SAJ PDS23-2SR75 User manual

PDS23 Solar Pump Controller
User Manual
Version code： PDS23-EN-602000561-1702

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Preface
Thank you for using PDS23 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 PDS23 Solar Pump Controller Model Description.................................................- 12 -
2.5 Outline &Installation Dimensions..........................................................................- 17 -
Chapter 3 Mechanical and Electrical Installation ....................................... - 20 -
3.1 Mechanical Installation..........................................................................................- 20 -
3.2 Electrical Installation.............................................................................................- 21 -
Chapter 4 Start-up and Operation............................................................. - 27 -
4.1 Keypad Description ...............................................................................................- 27 -
4.2 Keypad Operation Process.....................................................................................- 28 -
4.3 Trial operation........................................................................................................- 29 -
4.4 Running status panel display parameters ...............................................................- 30 -
4.5 User Definable Parameters.....................................................................................- 31 -
Chapter 5 Diagnostics and Troubleshooting.............................................. - 37 -
5.1 Fault Codes............................................................................................................- 37 -

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5.2 Common Faults and Remedies...............................................................................- 41 -
Chapter 6 Regular maintenance................................................................. - 43 -
6.1 Controller and Pump..............................................................................................- 43 -
6.2 Solar panels............................................................................................................- 43 -
6.3 Cable......................................................................................................................- 43 -
Chapter 7 BackupAC power...................................................................... - 44 -

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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 below 40℃,otherwise it may be damaged because of high
temperature.
◎When install the controller, you should avoid direct sunlight, 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 bythe 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 pump’s terminals .
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, it can change any two lines of the pump’s three power
lines.
◎When the water pump is 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, it will need to be
short. If a water level probe 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 that 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 1 How It Works
The PDS23 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
PDS23 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 when the water shortage pump is stopped. Figure 1 shows a typical
diagram of a PDS23 solar pumping system. The major parts and components in the
system are listed after the diagram.
Figure 1 PDS23 solar pumping system
The PDS23 solar pumping system is designed which consists of:
A. Solar Array
B. DC Breaker or Disconnect Switch
F. Water Tower
Float Switch
E. Well
Level Switch D. Pump
A. PV Array
C. PDS23 Solar Pump Controller
B. DC Breaker

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C. PDS23 series Solar Pump Controller
D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)
The PDS23 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 PDS23 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 PDS23
solar pump controller will be operating. Whenever the PDS23 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 PDS23 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 pump output is restored when the controller temperature cools to a safe level.
Level Control Switch
The PDS23 solar pump controller can access two water level switch detects
remotely control the pump automatically. Level switch for PDS23 solar pump
controller is optional, not mandatory.

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Switching to Backup AC Power
The PDS23 solar pump controller’s input power terminal may be switched manually
to a backup AC power source.
Note: Depending on the model number, PDS23 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 PDS23 solar pump controller simultaneously! Please check if the design is
in accordance with all applicable national and local electrical codes.