Lorentz PS200 Operation manual

PS200
PS600
PS1200
PS1800
INSTRUCTIONS FOR
INSTALLATION
OPERATION
SERVICE
Bernt Lorentz GmbH & Co. KG
Heidekoppel 16
D-24558Henstedt-Ulzburg
Germany
Tel. ++49.4193.7548-0
Fax ++49.4193.7548-29
www.lorentz.de
release07/08/05
SOLAR WATER
PUMPSYSTEMS

2
1 WARNINGS .......................................................................................................................................................... 4
2 SYSTEMREPORTFORM ..................................................................................................................................... 5
3 INTRODUCTION ................................................................................................................................................... 8
PHOTOGALLERY ......................................................................................................................................................... 9
4 INSTALLINGTHESOLARARRAY....................................................................................................................... 11
4.1 Location of the Solar Array ............................................................................................................................ 11
4.2 Solar Array Assembly Methods ..................................................................................................................... 11
4.3 SolarArray Mounting Rack............................................................................................................................ 11
4.4 Orienting the Solar Array to Solar South ....................................................................................................... 12
4.5 Setting the SolarArray TiltAngle ...................................................................................................................13
5 ELECTRICALINSTALLATION ............................................................................................................................. 14
5.1 Controller, Junction Box, and Conduit .......................................................................................................... 14
5.2 Grounding and Lightning Protection ............................................................................................................ 16
5.3 SolarArray Wiring..........................................................................................................................................18
5.4 Solar Array Disconnect Switch in the Junction Box ......................................................................................19
5.5 Junction Box (Controller Input) Wiring .......................................................................................................... 20
5.6 Maximum RPM Setting.................................................................................................................................. 21
5.7 Submersible Pump Cable and Splice.......................................................................................................... 22
5.8 Wiring Order for Correct Rotation ................................................................................................................. 23
5.9 Low-Water Probe for Dry-Run Protection ..................................................................................................... 24
5.10 Automatic Control For Full-Tank Shutoff.......................................................................................................25
5.11 Battery-Based Systems ................................................................................................................................27
5.12 Pressurizing Systems .................................................................................................................................. 28
6 PREPARINGTOINSTALLTHEPUMP ................................................................................................................ 30
6.1 WARNINGS about Handling Helical Rotor Pumps......................................................................................30
6.2 Drop Pipe ...................................................................................................................................................... 31
6.2 Safety Rope and Binding ..............................................................................................................................32
6.4 Installation in a Surface Water Source ......................................................................................................... 33
6.5 Deep Well Setting — How Deep? ................................................................................................................ 34
6.6 Coping with Dirty Water Conditions .............................................................................................................34
6.7 Utilizing a Low-Production Water Source..................................................................................................... 35
6.8 Installing the Pump Under a Windmill or Hand Pump Cylinder .................................................................. 35
7 IN-WELLASSEMBLYAND INSTALLATION ........................................................................................................ 36
7.1 Rubber Spacers (Models -07, -10, -14, -20 only) ......................................................................................... 36
7.2 Machine Installation......................................................................................................................................37
7.3 Hand Installation...........................................................................................................................................37
7.4 Sanitizing the Well ........................................................................................................................................ 38
8 OPERATINGTHEPUMP ..................................................................................................................................... 39
9 TROUBLESHOOTING ........................................................................................................................................ 41
9.1 If The Pump Doesn’t Run ............................................................................................................................. 41
9.2 Inspect The System ......................................................................................................................................42
9.3 Electrical Testing...........................................................................................................................................43
9.3.1 Table of AC running current for PS200 and PS600 systems ................................................................................................................44
9.3.2 Table of AC running current for PS1200 systems..................................................................................................................................44
9.4 If The Pump Runs But Flow Is Less Than Normal ......................................................................................46
9.5 Problem Report Form ................................................................................................................................... 47
9.6 Electrical Testing Illustrated .........................................................................................................................50
Contents

3
Contents continued
CAUTION
recommended to avoid disfunc-
tion or premature ageing of the
pump etc.
WARNING
disregard might lead to injury or
damage the installation
QUESTION AND ANSWER
gives explanation
ADVICE
Symbols
10 MAINTENANCE .................................................................................................................................................. 54
10.1 Controller and Pump .................................................................................................................................... 54
10.2 SolarArray ..................................................................................................................................................... 54
10.3 Electrical Wiring ............................................................................................................................................54
11 MANUFAC-TURER’SWARRANTY ...................................................................................................................... 55
12 STANDARDS,ENVIRONMENTALANDTEMPERA-TURESPECIFI-CATIONS ..................................................... 55
13 REFERENCESECTION ....................................................................................................................................... 56
13.1 Principles of Operation ................................................................................................................................. 56
13.2 Water Pipe Sizing Chart................................................................................................................................58
13.3 Wellhead Assemblies for Drilled Wells ....................................................................................................... 59
13.4 Water Storage for Solar Water Pumps ......................................................................................................... 60
13.5 Monitoring a Solar Pump System................................................................................................................. 61
13.6 Freeze Protection for Solar Water Pumps .................................................................................................... 61
13.7 Selecting and Using Meters for Electrical Testing ....................................................................................... 62
13.8 Measuring Solar Energy Intensity................................................................................................................. 62
13.9 Glossary of Solar Electricity and Water Pumping ........................................................................................ 63
13.10 Calculating Pumping Efficiency and Power Requirement........................................................................... 67
13.11 System Wiring Diagram for Solar-direct (non-battery) System .................................................................... 68

4
Open circuit (no-load) voltage above 100V for
PS200-, above 150V for PS600- and above
200V for PS1200 & PS1800 controllers will
destroy the controller. This may occur if the
solar array is wired incorrectly. (See Solar
Array Wiring, Section 5.3.)
Do not attempt to run the Motor without the
PSXXXcontroller.
Do not attempt to use the controller for any
purpose other than LORENTZ PS-Pump
Systems.
To be installed, connected and serviced by
qualified personnel only. Ensure all power
sources are disconnected when making
connections. Follow all appropriate electrical
codes. There are no user serviceable parts
inside the motor or the controller.
Solar pumps run at low flow rates, and have
closer tolerances than conventional pumps.
Extreme sand or silt concentration (greater
than 2% by volume) may cause the pump to
stop, or the pipe to fill with sand. Do not use
the pumps to clean out a dirty well. (See
Section 6.6. for advice about dirty water.)
Helical rotor pumps are sensitive to heat.
Protect the pump from sunshine or other
source of heat, or it may lock temporarily. If
the water source is, or will be warmer than
72° (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 safety
and lightning protection (See Section 5.2)
Do not touch the controller input or pump
wires together to test for a spark.
Do not run the pump dry. Exception: to test
direction of rotation, for maximum 15 seconds
(See Section 5.8)
Test the direction of motor rotation before
installing the pump (counter-clockwise looking
down). If direction is reversed, exchange the
connection of any two of the three power
wires to the pump. (See Section 5.8)
When pump is stopped by a shadow or by
action of float switch, it will restart after a 120
seconds.
The low water probe must be submersed, or
the pump will stop for 20 minutes. If the probe
is not to be used, connect the probe terminals
together in the junction box. (See section 5.5
and 5.9)
Helical rotor models (without a C in the model
#) are not self-draining. If drainage is required
for freeze-protection, install a weep hole or
draining device below freeze level. See
Section 13.6 Do not remove the check valve
in attempt to make it self-drain.
1 WARNINGS
Failure to follow
these instruc-
tions will void
the warranty.
Install this system in accordance with local
regulations and accepted codes of profes-
sional practice.
This manual is the property of the LORENTZ
Pump owner.
Please give it to the owner or maintenance
personnel when you are finished!
Request copies from your pump supplier or
download from www.Lorentz.de
This manual is for controller models
PS1800,PS1200, PS600, PS200 as
illustrated on the cover. For earlier models
(before July 2003) refer to Version 1 and 2
Copyright © 2002-2007 by BERNT LORENTZ
GMBH & CO KG

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 or PS1800
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 specific
temperature 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 12
for more about
temperature
specifications.

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 and
diagnose 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 taken
at full vertical lift, note here

8
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 technologies that were
very expensive until its introduction in 2002.
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 expect to pump water that
is very cold or very warm, check the “tempera-
ture range” specifications (Section 12). 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 essential information if any problems
occur.
This manual covers two types of systems,
battery and solar-direct.If you purchased
the Pump to connect to a battery system, you
can skip the sections about the solar array
and solar-direct systems.
REFERENCESECTION (Section13)Many
sInstallers are new to solar pumping, so we
provide helpful information—principles of
operation, instructions for wellhead assem-
bly, water storage, control and monitoring of
water supply, pipe sizing, freeze protection,
and a glossary of technical terms.
3 INTRODUCTION

9
PHOTO GALLERY
AMODELINSTALLATION
A PS600 300Wp solar-direct system
Colorado, USA
This system was installed by students in a
solar water pumping class.
- The array is set at summer tilt angle.
- The controller is mounted on the north
side of the pole, directly under the array.
This shades it from the hot mid-day sun.
- Mounting and ground-bonding details are
shown in Section 5.1.
- Electrical conduit runs from the PUMP
junction box to the wellhead to protect the
pump wires. The water pipe is all under
ground.
Courtesy of Dankoff Solar Products, NM, USA
This PV array was
assembled and
wired on the
ground, then lifted
with a crane.
Courtesyof DankoffSolar
Products,NM,USA
PS600 HR04-
300Wp system in
Colorado, USA,
installed by
students in a solar
pumping class.
The drop pipe is
0.75"
polyethylene.
Hand installation
requires caution
and is not always
recommended
(see Section 7.3)
Courtesyof DankoffSolar
ProductsNM,USA
PV array assembly. The mounting pole is short
enough to facilitate assembly without mechanical
assistance.
CourtesyofDankoff Solar Products, NM, USA
Setting an array
pole in con-
crete.
Courtesyof DankoffSolar
Products,NM,USA

10
A tracking solar array
The mounting pipe was extended to 11 feet (3
m), by welding it to a larger pipe. Wire is type
USE (outdoor rated). The wire is looped to
help it to shed water and to flex. Wires enter
the conduit through a “weather head”.
CourtesyofDankoff Solar Products, NM, USA
Owners of a domestic water system watch as
the pump fills their polyethylene storage tank.
The tank was buried later.
Photocourtesy of Dankoff SolarProducts,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 critical
for full performance of a solar-direct system.
Choose a location for the solar array that has
unrestricted sun exposure through the day
and through the year. The array can be placed
several hundred feet (100 m) or more from the
wellhead. There will be no loss of perform-
ance if the electrical wire is sized properly, but
naturally, the cost of wire will increase signifi-
cantly. The System Sizing Table specifies
wire size requirements for both normal and
extended wire lengths.
CAUTION Shading a small
portion of a PV array may cause
the pump to stop completely.
Each PV module (panel) contains
a series of solar cells (typically
36 or 72 cells). Every cell that is shaded acts
like a resistor, reducing the output of the
ENTIRE ARRAY. Shading just a few cells will
reduce the power disproportionately, and may
stop the pump. Consider this when deciding
where to install the array.
To determine where shadows may be cast at
any time of the year, you can survey the site
with a Solar Pathfinder®.This device is
especially useful in forested areas or wher-
ever there are obstructions nearby. It is
available directly from Solar Pathfinder (USA)
tel. [phone], fax [phone],
www.solarpathfinder.com.
Place the bottom edge of the array at least 2
feet (.6 m) above ground to clear rain spatter,
growing vegetation and snow. Keep in mind
that trees and perennial plants will grow taller
in the coming years.
There are two ways to install the solar array.
1. Assemble the array on the ground, wiring
and all, then lift the entire assembly onto the
pole or roof. A system of 300 watts or more
may require the assistance of a backhoe,
boom truck or crane to lift it over the pole.
2. Assemble the array piece-by-piece on the
pole. If the pole is higher than about 6 feet
(2m), it is best to construct a temporary
platform, like a scaffold assembly commonly
used in building construction). A scaffold
system can be rented from a local supplier.
4.3 SolarArray Mounting
Rack
WARNINGYourmounting
structure must be engineered
for 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 special
pole-mounted solar array rack that tilts
automatically to follow the daily path of the
sun. In clear summer weather, it can in-
crease your daily water yield by 40-50%. (It is
much less effective in winter and in cloudy
weather.)
4.1 Location of the Solar Array 4.2 SolarArrayAssembly
Methods

12
8
9
10 11 1 2
4
3
6
75
6
© 1996 by John Veltman
South
North
AM PM
West East
Jun
Aug
Sep
Oct
Nov
Dec
May
Apr
Mar
Feb
Jan
Jul
40
o
50
o
30
o
Sun Compass Instructions
1. Draw an arrow from Month dot to intersec-
tion of your Standard Time and Latitude
Northern (50° N to 70° N)
The gray line is an example: August, 2 PM at
40° N lat.
2. Stand and face your shadow.
3. Hold this page horizontally.
4.Point the arrow that you drew to center of
your shadow.
5. Sun Compass now points to the four
directions.
SUN COMPASS
4.4 Orienting the SolarArray to Solar South
Sun Compass™ is available for the following
latitudes:
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: John
Veltman PO Box 23533, Santa Fe, NM 87502
USA
For the USA
(lower 48 states)
and other 25° to
55° North latitude
regions.
Find True South
quickly and
accurately using
only your shadow.
No magnetic
compass needed!
For full performance, your solar array must
be oriented within 10° of true (solar) south.
Depending on your location, a compass
reading may show an error of as much as 20°.
To correct this discrepancy, apply the mag-
netic declination for your region. Many
regional maps indicate the magnetic declina-
tion. If you don’t have a compass but can see
your shadow and know the time of day, use
the Sun Compass™.

13
Solar Array Tilt
Angles by
Latitude
0-25° latitudes: Apply a minimum tilt angle of
10°, or dust and debris will accumulate.
4.5 Setting the SolarArray TiltAngle
CAUTION People often forget to make
seasonal adjustments.
Ideal angles (from horizontal) are:
Summer optimum = latitude - 15°
Winter optimum = latitude + 15°
Maximum performance is obtained from a
solar pump when its photovoltaic array is tilted
(elevated) to face the sun. The solar array
racks that are supplied with the Pump
Systems are adjustable to the desired tilt
angle. It is the responsibility of the installer to
perform this adjustment.
Some systems include a solar tracker, and
others with a fixed (non-tracking) rack. Both
types of array have a manual tilt-angle
adjustment. (The tracker follows the daily
path of the sun, but not the seasonal tilt
variation.)
The optimum tilt angle is determined by the
location (latitude). It also varies with the time
of the year. This data is presented in the table
below.
Should the tilt angle be adjusted periodically
through the year? This depends on the
seasonal water-use pattern, and also on
human factors. There are three options to
chose from.
Select one of these options for seasonal
management:
1. Year-round compromise (no seasonal
adjustment) Set the angle equal to the latitude
of the location and “forget it”. This is practical
because people often forget to adjust the
array. The performance displayed in the
System Sizing Table is based on this fixed
compromise setting of the tilt-angle.
2. Seasonally adjusted It is sufficient to
perform the adjustment only twice per year, at
the spring and autumn equinoxes, to the
summer and winter angles indicated below.
For central USA, this will increase the daily
water production by about 8% in summer, 5%
in winter compared to option 1.
3. Seasonal use only If the pump is to be
used no more than half of the year, set the
array to the appropriate seasonal angle
shown below, and “forget it”.
If you use the pump all year but do not want
seasonal adjustment to be required, set the
angle to year-round compromise (equal to
latitude).
noitacoL )selpmaxe( edutitaL remmuS tliT retniW tliT
dnuoR-raeY esimorpmoC eliT
nrehtuoS adanaC °05°53°56°05
drihTreppU ASUfo °54°03°06°54
drihTelddiM ASUfo °04°52°55°04
drihTrewoL ASUfo °53°02°05°53
lartneC ocixeM °02°5°53°02

14
5 ELECTRICAL INSTALLATION
5.1 Controller, Junction Box, and Conduit
WARNING To be
installed, con-
nected and
serviced by
qualified person-
nel only. Ensure
all power
sources are
disconnected
when making
connections to
the controller.
Follow all
appropriate
electrical codes.
There are no
user serviceable
parts inside the
motor or the
controller.
CAUTION Loose connections are the most
common cause of system failures.
Pull on each connection to confirm that it is
secure.
Location Place the controller close to the
solar array, not the pump. This will reduce the
risk of lightning damage.
Explanation — The controller’s input circuitry
is more sensitive to surges than its output. It
is safest to minimize the length of the input
wiring.
Protection from solar 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, on
the north side of the mounting pole. If shade
is not available, cut a piece of sheet metal
and bolt it behind the top of the controller.
Bend it over the controller to provide shade.
This is especially important in extremely hot
locations. Extreme heat may trigger a thermal
switch in the controller and cause it to turn off.
Location of controller Mount the controller
vertically to keep out rainwater. It is preferable
to mount it ON THE NORTH SIDE of a pole or
other structure, to help reduce solar heating.
This may also allow easiest access without
hitting your head on the lower (south) edge of
the array.
Junction Box (optionally) Apre-wired
junction box is available for your system. The
junction box terminals will handle pump wires
as large as #6 (13 sq. mm). If large wires
cannot be accommodated easily in the box,
you can join them to smaller wires in the
junction box. #12 (4 sq. mm) or larger is
acceptable for this very short length. Do NOT
remove terminal screws. If the key to the
junction box gets lost, it can be opened with a
screwdriver.
Mounting the controller and junction box
to a pole See photos on the following page.
The controller can be mounted onto the solar
array support pole using materials available
from your local electric supply store. The best
mounting hardware is “slotted strut” (Unistrut®
or equivalent) with matching conduit clamps to
fit around the mounting pole. This makes a
very strong assembly that is easy to adjust. In
North America, these materials are commonly
available from electric suppliers.
Electrical conduit is recommended We urge
you to use electrical conduit (pipe) to protect
outdoor wiring from the weather, from human
activities, and from chewing animals. See
photos on the following pages. If you don’t
use conduit, use strong, high-quality outdoor
cable. Where cables enter the junction box,
install sealed strain-relief cable clamps.
Keep the controller and junction box sealed
Unused holes must be sealed to keep out
animals, insects, water and dirt. Each hole is
supplied with a rubber plug that can be kept
in place for this purpose.
Battery system Batteries must be in a cool
location for best longevity, and in a protective
enclosure for cleanliness and safety. Place
the controller near the batteries but NOT in
the same enclosure. They must be safely
isolated from the battery terminals and from
corrosive gasses.

15
Typical assembly of controller and junction
box on the solar array mounting pole. Boxes
are secured using slotted strut and conduit
clamps.
Mount the
controller on the
north side of the
pole to reduce
solar heating.
Bare ground wires bond the PV modules to
the controller enclosure, and continue down to
the ground rod. Flat braid is flexible and
eliminates the need for terminal lugs.
slotted strut (Unistrut® or equivalent), cut to
the width of the box.
conduit clamp to fit slotted strut
hose clamp
Conduit holes
3 holes for 3/4" conduit (28mm)
1 hole for 1 1/4" conduit (45mm)
Holes are in a removable plate that can be
reversed.
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 the
most common causes of electronic controller
failures in solar water pumps. Damaging
surges can be induced from lightning that
strikes a long distance from the system, or
even between clouds. The risk of damage is
greatly reduced if these instructions are
followed.
Location of the pump controller Place the
controller close to the solar array, not the
pump. This will reduce the risk of lightning
damage. Explanation: The controller’s input
circuitry is more sensitive to surges than its
output. It is safest to minimize the length of
the input wiring.
Construct a discharge path to ground A
properly made discharge path to ground
(earth) will discharge static electricity that
accumulates in the above-ground structure.
This helps prevent the attraction of lightning. If
a lightning strike occurs at close proximity, a
well-grounded conductive structure can divert
the 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 effectively
grounded.
Earth connection – Create an effective
discharge 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 well
casing located near the array. Drill and tap a
hole to make a strong bolted connection to
the casing with good metallic contact. Bolt on
a brass terminal lug. After the connection is
made, seal the connection with silicone
sealant or other waterproof compound to
prevent corrosion. Protect the ground wire(s)
from physical damage so they aren’t stressed
by being stepped on, etc.
2. Install a copper plate or other specialized
grounding devices designed for the purpose.
Some systems use salts to improve the
conductivity of the surrounding soil.
3. Install one or more copper-plated ground
rods at least 8 feet (2.5m) long, preferably in
moist 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 ground
rods to be driven, bury BARE copper wire in a
trench at least 100 feet (30m) long. If a trench
is to be dug for burial of water pipes, ground
wire can be run along the bottom of the
trench. The wire size must be minimum #6 (16
sq. mm) or double #8 (10 sq. mm). Connect
one end to the array structure and controller.
Or, cut the ground wire shorter and spread it
in more than one direction.
Dry or rocky locations To achieve good
grounding at a dry or rocky site, consult a
local contractor who specializes in lightning
protection. It is best to plan the procedure in
advance, and to coordinate the effort with
other earth-excavating procedures that need
to be done. Reference: www.lightning.org
Bond (interconnect) all the metal structural
components and electrical enclosures
Interconnect the PV module (solar panel)
frames, the mounting rack, and the ground
terminals of the disconnect switch and the
controller, using wire of minimum size #8
(6mm2), and run the wire to an earth connec-
tion.
Ground connections at the controller The
controller and junction box have redundant
ground terminals inside. They are all con-
nected in common with the metal enclosures
of both the controller and the junction box.
Ground connections can be made to any of
these points.
Ground connections to aluminum This
applies to connections at the solar array
framework, and at the controller’s enclosure
box. Connections to aluminum must be made
using terminal lugs that have an aluminum-to-
copper rating (labeled “AL/CU”) and stainless
steel fasteners. This will reduce the potential
for corrosion.
WARNING
Failure to install
and connect an
effective ground-
ing system will
greatly increase
the risk of
lightning dam-
age and will void
your warranty.
We suggest you
wire the ground-
ing system FIRST
so it is not
overlooked. The
concrete footer of
a ground-
mounted array will
NOT provide
adequate electri-
cal grounding.

17
CAUTION
Ground the
cable shield at
the controller
end only, not at
the float switch.
WARNING
Isolate solar
pump wiring
from electric
fence systems.
Do not connect
the pump system
to the same
ground rod as an
electric fence. Do
not run power or
float switch cables
close to an
electric fence.
DO NOT GROUND the positive or the nega-
tive of the power circuit. The best lightning
protection results from grounding the metal-
lic structure only, and leaving the power
system ungrounded. This is called a “floating”
system.
Explanation: With a floating system and a
good structural ground, lightning induced
surges tend to reach ground through the
structure, instead of the power circuit. When
high voltage is induced in the power circuit,
the voltage in negative and the positive sides
tend to be nearly equal, thus the voltage
BETWEEN the two is not so high, and not
usually destructive. This method has been
favored for many decades by most engineers
in the remote power and telecommunications
fields.
Exception for battery systems: You can
connect the pump to a battery-based home
power system that has a negative ground. If
the wiring distance to the pump exceeds 100
feet (particularly in a high lightning area), DC-
rated surge protection devices are recom-
mended.
Legal exception: If the local electrical
authority requires grounding of the power
circuit, ground the PV ARRAY NEGATIVE
wire. This may increase the risk of lightning
damage.
Solar array wiring Bind the array wires close
together, or use multi-wire cable. Avoid
forming loops. This helps induced voltages in
each side of the circuit to equalize and cancel
each other out.
Wire twisting for long runs Twisting wires
together tends to equalize the voltage induced
by lightning. It reduces the voltage differential
between the wires. This reduces the probabil-
ity of damage. This method is employed in
telephone cable, and in many other applica-
tions. Some power cables are made with
twisted conductors. To twist wires yourself,
you can alternate the direction of the twist
about every 30 feet (10 m). This makes the
job much easier.
Float switch cable A long run of control cable
to a float switch in the storage tank can pick
up damaging surges from nearby lightning.
The best protection is to use shielded,
twisted-pair cable . Shielded cable has a
metallic foil or braid surrounding the two
wires. Ground the cable shield as illustrated
in Section 5.10.
Low water probe cable A long horizontal run
of wire to the low-water probe at the pump
can pick up damaging surges from nearby
lightning. Wire twisting is helpful. The best
protection is to use shielded, twisted-pair
cable, same as recommended for a remote
float switch. This product is suitable for direct
burial, but not for submersion in the well. At
the wellhead, make a transition to submers-
ible probe wires.
Additional lightning protection Thecontroller
has built-in surge protection devices. How-
ever, additional grounding measures or
surge protection devices are recommended
under any of the following conditions:
1. Isolated location on high ground in a
severe lightning area
2. Dry, rocky, or otherwise poorly conductive
soil
3. Long wire run (more than 100 feet / 30m)
from the controller to the wellhead, or to the
float switch.
Additional lightning protection devices (surge
arrestors) can be obtained from your pump
supplier. The device(s) for the controller’s PV
input, float switch and probe connections,
must be rated for DC. The device(s) for the
controller’s AC output to the motor must be
rated for 3-phase AC. In each case, the
clamping (bypass) voltage should be 90V or
higher, but not much higher.
In extreme cases, it is best to employ the
service of a local lightning protection contrac-
tor.
Reference www.lightning.org
Grounding and Lightning Protection continued

18
WARNING: The
photovoltaic
array generates
hazardous
voltages. A 48
Volt (nominal)
array can
generate nearly
100 volts when
disconnected
from load. A
short circuit or
loose connec-
tion will produce
an arc that can
cause serious
burns. All wiring
must be done by
qualified person-
nel, in compli-
ance with local,
state, and
national electri-
cal codes.
5.3 SolarArray Wiring
2 types of PV module junction systems
TOP Quick-connect system using “MC”
connectors.
BOTTOM Junction box with screw terminals
and conduit holes
The solar array can produce hazardous
voltage even under low light exposure. To
prevent shock hazard while wiring the array,
leave one or more wires disconnected or
cover it with opaque material.
Solar-direct (non-battery) systems use a
variety of array configurations. Some use 12V
(nominal) modules, and some use 24V
modules. Modules are connected in series
for 24 - 36 - 48V and up to 96V (for PS1200
Systems), and sometimes also in parallel to
increase the current. Refer to the System
Wiring Diagram for your system, attached at
the end of this manual. Be sure the modules
(panels) match the description on your
System Wiring Diagram.
Solar module connections The terminals in
the module junction boxes can be confusing.
Refer to the module manufacturer’s instruc-
tions that are packed with the modules. Make
strong connections that will hold for many
years. Most array failures are caused by
loose, corroded, or shorted connections.
Type of wire Use either electrical conduit or
outdoor UV-resistant wire. The solar array has
a life expectancy beyond twenty years. Don’t
degrade 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 appropriate
types of wire are: USE, UF, SE and SOOW.
Solar tracker wiring If you are installing a
solar tracker, pay careful attention to the wire
section that leads from the moving rack down
to the stationary mounting pipe. Use a highly
flexible wiring assembly. Form a drip loop to
shed water and to minimize stress. SEE
TRACKER PHOTO and caption in the PHOTO
GALLERY. Secure the assembly mechanically
at each end so the insulation and the connec-
tions are not stressed by the tracker’s motion.
Swing the tracker fully in each direction, at
various seasonal tilt angles, to verify that the
cable will not rub or restrict the tracking
motion.
MC connectors Some PV modules have
these quick connectors. If the connector is not
appropriate at some junctions, you can cut the
wire and make a conventional connection.

19
5.4 Solar Array Disconnect Switch in the Junction Box
CAUTION Loose
connections are a
comon cause of
failure. Pull each
connection to
confirm.
CAUTION If you
are not using a
low-water probe,
connect a small
wire between
terminals 1 and 2.
Note: Overload protection (fuses or circuit
breaker) is NOT required in the solar array
circuit.
Explanation:
1. Short circuit current from the solar array
can never reach the ampacity (maximum safe
amps capacity) of the recommended wire.
2. The PS- controller has internal overload
protection.
Disconnect Scwitch
The disconnect switch satisfies National
Electrical Code requirements for a safety
disconnect between the solar array and the
controller. During installation and mainte-
nance, switch off the disconnect switch to
prevent shock and arc burn hazard.

20
5.5 Junction Box (Controller Input) Wiring
WARNING TEST THE VOLTAGE before
connecting power to the controller. Voltage
(open circuit) must not exceed 100V for
PS200-, 150V for PS600 and 200V for
PS1200 systems. (Even in cloudy weather,
the open circuit voltage will be near maxi-
mum.)
WARNING Do not apply a direct connection
or an amp meter between + and – when the
controller is connected. A short circuit
here will cause a strong discharge.
WARNING SOLAR-DIRECT systems only —
Do not connect any electrical load to the
solar array if it is not part of the LORENTZ
Pump system. Connection of a battery
charger, active solar tracker controller, electric
fence charger, or other load simultaneously
with LORENTZ PS systems may “confuse”
the controller and prevent proper operation.
CAUTION If you
are not using a
low-water probe,
connect a small
wire between
terminals 1 and 2.
System Diagram For solar-direct systems,
refer to the System Diagram at the end of this
manual.
Ground connections The two ground
terminals in the junction box are bonded
together and are also bonded to the metallic
enclosures of both the junction box and the
controller. See Section 5.2
POWER IN Ensure that the solar array
DISCONNECT SWITCH (or battery fuse or
circuit breaker)- is OFF. Connect the power
from the solar array to the input terminals in
the junction box. Observe polarity. If your
wires are not clearly marked +/–, test them
using a DC voltmeter or multitester.
PUMP See Section 5.8.
Low Water Probe See Section 5.9
Float Switch See Section 5.10, Automatic
Control for Full-Tank Shutoff. A connection is
made at the factory between terminals 4 and
5. If you are NOT using a float switch, leave
this connection in place.