SAJ PDS33 Series User manual

PDS33 Solar Pump
ControllerUser Manual
Version code： PDS33-EN-60200589-1701

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Preface
Thank you for using PDS33 series products. This manual provides you with relevant
operation instructions and detailed description of parameters. Please read this
manual carefully before installation, running, maintenance or inspection.
Please make sure the wiring and the pump’s rotation direction is correct before use.

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Content
Preface............................................................................................................... - 1 -
Notes for Safe Operation.................................................................................. - 4 -
Chapter 1 How It Works.................................................................................. - 6 -
1.1 Features ...................................................................................................................... - 8 -
Chapter 2 General Information .................................................................... - 10 -
2.1 Inspection................................................................................................................. - 10 -
2.2 Descriptions and Features........................................................................................ - 10 -
2.3 Protection Features....................................................................................................- 11 -
2.4 PDS33 Solar Pump Controller Model Description.................................................. - 12 -
2.5 Outline &Installation Dimensions........................................................................... - 16 -
Chapter 3 Mechanical and Electrical Installation ....................................... - 19 -
3.1 Mechanical Installation............................................................................................ - 19 -
3.2 Electrical Installation ............................................................................................... - 20 -
Chapter 4 Start-up and Operation................................................................ - 26 -
4.1 Keypad Description.................................................................................................. - 26 -
4.2 Keypad Operation Process....................................................................................... - 27 -
4.3 Trial operation.......................................................................................................... - 28 -
4.4 Running status panel display parameters................................................................. - 29 -
4.5User Definable Parameters ....................................................................................... - 29 -
Chapter 5 Diagnostics and Troubleshooting................................................. - 35 -
5.1 Fault Codes............................................................................................................... - 35 -

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5.2 Common Faults and Remedies ................................................................................ - 39 -
Chapter 6 Regular maintenance.................................................................... - 41 -
6.1 Controller and Pump................................................................................................ - 41 -
6.2 Solar panels.............................................................................................................. - 41 -
6.3 Cable......................................................................................................................... - 41 -
Chapter 7 Backup AC power......................................................................... - 42 -

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Notes for Safe Operation
■Before Installation
WARNING
Do not install or operate the controller that is damaged or has missing parts. Otherwise, it
may result in equipment damage or harm life.
■ Installation
CAUTION
◎Hold the bottom of the controller when installing or moving the controller, can not just
hold the shell to prevent the injured or broken controller.
◎Install the controller on nonflammable material like metal. Otherwise it may cause a
fire.
◎When the controller is mounted in a protective cabinet, the cabinet need to set vents to
ensure ambient temperature is below40℃,otherwise it may be damaged because of high
temperature.
◎Avoid direct sunlightwhen installing the controller, it can be installed under the PV array.
WARNING
◎Ensure only qualified personnel to operate. Otherwise it can cause an electrical shock or
damage of the controller.
◎Make sure the controller is isolated from power supply by the circuit breaker. Otherwise it
may cause a fire.
◎Make sure that the ground terminal is grounded correctly.
◎Do not touch the power input terminals of the controller and the output terminalsfor
pump . Otherwise it may cause an electrical shock.

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■ Operation
CAUTION
◎Do not open or remove the front cover when operation. Otherwise it may cause an
electrical shock.
◎Before testing the pump must be installed; can not make the pump dry-
run for a long
time .In order to test the pump, the maximum dry-run time is not more than 15s
◎If the pump turning is reversed, change any two lines of the pump’s three power lines.
◎When the water pump stops due to the light shadow, it will restart the operation after
120s.
◎If a water level probe is installed in the well, when the water level is below the level of
water shortage, the water pump will stop. If there is no water level probe，or it is not used, the
controller terminal must be short.
■ Maintenance and check
WARNING
◎Only qualified or authorized professional personnel can maintain, replace and inspect the
controller. Otherwise it may cause damage and injury.
◎Wait at least 10 minutes after the power failure, or make sure thatthere is no residual
voltage before carry out maintenance and inspection, otherwise it may cause damage.
■Others
WARNING
◎If failing to follow these instructions, resulting in damage to the machine, can not enjoy
the warranty service.

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Chapter 1How It Works
The PDS33 solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable.The controller can
convert DC from the PV array to AC，and drive kinds of pumps. In sunny days, the
PDS33 solar pumping system can continuously pump water. The system without
batteries and other energy storage devices, it is recommended to take water pumped
to a reservoir for later use and water sources are those natural or special such as river,
lake, well or waterway, etc. A float switch can be installed in the water tower to
control the pump operation. And install a low-level probe in well to detect the well
water so that the pump will stop when thewater is shortage. Figure 1 shows a typical
diagram of a PDS33 solar pumping system. The major parts and components in the
system are listed after the diagram.
Figure 1 PDS33 solar pumping system
The PDS33 solar pumping system consists of:
A. Solar Array
B. DC Breaker or Disconnect Switch and Combiner Box
F. Water Tower
Float Switch
E. Well
Level Switch D. Pump
A. PV Array
C. PDS33 Solar Pump Controller
B. DC Breaker

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C. PDS33 series Solar Pump Controller
D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)
The PDS33 solar pump controller runs at variable speed while match the changing
power provided by the solar array. Variable speed operation means there is no
in-rush or surge of energy during the pump/motor start-up, helping to eliminate wear
on the motor and pumping system.
Pump Check Valve Requirements
Notice: In order to ensure maximum system reliability and water delivery, check
valves must be installed in the drop pipe. The first check valve must be installed at
the pump and additional check valves should be installed every 30m (100 ft) of
vertical pipe after the pump.

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1.1 Features
System Diagnostics
The PDS33 solar pump controller continuously monitors system performance and
detects a variety of abnormal conditions. In many cases, the controller will
compensate as needed to maintain continuous system operation; however, if there
is high risk of equipment damage, the controller will protect the system and display
the fault condition. If possible, the controller will try to restart itself when the fault
condition subsides. See Diagnostics and Troubleshooting section for a list of Fault
Codes and corrective actions.
Motor Soft-Start
Normally, when there is a demand for water and power is available, the PDS33
solar pump controller will be operating. Whenever the PDS33 solar pump
controller detects a need for water, the controller always “ramps up” the motor
speed while gradually increasing motor voltage, resulting in a cooler motor and
lower start-up current compared to conventional water systems. Due to the
controller’s soft-start feature this will not harm the motor.
Over Temperature Foldback
The PDS33 solar pump controller is designed for full power operation from a solar
array in ambient temperatures up to 45°C.In excess of 45℃temperature conditions,
the controller will reduce output power in an attempt to avoid shutdown. Full power
output is restored when the controller temperature cools to a safe level.
Level Control Switch
The PDS33 solar pump controller can access two water level switch to 8tremote
control of the pump automatically. Level switch or PDS33 solar pump controller is
optional, not mandatory.

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Switching to Backup AC Power
The PDS33 solar pump controller’s input power terminal may be switched manually
to a backup AC power source.
Note: Depending on the model number, PDS33 solar pump controllers support
power input either 220VAC single phase, or 380VAC three phase, Please contact
controller manufacturer or authorized agencies for details.
When the system is running on back-up AC power, please check for sufficient DC
primary source power every 30 minutes. If the primary DC power is available, shut
down the controller, switch back to primary power and attempt to run on DC
power supply.
NOTICE :A DC circuit switch and a generator power switch must be installed, and
these two switches must be mechanically interlocked each other to prevent
switching on together resulting the solar PV and the generator being connected to
the solar PDS33 solar pump controller simultaneously! Please check if the design is
in accordance with all applicable national and local electrical codes.

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Chapter 2 General Information
The PDS33 solar pump controller is a variable speed motor drive designed to run
any IEC three-phase asynchronous motor. The PDS33 solar pumping system
provides water to remote locations by converting high voltage, direct current from a
solar array into alternating current to run a standard three-phase asynchronous motor.
When solar power is not available, the controller can be switched manually to an
alternate single-phase or three-phase AC input such as a generator or inverter from
battery, if available. The controller provides fault detection, motor soft start, and
speed control. The PDS33 solar pump controller is designed to provide these
features with the plug and play ease of installation.
The PDS33 solar pump controller is designed with the high standard of reliability
expected of products. The controller attempts to drive the pump and motor to deliver
water even under adverse conditions, reducing output as necessary to protect the
system components from damage, and only shutting down in extreme cases. Full
operation is restored automatically whenever abnormal conditions subside.
2.1 Inspection
Before installation, inspect the PDS33 solar pump controller unit. Verify that the
part number is correct and that no damage has occurred during transportation.
NOTE: PDS33 solar pump controller is one component of a PDS33 solar pumping
system which has other two optional components, solar array and AC pump with
motor.
2.2 Descriptions and Features
The PDS33 solar pump controller is based on a standard PDS33 platform controlling
a standard three-phase asynchronous motor driving a pump powered by a solar array
or an optional AC generator backup.

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The PDS33 solar pump controller continuously monitors system performance and
incorporates a number of features for pumping system protection. In the event of a
fault, the PDS33 solar pump controller will indicate the type of fault through the
LED display mounted on the front cover of controller.
The PDS33 solar pumping system is optimized for pumping under adverse input
power conditions unique to solar arrays：
• Internal diagnostics will tolerate a lower input voltage.
• Whenever possible, the controller attempts to drive the pump load by maximizing
power output from the solar array.
•An easy way to use interface is to enhance configurability and enable remote
system monitoring.
• A LED display provides a detailed indication of system status.
• A small keypad offers flexibility for selection of user options.
2.3 Protection Features
Electronic monitoring gives the controller the capability to monitor the system and
automatically shut down in the event of:
• Dry well conditions – with low level switch
• Bound pump – with auto-reversing torque.
• High Voltage Surge
• Low Input Voltage
• Open motor circuit
• Short circuit
• Over heat
NOTE: This controller provides motor overload protection by preventing motor
current from exceeding rating current and by limiting the duty cycle in the event of
low water level. This controller does not provide over temperature sensing of the
motor.

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2.4 PDS33 Solar Pump Controller Model Description
2.4.1 Model Description
PDS33 -
①②③④⑤
4T5R5
Segment Description Options
①PDS series
②Series ID 3: Series of 3rd generation.
3: Apply to three-phase induction motor
③
Rated Output
Voltage 2: 220V three phase; 4: 380V three phase
④Input Voltage S: 310VDC rating, MPPT range 280VDC～360VDC(Note 1)
T: 540VDC rating, MPPT range 500VDC～700VDC(Note 2)
⑤Motor Power Rating 004:4kW;5R5:5.5kW;R: decimal point
Note 1: Supporting Alternating Current input, with voltage rating of 220VAC single phase connected
to terminal R&T.
Note 2: Supporting Alternating Current input, with voltage rating of 380VAC three phase connected to
terminal R, S and T.
2.4.2 PDS33 Solar Controller General Parameters
General Parameters
Protection
Surge Protection Integrated Overvoltage Protection Integrated
Under voltage Protection Integrated Locked pump Protection Integrated
Open circuit Protection Integrated Short circuit Protection Integrated
Overheated Protection Integrated Dry Run Protection Integrated
Communication
RS485 Isolation RS485
GPRS Optional
Others
Ambient Temperature Range -20°C～60°C;>45°C, Derating as Required
Cooling Method Fan Cooling
Ambient Humidity ≤ 95%RH
Standard Warranty(month）18
Certificates IEC/EN 61800-5-1,IEC/EN 61800-2:2004,IEC/EN61800-3:2004,CE

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2.4.3 PDS33 Solar Pump Controller Input and Output Data
PDS33-2SXX/4TXX Input and Output Data
Controller Model PDS33-2S2R2 PDS33-4T2R2 PDS33-4T004 PDS33-4T5R5
Input Data
Max Input Voltage(Voc) DC 450V DC 800V
Recommended Voltage, at MPP DC 280-360V DC 500-700V
Recommended PV Array Power [kW] 2.7～3.5 2.7～3.5 4.8～6.4 6.6～8.8
Alternate AC Generator
Input Voltage AC 220V(±10%) Three Phase AC 380(±15%)
Max Amps(RMS)[A] 23 5.8 10.5 14.6
Power and VA Capability[kVA] 4 4 5.9 8.9
Output Data
Output Voltage, Rated AC 220V(±10%) Three Phase AC 380(±15%)
Max Amps(RMS)[A] 10 5.1 9 13
Output Power, Rated[kW] 2.2 4 5.5 7.5
Output Frequency 0～50Hz/60Hz
Controller Model PDS33-4T7R5 PDS33-4T011 PDS33-4T015 PDS33-4T18R5
Input Data
Max Input Voltage(Voc) DC 800V
Recommended Voltage, at MPP DC 500-700V
Recommended PV Array Power[kW]9～12 13.2～17.6 18～24 22.2～29.6
Alternate AC Generator
Input Voltage Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 20.5 26 35 38.5
Power and VA Capability[kVA] 11 17 21 24
Output Data
Output Voltage, Rated Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 17 25 32 37
Output Power, Rated[kW] 7.5 11 15 18.5
Output Frequency 0～50Hz/60Hz

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Controller Model PDS33-4T022 PDS33-4T030 PDS33-4T037 PDS33-4T045
Input Data
Max Input Voltage(Voc) DC 800V
Recommended Voltage, at MPP DC 500-700V
Recommended PV Array Power[kW] 26.4～35.2 36～48 44～59.2 54～72
Alternate AC Generator
Input Voltage Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 46.5 62 76 92
Power and VA Capability[kVA] 30 40 57 69
Output Data
Output Voltage, Rated Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 45 60 75 91
Output Power, Rated[kW] 22 22 30 37
Output Frequency 0～50Hz/60Hz
Controller Model PDS33-4T055 PDS33-4T075 PDS33-4T093 PDS33-4T110
Input Data
Max Input Voltage(Voc) DC 800V
Recommended Voltage, at MPP DC 500-700V
Recommended PV Array Power[kW]66～88 90～120 112～149 132～176
Alternate AC Generator
Input Voltage Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 113 157 180 214
Power and VA Capability[kVA] 85 114 134 160
Output Data
Output Voltage, Rated Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 112 150 176 210
Output Power, Rated[kW] 55 75 93 110
Output Frequency 0～50Hz/60Hz

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Controller Model PDS33-4T132
PDS33-4T160 PDS33-4T200 PDS33-4T220
Input Data
Max Input Voltage(Voc) DC 800V
Recommended Voltage, at MPP DC 500-700V
Recommended PV Array Power[kW]159～211 192～256 240～320 264～352
Alternate AC Generator
Input Voltage Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 256 307 385 430
Power and VA Capability[kVA] 192 231 250 280
Output Data
Output Voltage, Rated Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 253 304 377 426
Output Power, Rated[kW] 132 160 200 220
Output Frequency 0～50Hz/60Hz
Controller Model PDS33-4T250 PDS33-4T280 PDS33-4T315 PDS33-4T350
Input Data
Max Input Voltage(Voc) DC 800V
Recommended Voltage, at MPP DC 500-700V
Recommended PV Array Power[kW]300～400 336～448 378～504 426～568
Alternate AC Generator
Input Voltage Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 468 525 590 665
Power and VA Capability[kVA] 355 396 445 500
Output Data
Output Voltage, Rated Three Phase AC 380V(±15%)
Max Amps(RMS)[A] 465 520 585 650
Output Power, Rated[kW] 250 280 315 350
Output Frequency 0～50Hz/60Hz
Note: according to different regions, the recommended PV array power is 1.2 ~ 1.6
times the power of the controller.

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2.5 Outline &Installation Dimensions
Figure 2-1 2.2kW Outline &installation dimensions diagram
Figure 2-2 4-5.5kW Outline &installation dimensions diagram
Figure 2-3 7.5-11kW Outline &installation dimensions diagram
１３０
１８６
１５４．８ １２０
５．２
１２０ ５．２
１７６
１８０．２ Φ５．５ １５０．５
２３１ ２４１
１６２
１５０．５ ５．５
１９５．４
３４８
３６０．５
１８２ １５６
３２３．５
Φ１２
６．２
６．２
１５６

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Figure 2-4 15-18.5kW Outline &installation dimensions diagram
Figure 2-5 22-30kW Outline &installation dimensions diagram
３７３
３８５．５
２１９ １９６．９ １５６
３４８．５
１５６
Φ１２
６．２
６．２
１９９
４０６．５
７
Φ１２ ７
２２８．６
２５６
４３０
４４５

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Figure 2-6 37-45kW Outline &installation dimensions diagram
Figure 2-7 55-93kW Outline &installation dimensions diagram

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Chapter 3Mechanical and Electrical Installation
3.1 Mechanical Installation
3.1.1 Installation environment
Install the PDS33 solar pump controller in a control box with control terminals and
power wiring. Install the control box out of direct sunlight to prevent overheating
and reduced performance. The optimum location is on the mounting pole for the
solar array underneath the array for protection from the sun, heat, and weather
elements. Placing the control box in direct sunlight or high ambient temperatures
will result in poor performance due to temperature foldback protection of the PDS33
solar pump controller. For optimum performance, maximize the shading of the
control box.
It is recommended to use a wire tube to protect the electric wire from the destruction
of wildlife and natural weathering, and bury the wire tube into the ground to
strengthen protection. Use a higher quality outdoor cableif there is no wire tube.
3.1.2 Location Selection
The PDS33 solar pump controller is intended for
operation in ambient temperatures up to 60℃, but
in order to avoid overheating, it is recommended to
install the controller in the shadow position.
Figure 3Control Box Location