bar / PSI
Additional Suction Lift m / ft
Total Pipe Length, Pressure Side m / ft
Total Pipe Length, Suction Side m / ft
Pipe
Size
Type

5
5 INSTALLATION CONTROLLER PS150
5.1 General Information
> Controlling and monitoring of the motor
> Integrated MPP-tracking and LVD battery protection
> LVD protection (low voltage disconnect) for 12 and
24V batteries
> Hig Run battery function to avod cycling of battery
> Check and display the operating states
> Two control inputs for float- or pressure switches,
remote control, etc.
> 92% max. efficiency (motor + controller)
> Adjustable maximum RPM setting, refer to pump
manual for details
5.2 Technical Data
Input voltage battery: 12 V - 24 V DC
PV max. open circuit: 50 V DC
Input current, max. 20A
Battery low voltage disconnect: 11/22 V DC
Restart voltage: 13/26 V DC
Ifin HighRun mode:
Battery low voltage disconnect: 12,3/24,6 V DC
Restart voltage: 13,3/26,6 V DC
Output: 4-18V EC PWM 3-phase
Type of enclosure: IP 54
Ambient temperature: -20 °C to +50 °C
Weight: 1.5 kg
Dimensions: 260 x 175 x 100 mm
Open circuit (no-load) voltage above 50 V will destroy
the controller. This may occur if the wrong PV modules
(solar panels) are used, or if the solar array is incor-
rectly wired. Measure the array voltage before connect-
ing to the controller. A “12 V” (nominal) array should
produce an open circuit voltage around 22-25 V under
any daylight conditions.
Do not attempt to use thiscontroller for any motors
other than ECDRIVE®.
To be installed, connected and serviced by qualified
personnel only. Ensure all power sources are discon-
nected when making connections to this unit. Follow all
appropriate electrical codes. There are no user service-
able parts inside the motor or the controller.
5.2 Warnings to Installer
Location Place the controller close to the solar array,
not the pump. This will reduce the risk of lightning
damage.
Protection from heat Electronic devices are most
reliable when they are protected from heat. Mount the
controller in the shade of the mid-day sun. An ideal
location is directly under the solar array or in a nearby
shaded location. An alternative is to fold a piece of
sheet metal so that it mounts behind the controller and
curves over it to provide shade. This provides protection
in extremely hot climates.
5. 3 Mechanical Installation
Installproper grounding for safety and lightning
protection
Do not touch the controller input or motor wires
together to test for a spark.
TEST THE VOLTAGE beforeconnectingpower to the
controller. Voltage (open circuit) must not exceed 50 V.
Some thin-film PV-modules may produce excessive
voltage, especially when they are new. If the open circuit
voltage exceeds 50 V, DO NOT connect power to the
controller. Contact your supplier.
Battery system Place the controller near the batteries
but safely isolated from the battery terminals and from
corrosive gases. (Batteries must be in a cool location
for best longevity and enclosed for cleanliness and
safety.) Connect the battery (12 or 24 V) directly with the
+ and – Terminal of the controller. Do not use the load
terminals of the charge controller as they maybe not
strong enough to allow the start current to flow. The
PS150 controller has a low voltage function to protect
the batteries from deep discharge. The charger (addi-
tional) is only needed for charging the batteries.
Position If it is outdoors, mount the controller in a
vertical position to assure that rain will not enter the
box.

6
Power IN For PV-direct systems, a two-pole discon-
nect switch may be installed between the solar array
and the controller. Switch it off to prevent shock and arc
burn hazard during installation and maintenance, or if
the system will be shut down for the season. For
battery systems a 30 Amp slow blow fuse must be
installed between the controller and the battery.
Ground Connect the ground wire to the ground
connection in the controller. Grounding helps to prevent
shock hazard if there is a fault in the motor.
L1 – L2 – L3 ECDRIVE®requires four-conductor (four-
wire) cable between the controller and the motor. The
three wires L1, L2 and L3 carry power. The fourth wire
carries ground. To reverse direction of rotation reverse
any two wires.
No. 1 and 2 In order to protect a pump from being
damaged by dry running connect one well probe cable
SYSTEM
Green light indicates “SYSTEM ON”
PUMPON
Green:“MOTOR/ PUMP ON”
Red: Motor OFF caused by overload protection
PUMPSPEED
PUMP ON LED will flash in following sequence:
> 700 RPM PUMP ON LED IS ON
> 1200 RPM 1 Flash
> 1600 RPM 2 Flash
> 2000 RPM 3 Flash
> 2400 RPM 4 Flash
> 2800 RPM 5 Flash
5.5 Monitoring
5.4 Electrical Installation-Terminals
LEDs for Monitoring
SOURCELOW
Red light: Water level is low. After recovering the motor
will start within 20 minutes.
Red light will remain ON to indicate low water level has
occurred. For “Reset” press the ON/OFF switch.
TANKFULL
Red light: The motor has been switched OFF by
remote switch.
BATTERYLOW
Red light flashing: “LOW VOLTAGE DISCONNECT”
when battery is empty (in battery mode only)
to each terminal. If dry run protection is not needed,
short cut these two terminals.
No. 3, 4 and 5 Connect any kind of external switch (NO
or NC type) for remote control of the controller. In case
no switch is used the terminals No. 4 and 5 have to be
connected with a short cable (factory setting). In case a
NO-switch is used (connected to the terminals No. 3
and 4) the short cable (connecting the terminals No. 4
and 5) must remain installed.
No. 6 and 7 Connect these two terminals to switch the
controller to battery mode. The motor will be switched
OFF by the controller if the input voltage is below 11 V
for a 12 V battery system and 22 V for a 24 V battery
system in order to protect the battery. If the battery
voltage increases to 13 or 26 V the motor will be
switched ON automatically. ( High run function with 13,3
and 26,6V)
L
1L
2L
3
++ --
low water sensor probes
connect for battery mode
remote
float switch
Battery or
Solar Direct
50 V max.
Solar for
Battery Charging
NC Com NC
SYSTEM
PUMP ON
OVERLOAD
WELL DRY
TANK FULL/FLASH BATT LOW
BATTERY VOLTAGE
RPM

7
5.6 Wiring Order for Correct Rotation
The power wires on the pump are black with
white lettering to indicate L1, L2 and L3.
WRITE DOWN the colors that you splice to
L1/ L2 / L3 so you can match them with the
L1/ L2 / L3 terminals in the pump controller.
If your pump cable has the standard RED,
BLACK and YELLOW colors, use this
sequence:
DER KCALB WOLLEY NEERG
1L 2L 3L dnuorG
The power wires on the pump may also be
broun-black-grey for Motors delivered Q2
2005. Then use broun as L1, black as L2
and grey as L3
Testing the pump for direction Helical rotor
pumps will produce water flow only if they are
rotating in the right direction. If you place it in
a water tank or a bucket, you will observe flow
if the rotation is correct. (Submerge at least
75% to observe full flow).
Alternative, dry test If you don’t have a water
vessel to test the pump in, you can test it dry
by watching the pump shaft and running it for
only a few seconds. The metal label on the
pump has an arrow to indicate the proper
direction of rotation. If the pump is new from
the factory, it is lubricated so it can run dry for
about 90 seconds without risk. If the pump is
not new, it can be run dry safely for about 15
seconds. Either way, this is more than
enough time to observe the direction of the
shaft.
If you did not write down the color match (or
the wind blew your note away) connect the
three power wires to the controller in ANY
random order. Apply power. Observe the
pump shaft rotation, then turn the power off. If
the direction is wrong, exchange ANY TWO of
the power wires at the controller. In any case,
when you are finished connecting the pump
to the controller, test it to assure the proper
direction.
Did you install the pump in the well without
checking the wiring order or the direction?
OR – Is it running but not pumping?
HELICALROTOR pump (model number does
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 observe again. If
you cannot observe air rise, chose whichever
direction is quieter (less vibration). There is
risk of dry-run damage if it runs too long in
reverse. If the pump is new from the factory, it
is lubricated so it can run dry for about 90
seconds without risk. If the pump has been
used, it must not be run for more than about
15 seconds. In many cases, a pump that is
reversed will turn off due to overload.
CENTRIFUGALpump (model withC inthe
name) in reverse will produce no flow (or very
little). This will NOT damage the pump. If the
flow is not normal, reverse any two motor
wires.
Question The motor shaft is hard to turn by
hand, and moves in a bumpy manner. Is this
normal?
Answer YES. This is caused by permanent
magnets in the motor. It is especially hard to
turn when it is connected to the controller, or
if the pump wires are connected together.
WARNING If the
pump wires are
in the wrong
order, the motor
will run in
reverse and the
pump will not
function. Dam-
age may result.
Check the
direction BE-
FORE installing
the pump. The
proper direction
is COUNTER-
CLOCKWISE
when viewed
from above.
WARNING When
testing for
direction, do not
run the pump dry
for more than 15
seconds.

8
7.2 System Wiring for 24 V Battery Installation
“Series” Wiring is shown, for
nominal 24 V system: Voltage from
panels will read 45 V when discon-
nected (open circuit).
Installing a Solar Tracker? Use
stranded wire for flexibility. Secure
the wires to tracker with plenty of
tape. Leave a good slack loop to
allow free motion of tracker.
Remote Tank Float Switch: Con-
nect float switch to terminals 4-5 of
the pump controller when it breaks
contact on rise, to turn the pump
OFF.
Otherwise use terminals 3-4 for
opposite function.
Grounding: Connect
either battery minus or
solar minus to ground,
never connect both to
ground!
7.1 System Wiring for 12 V Battery Installation
12 V system: Voltage from panels
will read 22-25 V when discon-
nected (open circuit).
Connect the pump controller directly
to battery bank.
Remote Tank Float Switch: Con-
nect float switch to terminals 4-5 of
the pump controller when it breaks
contact on rise, to turn the pump
OFF.
Otherwise use terminals 3-4 for
opposite function.
Grounding: Connect
either battery minus or
solar minus to ground,
never connect both to
ground!
L
1L
2L
3
++ --
low water sensor probes
connect for battery mode
remote
float switch
Battery or
Solar Direct
50 V max.
Solar for
Battery Charging
NC Com NC
SYSTEM
PUMP ON
OVERLOAD
WELL DRY
TANK FULL/FLASH BATT LOW
BATTERY VOLTAGE
RPM
2 Batteries, 12 V
Fuse
Controller PS150
combined charge and pump controller
2 Solar Panels, 12 V PS150 Boost
L
1L
2L
3
++ --
low water sensor probes
connect for battery mode
remote
float switch
Battery or
Solar Direct
50 V max.
Solar for
Battery Charging
NC Com NC
SYSTEM
PUMP ON
OVERLOAD
WELL DRY
TANK FULL/FLASH BATT LOW
BATTERY VOLTAGE
RPM
1 Batteriy, 12 V
Fuse
Controller PS150
combined charge and pump controller
1 Solar Panel, 12 V PS150 Boost
30A
30A

9
7.5 Power Control for Solar Direct Operation
PS150 pumps require different current depending on
speed and lift. When low light conditions are present,
the PV array cannot supply the required current.
If you dont use a controller the voltage will drop to
nearly zero, and the pump will “stall” (like a truck trying
to start in 4th gear).
The PUMP CONTROLLER, also called LINEAR CUR-
RENT BOOSTER (LCB) including Maximum Power
Point Tracking ( MPPT) acts like a “gear box” in your car.
This device will match the power source to the load by
transforming the voltage down while increasing the
current delivered to the motor (like an automatic
transmission).
7.3 System Wiring for 12-24 V Solar Direct Operation
L
1L
2L
3
++ --
low water sensor probes
connect for battery mode
remote
float switch
Battery or
Solar Direct
50 V max.
Solar for
Battery Charging
NC Com NC
SYSTEM
PUMP ON
OVERLOAD
WELL DRY
TANK FULL/FLASH BATT LOW
BATTERY VOLTAGE
RPM
Controller PS150
combined charge and pump controller
1 or 2 Solar Panels, 12 V PS150 Boost
12-24 V Solar direct system:
Voltage from panels will read 22-
44 V when disconnected (open
circuit).
Use the left power terminals to
connect the solar array with the
controller
Note: The jumper wire on
terminal 6 and 7 must be taken
out for solar direct mode.
Remote Tank Float Switch:
Connect float switch to terminals
4-5 of the pump controller when it
breaks contact on rise, to turn the
pump OFF.
Otherwise use terminals 3-4 for
opposite function.
7.4 Battery High Run Jumper
In order to set the Battery High Run function set the
jumper as shown in above picture. This will increase
the Low Voltage Disconnect settings to 12,3 / 24,6V and
the re-start voltages to 13,3 / 24,6V to allow pumping
only when the batteries receives charging current from
the solar array. The lifetime of the battery will be
increased considerably as cycling is avoided.

10
Your pump is warranted to be free from defects in
material and workmanship for two (2) YEARS from date
of purchase.
Failure to provide correct installation, operation, or care
for the product, in accordance with instructions, will void
the warranty.
Product liability, except where mandated by law, is
limited to repair or replacement, at the manufacturer’s
discretion. No specific claim of merchantability shall be
assumed or implied beyond what is printed on the
manufacturer’s printed literature. No liability shall exist
from circumstances arising from the inability to use the
product, or its inappropriateness for any specific
purpose. It is the user’s responsibility to determine the
suitability of the product for any particular use.
Pump Rotor / Stator / Impeller of PS150 Motor / Pump
are considered to be normally wearing parts, and are
not covered under warranty. Warranty does not cover
damage due to sand or abrasive silt in the water,
mishandling or other abusive conditions, lightning or
other acts of nature.
Warranty of pump controllers does not cover damage
due to: mishandling or abuse; failure to protect from
weather exposure; failure to protect from overheating
due to sun exposure; failure to seal out insects,
spiders or rodents; lightning, flood or other acts of
nature.
In all cases, it shall be the responsibility of the cus-
tomer to insure a safe installation in compliance with
local, state and national electrical codes.
9 WARRANTY
8 TROUBLESHOOTING
Please read this section before calling for
help.
If you call for help, please refer to the model
and serial numbers.
If The Pump Doesn’t Run
Most problems are caused by wrong connec-
tions (in a new installation) or failed connec-
tions, especially where a wire is not secure
and falls out of a terminal. The System ON
light will indicate that system is switched on
and connected to the controller. It indicates
that VOLTAGE is present but (in a solar-direct
system) there may not be sufficient power to
start the pump. It should attempt to start at
intervals of 120 seconds.
Pump attempts to start every 120 seconds
but doesn’t run
The controller makes a slight noise as it tries
to start the pump. The pump will start to turn
or just vibrate a little.
1. There may be insufficient power reaching
the controller. A solar-direct (non-battery)
system should start if there is enough
sun to cast a slight shadow. A battery
system should start if the supply voltage
is greater than 12V (12V system) or 24V
(24V system).
2. If the pump was recently connected (or
reconnected) to the controller, it may be
running in reverse direction due to wiring
error. See Section 5.6.
3. If the motor shaft only vibrates and will not
turn, it may be getting power on only two
of the three motor wires. This will happen
if there is a broken connection or if you
accidentally exchanged one of the power
wires with the ground wire.
4. The pump or pipe may be packed with
mud, clay, sand or debris.
5. Helical rotor models: The pump may have
run dry. Remove the pump stator (outer
body) from the motor, to reveal the rotor. If
there is some rubber stuck to the rotor,
the pump end must be replaced.
6. Helical rotor models: The check valve on
the pump may be faulty or stuck, allowing
downward leakage when the pump is off.
This can prevent the pump from starting.
PUMPOVERLOAD (PUMPON lightshows
red instead of green) The system has shut
off due to an overload. This can happen if the
motor or pump is blocked or very difficult to
turn and is drawing excessive current (hard
to turn). Overload detection requires at least
250 Watt output of the solar array. This can
be caused by a high concentration of solids
in the pump, high water temperature, exces-
sive pressure due to high lift or a restriction
in the pipe, or a combination of these factors.
The controller will make 3 start attempts
before shutting down the system. The
System ON LED will be OFF and the red
OVERLOAD LED ON. The system will not
reset until the ON / OFF switch is turned OFF
and ON again.