SAJ PDS23 Plus User manual

PDS23 Plus Solar Pump
ControllerUser Manual
Version code：PDS23 Plus-EN-60200183-1707

PDS23 Plus Series
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Preface
Thank you for using PDS23Plus solar pump controller. 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 1How It Works................................................................................... - 6 -
1.1 Features....................................................................................................................- 7 -
Chapter 2 General Information.................................................................... - 9 -
2.1 Inspection ................................................................................................................- 9 -
2.2 Descriptions and Features........................................................................................- 9 -
2.3 Protection Features ................................................................................................- 10 -
2.4 PDS23Plus Solar Pump Controller Model Description..........................................- 11 -
2.5 Outline &Installation Dimensions..........................................................................- 13 -
Chapter 3 Mechanical and Electrical Installation ....................................... - 14 -
3.1 Mechanical Installation..........................................................................................- 14 -
3.2 Electrical Installation.............................................................................................- 15 -
Chapter 4 Start-up and Operation............................................................. - 20 -
4.1 Keypad Description ...............................................................................................- 20 -
4.2 Keypad Operation Process.....................................................................................- 21 -
4.3 Trial operation........................................................................................................- 22 -
4.4 Running status panel display parameters ...............................................................- 23 -
4.5User Definable Parameters......................................................................................- 23 -
Chapter 5 Diagnostics and Troubleshooting.............................................. - 28 -
5.1 Fault Codes............................................................................................................- 28 -

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5.2 Common Faults and Remedies...............................................................................- 31 -
Chapter 6 Regular maintenance................................................................. - 33 -
6.1 Controller and Pump..............................................................................................- 33 -
6.2 Solar panels............................................................................................................- 33 -
6.3 Cable......................................................................................................................- 33 -
Chapter 7 BackupAC power...................................................................... - 34 -

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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 ofthe controllerwhen installingormovingthe controller, can not
justhold theshellto prevent theinjuredorbrokencontroller.
◎Install the controller on nonflammable material like metal. Otherwise it may cause a
fire.
◎When thecontroller is mountedin a protectivecabinet, the cabinet need to
setventstoensureambient temperature is below40℃,otherwise itmay 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 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
PDS23 Plus solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable.PDS23 Plus solar
pump controller can convert DC from the PV array to AC, and drive kinds of pumps.
In sunny days, the 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 thatwhen thewater shortagepump is stopped. Figure 1 shows a
typical diagram of the pumping system. The major parts and components in the
system are listed after the diagram
Figure 1 PDS23 Plus solar pumping system
PDS23 Plus solar pumping system is designed which consists of:
A. Solar Array
B. DC Breaker or Disconnect Switch
C. PDS23 Plus series Solar Pump Controller
F. Water Tower
Float Switch
E. Well
Level Switch D. Pump
A. PV Array
C. PDS23 Plus Solar Pump Controller
B. DC Breaker

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D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)
PDS23Plus 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.
1.1 Features
System Diagnostics
PDS23Plus 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, PDS23Plus
solar pump controller will be operating. Whenever the controller detects a need for
water, the controller always “ramps up” the motor speed while gradually

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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
PDS23Plus solar pump controller is designed for full power operation from a solar
array in ambient temperatures up to 45 °C.In excess of45 ℃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
PDS23Plussolarpumpcontroller canaccesstwowater level switch
detectsremotelycontrol the pumpautomatically.Level switchforthe controlleris
optional,not mandatory.
Switching to Backup AC Power
The input power of the PDS23 Plus solar pump controller can be switched to
standby AC power through a power switch box.
Note: the controllers support power input 380VAC three-phase.
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 switch and aAC switch must be installed in the power switch box,
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 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
PDS23Plus solar pump controller is a variable speed motor drive designed to run
any IEC three-phase asynchronous motor. PDS23Plus 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 to an alternate
three-phase AC input such as a generator, if available. The controller provides fault
detection, motor soft start, and speed control. The controller is designed to provide
these features with the plug and play ease of installation.
The PDS23Plus 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 you begin, receive and inspect the controller unit. Verify that the part number
is correct and that no damage has occurred during transit.
NOTE: PDS23Plus solar pump controller is one component of the PDS23Plus solar
pumping system which has other two components, solar array and AC pump with
motor.
2.2 Descriptions and Features
The PDS23Plus solar pump controller is based on a standard PDS23Plus 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 controller continuously monitors system performance and incorporates a
number of features for pumping system protection. In the event of a fault, the
PDS23Plus solar pump controller will indicate the type of fault through the LED
display mounted on the front cover of controller.
Thepumping 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 to use interface is provided 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 PDS23Plus Solar Pump Controller Model Description
2.4.1 Model Description
PDS23Plus2.2K
①②③④
Segment
Description
Options
①
PDS series
②
Series ID
2: Series of 2nd generation.
3: Apply to three-phase induction motor
③
Plus
Enhancement type
④
Motor Power Rating
2.2K: 2.2kW; K: kW
Note 1:Rated input voltage 540VDC , recommended Voltage(MPP) 500VDC-700VDC ;
2:Supporting alternating current input, with voltage rating of 380VAC three phase
connected to terminal R, S and T.
2.4.2General parameters of PDS23 Solar Pump Controller
General Parameters
Protection
Surge Protection
Integrated
Overvoltage Protection
Integrated
Undervoltage Protection
Integrated
Locked pump Protection
Integrated
Open circuit Protection
Integrated
Short circuit Protection
Integrated
Overheated Protection
Integrated
Dry Run Protection
Integrated
Communication
MODBUS Communication
RS-485 Isolated
Others
Ambient Temperature Range
-20°C～60°C;>45°C, Derating as Required
Cooling Method
Fan Cooling
Ambient Humidity
≤ 95%RH
Level of Protection
IP65
Certificates
IEC/EN 61800-5-1,IEC/EN 61800-2:2004,IEC/EN61800-3:2004,CE

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2.4.3 Input and Output Parametersof PDS23 Plus Solar Pump Controller
Controller Model
PDS23
Plus 2.2K
PDS2Plus
4K
PDS23Pl
us 5.5K
PDS23Pl
us 7.5K
PDS23Pl
us 11K
Input Data
PV Source
Max Input Voltage(Voc)
DC800V
Recommended Voltage, at MPP
DC500～700V
Recommended PV Array Power
[kW]
2.7～3.5
4.8～6.4
6.6～8.8
9～12
13.2～
17.6
Alternate AC Generator
Input Voltage
380/400/415/440VAC(±15%), Three Phase
Power and VA Capability[kVA]
4.0
5.9
8.9
11.0
17
Output Data
Output Power, Rated[kW]
2.2
4.0
5.5
7.5
11
Output Voltage, Rated
380/400/415/440VAC(±15%), Three Phase
Rated Output Amps(RMS)[A]
5.1
9.0
13.0
17.0
25.0
Max Amps(RMS)[A]
9.0
13.0
17.0
25.0
32.0
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
2.5.1 Outline &installation dimensions diagram
(Unit: mm)
155.6
179
240
191.3
168
150
50
50
144.3
22
Figure 2 PDS23 Plus 2.2K，PDS23 Plus 4K
Outline &installation dimensions diagram
Figure 3PDS23 Plus 5.5K，PDS23 Plus 7.5K，PDS23 Plus 11K
Outline &installation dimensions diagram
214
202
300
235
117.5
195
65
65
154
20

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Chapter 3Mechanical and Electrical Installation
3.1 Mechanical Installation
3.1.1Overheat protection
Theprotection level of PDS23 Plussolar pump controller reached IP65; if installed
in the outdoor, the controllers should be installed in a well ventilated place, and
avoid direct sunlight and rain.The best installation location is below the solar array,
which can prevent the equipment from overheating and performance degradation.
In extremely high temperature, high temperature may cause the controller stop to
protect itself.
3.1.2 Location Selection
The PDS23Plus solar pump controller is
intended for operation in ambient
temperatures up to 60℃, but in order to avoid
failure caused by overheating, it is
recommended to install the controller in
shadow position.
PDS23 Plus solar pump controller can be
installed outdoors, but to avoid direct sunlight;
it can be installed in the bracket under the
solar module.
Figure 4Installation Location

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3.2 Electrical Installation
3.2.1 Terminals
The following are typical figures of terminal blocks.
Figure 5 Main terminals (The sequence may be different from actual product)
Figure6 Control terminals (The sequence may be different from actual product)
Note：The terminals not referred in the user manual are invalid.
3.2.2 Power in DC Wiring
For a solar pumping system, a two-pole DC disconnect switch must be installed
between the solar array and the PDS23Plus solar pump controller. Connect the
cables which comes from the two-pole DC disconnect Switch downstream
terminals marked with “+” and “-” (positive and negative poles of Solar panel
output), to PDS23Plus solar pump controller’s terminals block labeled as “R/+”,
“T/-”.
M1 M2 M3 COM M4 M5 M6 COM
NC
N0
Remote Float Switch
Low-water
sensor probe
No Function
S+ S-
RS485
Interface
R/+
S
T/-
U V W
DC/AC INPUT
GROUND
PUMP
To reverse direction,
reverse any two
wires.
The DC and AC can't
input at the same
time.

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WARNING
Before connect DC wiring, following the steps below to prevent hazardous electric shock
resulting in serious injury or device burning.
• Make sure that the external DC disconnect switch is off.
•Make sure that AC power is disconnected (If AC power supply is wired as backup
power,AC and DC power supply can not simultaneously put into the controller, otherwise it
will damage the controller.)
3.2.3 Junction box connection
If there are a large number of solar modules, it is needed to use a junction box to
converge the bus to the solar array.Thejunction box need to install fuses, lightning
protection device and DC switch.The fuse and the DC switch can prevent the short
circuit protection; the lightning protection device can play the direct current side the
lightning protection function. The junction box must be sealed, and water can not
enter.
3.2.4 Ground Wiring
Ground terminal (GND) is labeled as this icon . Please connect it to the ground
Correct grounding helps to prevent shock hazard if there is a fault in the motor.
3.2.5 Motor Wiring
Connect the cable with four wires from the Motor to the controller terminal block to
terminals U, V, W, and GND (See Figure 9). Check motor lead color to ensure
correct installation.。
Note: To reverse direction of motor rotation, reverse any two wires
US
Black（BLK）
Red（RED）
Yellow（YEL）
Ground（GND）
International
Gray（GRY）
Black（BLK）
Brown（BRN）
Ground（GND）

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It is recommended that 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. If you do not use a wire tube, you can use a higher
quality outdoor cable.
3.2.6Low water level probe wiring (optional)
In order to avoid dry pumping lead to pump damage, a wells probe can be
connected to the terminals of the PDS23Plus solar pump controller, so as to detect
the water level in wells; and the wire maximum length can not more than 50m. If
there is no water level probe for the detection of the water level, please keep the
two terminals of the controller short. The controller can also detect water through
the built-in software water detection function;look upFD function group in section
4.5.
3.2.7 Water tank level float wiring (optional)
Use a floating ball switch to prevent reservoir overflow is recommended. When the
reservoir is full, the pump will stop; when the water level is lower than the low level,
the pump will be restarted. It can prevent the overflow, limit the unnecessary pump
wear. The PDS23Plus controller allows the use of small signal line to connect to
remote float switch, even if the position of the reservoir is far away.
Figure 7FloatingBallDiagram
position
pump off
position
pump on
pumping
range
cable
weight
sealed cable
clamp

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Floating ball switch request:
1. Three signal line
2. The minimum requirements for 1 mm²line diameter, the distance up to 600m
3. I f the application is in a long distance transmission, the need to use the shielded
wire.The end of the shielding layer close to the controller needs to be grounded, the
end close to the floating ball switch;the end close to the float switch is not required
to be grounded.
If the float switch is not used, the M6 and COM are kept short.
Figure 8 Float ball wiring diagram
3.2.8Electrical conduit
When the system installed in the outdoor, electricalconduit can be used to protect the
outdoor electric wires, so as to avoid the impact from the weather, human activities,
chewing animals. If you do not use the electrical conduit, use the higher quality
outdoor wire.
M5 M6 COM
NC
N0
Remote
Float
Switch
COM
Float Switch
N0
NC
COM
if cable is shielded,
ground this end only
UP: closed
DOWN: open
normal: open

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3.2.9 System Wiring Diagram
Figure 9 System Wiring Diagram
NOTE:
1. The float switch is optional; if not use, please keep the terminal M6 and COM
short.
2. Low water level probe is optional; if not use, please keep the terminal M4 and
COM short.
In the case of conventional 250W polycrystalline components, the peak voltage is
30.6V and the open circuit voltage is 37V. Description of the number of input
components in series:
The PDS23Plus series controller is connected in series with the serial number of the
input components of the 18～20 block, and the 250W 500～700VDC (MPPT) is
satisfied.
DC/AC INPUT
Pump
To reverse direction,
reverse any two
wires
The DC and AC
can't input at the
same time .
Remote Float
Switch
Low-water
sensor probe
Submersible
Cable Splice
Pump Motor
Low Water
Level Probe
(optional)
Float Switch
(optional)
Earth Ground
PV Array
R/+
S
T/-
U V W
COM M4 M5 M6 COM
NC
N0
GROUND