SAJ PDS33 Series User manual

PDS33 Solar Pump Controller
User Manual
Version code：6.0004.0358-00-PDS33-E-V03-1907

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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
using.

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Contents
Preface................................................................................................................. - 1 -
Notes for Safe Operation....................................................................................- 5 -
■Before Installation............................................................................................- 5 -
■ Installation...................................................................................................... - 5 -
■ Operation........................................................................................................ - 6 -
■ Maintenance and check................................................................................. - 6 -
■ Others.............................................................................................................. - 6 -
Chapter 1 How It Works....................................................................................- 7 -
1.1 Features......................................................................................................... - 9 -
Chapter 2 General Information.......................................................................- 11 -
2.1 Inspection.....................................................................................................- 11 -
2.2 Descriptions and Features..........................................................................- 11 -
2.3 Protection Features.....................................................................................- 12 -
2.4 PDS33 Solar Pump Controller Model Description..................................- 13 -
2.4.1 Model Description....................................................................................- 13 -
2.4.2 PDS33 Solar Controller General Parameters........................................- 13 -
2.4.3 PDS33 Solar Controller Input and Output Data.................................. - 14 -
2.5 Outline &Installation Dimensions.............................................................- 16 -

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2.5.1 Outline &installation dimensions diagram........................................... - 16 -
Chapter 3 Mechanical and Electrical Installation.........................................- 19 -
3.1 Mechanical Installation..............................................................................- 19 -
3.1.1Overheat protection..................................................................................- 19 -
3.1.2 Location Selection....................................................................................- 19 -
3.2 Electrical Installation................................................................................. - 21 -
3.2.1 Terminals.................................................................................................. - 21 -
3.2.2 Power in DC Wiring................................................................................ - 22 -
3.2.3 Junction box connection..........................................................................- 22 -
3.2.4 Ground Wiring.........................................................................................- 23 -
3.2.5 Motor Wiring........................................................................................... - 23 -
3.2.6 Low water level probe wiring (optional)............................................... - 23 -
3.2.7 Water tank level float wiring (optional).................................................- 24 -
3.2.8 Electrical conduit.....................................................................................- 25 -
3.2.9 System Wiring Diagram..........................................................................- 25 -
Chapter 4 Start-up and Operation..................................................................- 26 -
4.1 Keypad Description.................................................................................... - 26 -
4.2 Keypad Operation Process........................................................................ - 27 -
4.2.1 Parameter Setting.................................................................................... - 27 -
4.2.2 Fault Reset................................................................................................- 28 -

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4.3 Trial operation............................................................................................ - 28 -
4.4 User Definable Parameters........................................................................ - 30 -
Chapter 5 Diagnostics and Troubleshooting.................................................. - 40 -
5.1 Fault Codes..................................................................................................- 40 -
5.2 Common Faults and Remedies..................................................................- 44 -
Chapter 6 Protocol.........................................................................................- 46 -
6.1 Address of control orders...........................................................................- 46 -
6.2 Address of parameter status...................................................................... - 46 -
6.3Description of controller’s status and faults............................................. - 48 -
Chapter 7 Regular maintenance......................................................................- 50 -
7.1 Controller and Pump..................................................................................- 50 -
• Controller........................................................................................................- 50 -
• pump................................................................................................................- 50 -
7.2 Solar panels................................................................................................. - 50 -
7.3 Cable............................................................................................................ - 50 -
Chapter 8 Backup AC power...........................................................................- 51 -

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Notes for Safe Operation
■Before Installation
WARNING
Do not install or operate the controller which is damaged or has missing parts.
Otherwise, it may result in equipment damage or life harm.
■ Installation
CAUTION
◎Hold the bottom of the controller when installing or moving the controller, you must
not just hold the shell，in order to prevent the injury or breaking of 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 needs to set vents
to ensure ambient temperature is below 40℃,Otherwise it may be damaged because of high
temperature.
◎When installing the controller, you should avoid direct sunlight, the controller can be
installed under the PV arrays.
WARNING
◎Ensure only qualified personnel can install and operate the controller. 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 or 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 during operation. Otherwise it may cause an
electrical shock.
◎Before testing the pump must be installed; you cannot 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 cables of the pump’s three power
cables.
◎When the water pump is stopped due to the light shadow, it will restart the operation
after 300s.
◎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 connection of controller’s related terminals. If a water level probe is not used, the
controller’s terminals must be short connected
■ 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
◎Failing to follow these instructions, which result in damage to the machine, cannot
enjoy the warranty service.

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Chapter 1 How 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 power from the PV array to AC power，and drive variable kinds of
pumps. In sunny days, the PDS33 solar pumping system can continuously pump
water. The system is without batteries and other energy storage devices, it is
recommended to take water 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 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 is designed which consists of:
A. Solar Array

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B. DC Breaker or Disconnecting Switch
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 matching 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 Monitoring
The PDS33 solar pump controller can be operated at full power when the ambient
temperature reaches 45 °C. At temperatures above 45 °C, the controller reduces the
carrier frequency and maintains operation as much as possible.
Level Control Switch
The PDS33 solar pump controller can access two water level switch detects
remotely control the pump automatically. Level switch for PDS33 solar pump
controller is optional, not mandatory.
Switching to Backup AC Power

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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 from 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 motors. 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 starting ，inspect the PDS33 solar pump controller unit. Verify that the part
number is correct and that no damage has occurred during transit.
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

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a solar array or an optional AC generator backup.
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 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 PDS33 Solar Pump Controller Model Description
2.4.1 Model Description
PDS33 - 4 T 5R5
① ② ③ ④ ⑤
Segment
Description
Options
①
PDS series
②
Series 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
④
Input Voltage
S: DC 310V rating, MPPT range DC 275V～380V (Note 1)
T: DC 540V rating, MPPT range DC 500V～750V (Note 2)
⑤
Motor Power Rating
004:4kW;5R5:5.5kW;R: decimal point
Note 1: Supporting Alternating Current input, with voltage rating of AC 220V single phase
connected to terminal R&T.
Note 2: Supporting Alternating Current input, with voltage rating of AC 380V 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
MODBUS Communication Card
Optional RS-485
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 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 275-380V
DC 500-750V
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(±15%)
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(±15%)
Three Phase AC 380(±15%)
Max Amps(RMS)[A]
9.6
5.1
9
13
Output Power, Rated[kW]
2.2
2.2
4
5.5
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 500-750V
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 500-750V
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
30
37
45
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 500-750V
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
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
Figure 2 2.2kW-7.5kW Outline Dimension
Type
Outline Dimension
Installation Dimension
Hole Size
H
W
D
H1
W1
d
PDS33-2S2R2
187
88
138
177
73
5
PDS33-4T2R2
PDS33-4T004
207
100
147
197
85
5
PDS33-4T5R5
247
130
167
237
113
5
PDS33-4T7R5

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Figure 3 11kW-37kW Outline Dimension
Type
Outline Dimension
Installation Dimension
Hole Size
H
W
D
H1
W1
d
PDS33-4T011
360
182
197
331
156
7
PDS33-4T015
PDS33-4T18R5
385
219
197
356
156
7
PDS33-4T022
PDS33-4T030
442
256
228
414
199
7
PDS33-4T037

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Figure 4 45kW-110kW Outline Dimension
Type
Outline Dimension
Installation Dimension
Hole Size
H
W
D
H1
W1
d
PDS33-4T045
557
300
282
524
245
10
PDS33-4T055
PDS33-4T075
597
338
322
560
270
10
PDS33-4T093
PDS33-4T110

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Chapter 3 Mechanical and Electrical Installation
3.1 Mechanical Installation
3.1.1Overheat protection
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 reduced 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 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.
3.1.2 Location Selection
The PDS33 solar pump controller is intended for
operation in ambient temperatures up to 60℃, but
in order to avoid overheating caused by the
failure, it is recommended to install the controller
in the shadow position.
Figure 5 Control Box Location