SAJ PDS51 User manual

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PDS51 Solar Pump Controller
User Manual
Data Code：30301509 PDS51-E-V01-2205

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Preface
Thank you for choosing PDS51 solar pump controller. This manual provides you
with relevant operating instructions and detailed explanations of parameters. Please
read this manual carefully before installation, operation, maintenance or
inspection.
Before using, be sure to confirm whether the wiring is correct and whether the
rotation direction of the pump is correct.

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Contents
CHAPTER 1 SYSTEM INTRODUCTION................................ -6-
1.1 SYSTEM OVERVIEW............................................................................................... - 6 -
1.2 SYSTEM COMBINATION..........................................................................................- 7 -
1.3 SYSTEM FUNCTION................................................................................................- 7 -
CHAPTER 2 PRODUCT INFORMATION............................... -9-
2.1 INSPECTION............................................................................................................- 9 -
2.2 DESCRIPTION AND FEATURES................................................................................ - 9 -
2.3 PROTECT FUNCTIONS...........................................................................................- 10 -
2.4 MODEL DESCRIPTION.......................................................................................... - 11 -
2.5 SPECIFICATION SELECTION TABLE.......................................................................- 11 -
CHAPTER 3 MECHANICAL AND ELECTRICAL
INSTALLATION............................................................................ - 13 -
3.1OVERALL STRUCTURE AND DIMENSION DRAWING（UNIT：MM）....................- 13 -
3.2 KEYPAD STRUCTURE AND DIMENSION DRAWING............................................... - 14 -
3.3 MECHANICAL INSTALLATION...............................................................................- 14 -
3.5 ELECTRICAL INSTALLATION.................................................................................- 17 -
CHAPTER 4 SCREEN DISPLAY AND OPERATION...........- 23 -
4.1 DISPLAY INTRODUCTION......................................................................................- 23 -
4.2 FUNCTION OF INDICATORS AND BUTTON............................................................ - 23 -
4.3 DISPLAY OF CONTROL MODES............................................................................ - 24 -
4.4 USAGE OF EXTERNAL KEYPAD............................................................................- 25 -
4.5 POWER ON AND COMMISSIONING....................................................................... - 26 -

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CHAPTER 5 PARAMETERS LIST.............................................- 27 -
CHAPTER 6 DIAGNOSE AND TROUBLESHOOTING...... - 37 -
6.1 ERROR CODES..................................................................................................... - 37 -
6.2 TROUBLESHOOTING AND COUNTERMEASURES................................................... - 40 -
CHAPTER 7 RECOMMENDED PV PANEL CONFIGURATION- 42 -
7.1 RECOMMENDED PV PANEL CONFIGURATION...................................................... - 42 -
CHAPTER 8 WARRANTY POLICY...........................................- 43 -
CHAPTER 9 PRODUCT WARRANTY CARD..........................- 45 -

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Safety Precaution
■Arrival Inspection
◎If the controller is damaged or parts are missing, do not install or operate it.
Otherwise it may result in equipment damage or personal injury.
■Installation
◎When installing and moving, please hold the bottom of the product, not just the
casing, to prevent injury or damage to the controller.
◎The controller should be kept away from flammable and explosive objects, away
from heat sources, and installed on flame retardant objects such as metal.
◎When installing the controller, avoid direct sunlight, it can be installed under the
solar panel arrays.
◎The wiring must be completed by qualified professional electrical engineers and
comply with local electrical regulations, otherwise it may cause electric shock or damage to
the controller.
◎Before starting wiring, make sure that the power supply is disconnected, otherwise
it may cause electric shock or fire.
◎The grounding terminal should be grounded reliably.
◎Do not touch the input wire of the controller and the connection terminals of the
water pump, otherwise there is a danger of electric shock.

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■Running
◎The controller can be powered on after the wiring is completed and the cover is
installed. It is strictly forbidden to remove the cover when the power is on, otherwise it may
cause electric shock.
◎The water pump must be installed before testing the steering of the water pump. The
water pump should not be allowed to do dry run for a long time. In order to test the steering
of the water pump, the maximum running time of dry running should not exceed 15s.
◎If the rotation of the water pump is reversed, any two of the three cbales of the
controller output side can be changed.
◎When the water pump stops due to weak sunlight or sudden shadow, it will restart
after 300s.
◎If there is a water level probe installed in the well, the pump will stop running when
it is lower than the water shortage level.
■Maintenance and Inspection
◎Please designate qualified electrical engineers for maintenance, inspection or
replacement of parts.
◎Wait at least 10 minutes after the power is turned off or after confirming that there
is no residual voltage before maintenance and inspection, otherwise it may cause personal
injury.
■Others
◎If the controller is damaged due to failure to follow the above instructions, the
warranty service will not be available.

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Chapter 1 System Introduction
1.1 System Overview
The PDS51 solar water pump system can supply water to remote areas with no or
unstable power supply. The solar pump controller can convert the DC power generated by
the solar panels into AC power to drive various three-phase water pumps. The system can
pump water continuously when the weather is good. The system does not have energy
storage devices such as batteries, so it is recommended to pump water to the reservoir for
subsequent use. The water source can be natural or special water sources such as rivers,
lakes, wells or channels. The system can install a float switch in the reservoir or water tower
to control the running of the pump. A low water level probe can be installed in the well to
detect the water level in the well so that the pump can be stopped when the water level in
the well is low. Figure 1-1-1 shows a typical PDS51 solar water pump system. The main
parts and components of the system are listed after Figure 1-1-1.
Figure 1-1-1 Solar Pump System

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1.2 System Combination
■PDS51 Solar Water Pump System Combination：
A、Solar Arrays
B、PDS51 Solar Pump Controller
C、Water Pump
D、Water Well and Optional Level Probe
E、Water Tank
The PDS51 solar pump controller can start the water pump smoothly and match the
changing power provided by the solar panel. The benefit of soft start is that the pump/motor
has no surge and energy shock during startup, which helps reduce wear and tear on the
motor and pump system.
■Requirement for Check Valve：
Note：To ensure maximum reliability of the system and water supply, check valves
must be installed in the output pipe. The first check valve must be installed on the water
pump outlet, and the remaining check valves should be installed on the vertical pipeline
every 30 meters (100 feet) behind the pump.
1.3 System Function
■System Diagnose
The PDS51 solar water controller continuously monitors the performance of the system
and can detect various abnormal conditions. In many cases, the controller will provide
compensation as needed to maintain uninterrupted running of the system. If there is a
possibility of equipment damage, the controller will protect the system and display the fault
status; if possible, the controller will restart after the fault status is eliminated. For
information on fault codes and corrective actions, see the Diagnosse and Troubleshooting
chapter.
■Soft Start of Motor
Typically, the PDS51 solar pump controller will run when there is a demand for water
and electricity is available. Every time the PDS51 solar pump controller detects a water

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demand, the controller always slowly increases the motor speed while gradually increasing
the motor voltage. Compared with the traditional water supply system, the motor
temperature and starting current of the solar water pump system are lower. Since the
controller has a soft start function, there is no damage to the motor.
■Overheat Monitoring
The PDS51 solar pump controller can also run at full power when the ambient
temperature reaches 45°C. At temperatures above 45°C, the controller reduces the carrier
frequency （switching frequency of IGBT）and maintains operation as much as possible.
■Level Probe（or Float Switch）
The PDS51 solar pump controller can be connected to 2 water level detection switches
to remotely control the operation of the water pump. The water level switch is optional for
the PDS51 solar water pump controller, but not mandatory.

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Chapter 2 Product Information
The PDS51 solar pump controller is a speed-adjustable motor driver designed for
three-phase asynchronous motors and permanent magnet synchronous motors. The PDS51
solar water pump system converts the high-voltage DC power from the solar arrays into AC
power to drive the water pump to supply water to remote areas. When the solar energy is
insufficient, the controller can automatically switch to a backup single-phase or three-phase
AC power source, such as generator and grid power. The controller provides fault detection,
motor soft start and speed control. PDS51 solar pump controller is designed with
plug-and-play function and easy installation.
PDS51 solar pump controller is a high standard and high reliability product. In weak
light conditions, the controller will also try to drive the pump to lift water. If the light
continues to be weak, the controller will decrease the pump speed to protect the components
of the system from damage, and only shut down in extreme cases. When the abnormal
situation disappears, the controller will re-drive the pump to run.
2.1 Inspection
Before usage ，check the PDS51 solar pump controller . Make sure that the
information on using the device is correct and that the device was not damaged in transit.
Note: The PDS51 solar pump controller is an integral part of the PDS51 solar water
pump system, which has two other optional components, the solar arrays and the water
pump.
2.2 Description and Features
The PDS51 solar pump controller is designed based on the standard PDS51 platform,
which is powered by solar arrays or an optional backup generator and controls a standard
three-phase asynchronous motor or permanent magnet synchronous motor to drive the water
pump.
The PDS51 solar water pump controller continuously monitors system performance
and integrates multifunctional pumping system protection. When a fault occurs, the PDS51

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solar water pump controller displays the fault type through the display on the front cover of
the controller, and can automatically reset the normal faults.
We have optimized the pumping function of the PDS51 solar water pump system under
the condition of poor solar array input power supply as follows:Internal diagnostics allow
for lower input voltages.Whenever possible, the controller will maximize the output of the
solar array to drive the water pump.Provides users with an easy-to-use interface for
enhanced configurability and remote monitoring of the system.
2.3 Protect Functions
Electronic monitoring enables the controller to monitor the system and automatically
shut down when:
1The well level is low
2The water tower（or water tank）is full of water
3The pump is blocked or overloading.
4High voltage surge
5Low voltage input
6Motor phase loss
7Short circuit
⑧Controller inner overheating
NOTE: This controller provides overload protection for the motor by preventing motor
current from exceeding rated current and limited load operation at low water levels. The
controller does not provide motor overheat detection.

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2.4 Model Description
PDS51 - 4 T 5R5
① ② ③ ④ ⑤
Item
Content
Description
1
Solar Pump Drive
PDS
2
Series
5: IP65, 1: 1st generation
3
Pump Rated Voltage
2: 220V 3 phase, 4: 380V 3 phase
4
Voltage Range of
Solar Arrays
S:Rated 330VDC ,recommended 200VDC-400VDC(Note1)
T: Rated 560VDC ,recommended 400VDC-750VDC(Note2)
5
Rated Power of Pump
004:4kW; 5R5:5.5kW; R:Decimal Point
Note 1: Supports rated single phase AC 220V input，into L & N terminals
Note 2:Supports rated 3 phase AC 380V input，into R & S & T terminals
Table 2-4-1 Model Description
2.5 Specification Selection Table
Model
PDS51-2S2R2-E
PDS51-4T2R2-E
PDS51-4T004-E
PDS51-4T5R5-E
PDS51-4T7R5-E
PDS51-4T011-E
Input Power （DC）
Maximum
Voltage(V)
450
800
Startup Voltage(V)
100
220
Lowest Voltage(V)
70
200
Recommended
MPPT Voltage(V)
200-400
400-750
Best Working
Voltage(V)
330
560
Quantity of DC
Input Circuits
（MC4）
1
2
Input Power(AC)
Input Voltage
Range(V)
150-230
280-440
Input Power
Frequency(Hz)
50/60
Output Power（3 phase AC）
Output Power（kW）
2.2
2.2
4
5.5
7.5
11
Rated Current(A)
9.6
5.1
9
13
17
25

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Output Voltage(V)
3 phase 220V
±15%
3 phase 380V ±15%
Output Frequency
(Hz)
0-50/60
Control Performance
Control Mode
V/F mode & SVC(Sensorless Vector Control)mode
Type of Motor
Asynchronous Motor ，PMSM
Overload
Performance
120% Rated Current:1 min；150% Rated Current:10 secs
Other Features
Protection Class
IP65
Cooling
Natural Air Cooling
External Interface
External LED Keypad
Communication Port
4G/2G GPRS DTU
Ambient
Temperature
-20℃～60℃;>45℃,Derating as required
Altitude
Below 3000 meters, derate by 1% for each additional 100 meters above 2000 meters,
Notes: 1. Total power of PV arrays can be 1.2~1.6 times of power of water pump as per irradiation conditions in different countries and areas.
2. Inductor is suggested to be added to the solar pumping system if the distance between solar pump controller and water pump is over 50m.

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Chapter 3 Mechanical and Electrical Installation
3.1Overall Structure and Dimension Drawing（Unit：mm）
W
H
H2
H1
DW2
L
D1
?d
W1
Figure 3-1-1 2.2kW-11kW Outline Dimension
Inverter model
Outline Dimension
Installation
Dimension
Hole
Size
W
H
D
W1
H1
H2
D1
W2
L
d
PDS51-2S2R2-E
396
295
180.5
360
371
389
184
270
140
8
PDS51-4T2R2-E
PDS51-4T004-E
PDS51-4T5R5-E
430
315
186
385
401
408
189
270
137
8
PDS51-4T7R5-E
PDS51-4T011-E

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3.2 Keypad Structure and Dimension Drawing
■ External Keypad Dimension（Unit：mm）
Figure 3-2-1 Keypad Dimension
3.3 Mechanical Installation
3.3.1 Overheat Protection
If installed outdoors, to prevent overheating and performance degradation of the
equipment, in places with extreme heat, the high temperature may cause the controller to
shut down in self-protection. For best performance, avoid placing solar panels around any
obstructions that will cast shadows and reduce sunlight reaching these arrays.
Conduit is recommended to protect the wires from wildlife and natural weathering, and
to bury the conduit in the ground for added protection. If conduit is not used, a higher
quality outdoor cable should be used.
3.3.2 Installation Location
Although the applicable working ambient temperature of the PDS51 solar pump controller
can reach 60°C, in order to avoid failure caused by overheating, it is recommended to install
the controller in a shaded location.
Figure 3-3-2 Installation Location

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3.4.3 Whole machine wall-mounted installation
270
9 5
4 5
66
270
Figure 3-4-3-1 Hanging plate size and accessories requirements
Figure 3-4-3-2 Fixed installation of hanging plate
Figure 3-4-3-3 Controller hanging

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Figure 3-4-3-4 Screw fixing on the side of the controller
3.4.4 Communication module installation
Figure 3-4-4 Remote monitoring module installation
3.4.5 DC input side wiring
8mm
Figure 3-4-5 Connecting component terminals

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3.5 Electrical Installation
3.5.1 Wiring Ports
The following is a schematic diagram of the wiring port layout.
Figure 3-5-1 Main Circuit Wiring Ports
Item
Port Name
Description
Technical Features
①
PV1+
1st PV Panel Positive Input Port
≤20A
②
PV1-
1st PV Panel Negative Input Port
≤20A
③
PV2+
2nd PV Panel Positive Input Port（only
available on 5.5-11kW models）
≤20A
④
PV2-
2nd PV Panel Negative Input Port（only
available on 5.5-11kW models）
≤20A
⑤
AC Input
The controller with AC input function can
be connected to the grid or generator
Single Phase 220V/
3 Phase 380V
⑥
AC Output
Can be connected to pumps with ordinary
asynchronous motor or permanent magnet
synchronous motor（PMSM）
3 Phase 220V/380V
⑦
Signal Port
For water level signal wire or
communication wire
⑧
GPRS Module
Port
Optional GPRS-2G/4G DTU module for
remote monitoring
⑨
External
Keypad Port
Optional external keypad for parameter
adjustment
⑩
Breather Valve
It can keep the pressure balance inside and
outside the machine and prevent
condensation

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R/L S T/N PE UV W S-
SO S+
GND
24V
+10V
A1
GND
DI3
DI2
DI1
GND
Figur 3-4-2 Controller Wiring Terminals
Symbol
Name
Technical Specifications
R/L,S,T/N
AC Input Terminals
R/L and T/N for single phase 220V input
R/L and S and T/N for 3 phase 380V input
PE
Grounding Terminal
Power input and motor output ground terminal
U,V,W
AC Output Terminals
The 3-phase pump motor is connected to the
U/V/W output terminals respectively. If you need
to connect a single-phase motor, please refer to
the specific connection instructions.
DI1～DI3
Multi functional Digital
Input Terminals
1. Optocoupler isolated unidirectional input
2. ON when connected to GND, OFF when
disconnected to GND
3. Input voltage range: 9～36VDC
4. Input impedance: 4kΩ
24V
Analog Reference
Voltage
24V,±5%,Maximum output current 100mA
+10V
Analog Reference
Voltage
10V,±5%,Maximum output current 50mA
AI
Analog Input Terminal
Default as 4~20mA input, can be set to 0-10V
input, the default resistance is 500Ω.

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GND
Analog GND
It is the reference zero potential of the analog
reference voltage.
S+/S0/S-
Communication Port
for Multi Drive System
（CAN Protocol）
Standard CAN communication interface, please
use twisted pair or shielded wire and connect S+,
S0, S- when building multi-drive system
3.5.2 DC Input Power Wiring
For the solar water pump system, after specifying the number of solar panel in strings
and parallel with reference to the panel selection table, connect the PV+ of the aggregated
panels to the PV+ port of the controller, and connect the PV- of the panels to the PV- port of
the controller; If there are multiple ways pf panel arrays, you need to connect the positive
and negative of the same way to the same input port of the controller.
3.5.3 AC Input Power Wiring
If the user has access to the grid, the connection can be made through the junction box
in the middle of controller bottom. First remove the junction box, pass the AC input wire
through the waterproof connector, and connect the input single-phase AC to the R/L and
T/N terminal of the machine, The three-phase AC is connected to the R/L and S and T/N
terminal, and the ground wire is connected to the PE terminal.
3.5.4 Ground Wiring
The ground port on the controller is marked as PE, please connect to earth, if the motor
fails, proper grounding helps eliminate the risk of electric shock.
3.5.5 Motor Wiring
Connect 4 cables from the motor to the U, V, W, PE ports of the controller. It should
also be connected to the controller through the waterproof connector of the junction box.
The international standard wiring of the motor is shown in the table below. Check motor
wirings to ensure proper installation.
Note: If the pump is running reversely, swap any two of the cables connected to U
& V & W terminals.
U
V
W
PE
US Standard
Black
Gery
Yellow
Green or
Yellow-Green
International
Standard
Grey
Black
Brown
Yellow-Green
Table 3-5-3 Motor Wiring