lorentz pump manual

7/22/2019 Lorentz Pump Manual

1/68

PS200

PS600

PS1200

INSTRUCTIONS FOR

INSTALLATION

OPERATION

SERVICE

For more informationplease contact your installer or:

Dankoff Solar Products, IncSanta Fe, NM 87507

[email protected]

Tel. 505-473-3800

Fax 505-473-3830

release 05/01/10

SOLAR WATER

PUMP SYSTEMS


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2

1 WARNINGS .......................................................................................................................................................... 4

2 SYSTEM REPORT FORM ..................................................................................................................................... 5

3 INTRODUCTION ................................................................................................................................................... 8

PHOTO GALLERY ......................................................................................................................................................... 9

4 INSTALLING THE SOLAR ARRAY....................................................................................................................... 11

4.1 Location of the Solar Array ............................................................................................................................ 114.2 Solar Array Assembly Methods ..................................................................................................................... 114.3 Solar Array Mounting Rack ............................................................................................................................ 114.4 Orienting the Solar Array to Solar South ....................................................................................................... 12

4.5 Setting the Solar Array Tilt Angle ................................................................................................................... 135 ELECTRICAL INSTALLATION............................................................................................................................. 14

5.1 Controller, Junction Box, and Conduit .......................................................................................................... 145.2 Grounding and Lightning Protection ............................................................................................................ 165.3 Solar Array Wiring.......................................................................................................................................... 185.4 Solar Array Disconnect Switch in the Junction Box ...................................................................................... 195.5 Junction Box (Controller Input) Wiring .......................................................................................................... 205.6 Maximum RPM Setting .................................................................................................................................. 215.7 Submersible Pump Cable and Splice.......................................................................................................... 225.8 Wiring Order for Correct Rotation ................................................................................................................. 235.9 Low-Water Probe for Dry-Run Protection ..................................................................................................... 245.10 Automatic Control For Full-Tank Shutoff ....................................................................................................... 255.11 Battery-Based Systems ................................................................................................................................ 27

5.12 Pressurizing Systems .................................................................................................................................. 28

6 PREPARING TO INSTALL THE PUMP ................................................................................................................ 30

6.1 WARNINGS about Handling Helical Rotor Pumps ...................................................................................... 306.2 Drop Pipe ...................................................................................................................................................... 316.2 Safety Rope and Binding .............................................................................................................................. 326.4 Installation in a Surface Water Source ......................................................................................................... 336.5 Deep Well Setting How Deep? ................................................................................................................ 346.6 Coping with Dirty Water Conditions ............................................................................................................. 346.7 Utilizing a Low-Production Water Source ..................................................................................................... 356.8 Installing the Pump Under a Windmill or Hand Pump Cylinder .................................................................. 35

7 IN-WELL ASSEMBLY AND INSTALLATION........................................................................................................ 36

7.1 Rubber Spacers (Models -07, -10, -14, -20 only) ......................................................................................... 36

7.2 Machine Installation ...................................................................................................................................... 377.3 Hand Installation........................................................................................................................................... 377.4 Sanitizing the Well ........................................................................................................................................ 38

8 OPERATING THE PUMP ..................................................................................................................................... 39

9 TROUBLE SHOOTING ........................................................................................................................................ 41

9.1 If The Pump Doesnt Run ............................................................................................................................. 419.2 Inspect The System ...................................................................................................................................... 429.3 Electrical Testing........................................................................................................................................... 439.3.1 Table of AC running current for PS200 and PS600 systems ................................................................................................................ 44

9.3.2 Table of AC running current for PS1200 systems ..................................................................................................................................44

9.4 If The Pump Runs But Flow Is Less Than Normal ...................................................................................... 469.5 Problem Report Form ................................................................................................................................... 47

9.6 Electrical Testing Illustrated ......................................................................................................................... 50

Contents


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Contents continued

CAUTION

recommended to avoid disfunc-tion or premature ageing of thepump etc.

WARNING

disregard might lead to injury ordamage the installation

QUESTION AND ANSWER

gives explanation

ADVICE

Symbols

10 MAINTENANCE .................................................................................................................................................. 5410.1 Controller and Pump .................................................................................................................................... 5410.2 Solar Array ..................................................................................................................................................... 5410.3 Electrical Wiring ............................................................................................................................................ 54

11 MANUFAC-TURERS WARRANTY ...................................................................................................................... 55

12 STANDARDS, ENVIRONMENTAL AND TEMPERA-TURE SPECIFI-CATIONS ..................................................... 55

13 REFERENCE SECTION ....................................................................................................................................... 56

13.1 Principles of Operation ................................................................................................................................. 5613.2 Water Pipe Sizing Chart ................................................................................................................................ 5813.3 Wellhead Assemblies for Drilled Wells ....................................................................................................... 59

13.4 Water Storage for Solar Water Pumps ......................................................................................................... 6013.5 Monitoring a Solar Pump System ................................................................................................................. 6113.6 Freeze Protection for Solar Water Pumps .................................................................................................... 6113.7 Selecting and Using Meters for Electrical Testing ....................................................................................... 6213.8 Measuring Solar Energy Intensity ................................................................................................................. 6213.9 Glossary of Solar Electricity and Water Pumping ........................................................................................ 6313.10 Calculating Pumping Efficiency and Power Requirement ........................................................................... 6713.11 System Wiring Diagram for Solar-direct (non-battery) System .................................................................... 68


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Open circuit (no-load) voltage above 100V forPS200-, above 150V for PS600- and above200V for PS1200 controllers will destroy thecontroller. This may occur if the solar array iswired incorrectly. (See Solar Array Wiring,Section 5.3.)

Do not attempt to run the Motor without thePSXXX controller.

Do not attempt to use the controller for anypurpose other than LORENTZ PS-PumpSystems.

To be installed, connected and serviced byqualified personnel only. Ensure all power

sources are disconnected when makingconnections. Follow all appropriate electricalcodes. There are no user serviceable partsinside the motor or the controller.

Solar pumps run at low flow rates, and havecloser tolerances than conventional pumps.Extreme sand or silt concentration (greaterthan 2% by volume) may cause the pump tostop, or the pipe to fill with sand. Do not usethe pumpsto clean out a dirty well. (SeeSection 6.6. for advice about dirty water.)

Helical rotor pumps are sensitive to heat.Protect the pump from sunshine or other

source of heat, or it may lock temporarily. Ifthe water source is, or will be warmer than72 (22C), a special model may be required.(See Section 6.4.)

Undersized wire will cause failure to start.(See Section 5.7.)

Install proper system grounding for safetyand lightning protection (See Section 5.2)

Do not touch the controller input or pumpwires together to test for a spark.

Do not run the pump dry. Exception: to testdirection of rotation, for maximum 15 seconds(See Section 5.8)

Test the direction of motor rotation beforeinstalling the pump (counter-clockwise lookingdown). If direction is reversed, exchange the

connection of any two of the three powerwires to the pump. (See Section 5.8)

When pump is stopped by a shadow or byaction of float switch, it will restart after a 120seconds.

The low water probe must be submersed, orthe pump will stop for 20 minutes. If the probeis not to be used, connect the probe terminalstogether in the junction box. (See section 5.5and 5.9)

Helical rotor models (without a C in the model#) are not self-draining. If drainage is requiredfor freeze-protection, install a weep hole or

draining device below freeze level. SeeSection 13.6 Do not remove the check valvein attempt to make it self-drain.

1 WARNINGS

Failure to follow

these instruc-tions will void

the warranty.

Install this system in accordance with localregulations and accepted codes of profes-sional practice.

This manual is the property of the LORENTZPumpowner.

Please give it to the owner or maintenancepersonnel when you are finished!

Request copies from your pump supplier ordownload from www.Lorentz.de

This manual is for controller modelsPS1200, PS600, PS200 as illustrated on thecover. For earlier models (before July 2003)refer to Version 1 and 2

Copyright 2002-2004 by BERNT LORENTZGMBH & CO KG and DANKOFF SOLARPRODUCTS, INC. All rights reserved


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2 SYSTEM REPORT FORM

System and Components

System Voltage V

Date of Purchase

Purchased from

Battery System? yes no

if not: Quantity of Solar Modules (panels)

Solar Module Brand

Module Model #

Controller Model PS1200

PS600

PS200

other, i.e.:

Controller Serial #

Pump End Model #

Pump End Serial #

Temperature Range

Helical rotor pumps (without C in the model number) work optimally only in a specifictemperature range. Last digit of Pump End Model # indicates temperature class.If a special temperature range was not specified, the last digit of model number (X) will be 1.

Class 0 32 F to 54 F 0 C to 12 C

Class 1 46 F to 72 F 8 C to 22 C Class 1 is the standard class.

Class 2 64 F to 90 F 18 C to 32 C

Class 3 82 F to 108 F 28 C to 42 C

Class 4 100 F to 126 F 38 C to 52 C

See Section 12

for more about

temperature

specifications.


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Installation Report

Installation Date

by

Well Depth m / ft

Pump depth m / ft

Additional Vertical Lift (up to top of tank) m / ft

Static Water Level m / ft

Drawdown level m / ft

Drop Pipe (vertical from the pump)

Size mm2 / inch

Type

Length m / ft

Additional Pipe Length (to tank)

Size mm2 / inch

Type

Length m / ft

Submersible Pump Cable

Wire size mm2/ AWG

Total Length (controller to pump) m / ft

MAX RPM CONTROL

(See Section 5.6) Factory setting is Maximum.

If this setting was reduced, enter setting here:

System Report Form continued

yes no


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System Report Form continued

Performance Report

When the pump is operating, record this data. This will help you to assess its performance anddiagnose any problems that may occur in the future.

Flow rate observed US-Gal./min / lpm

Notes

AC current through any one pump wire Amps(See Section 13.7)

If these measurements were not takenat full vertical lift, note here


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Thank you for purchasing a LORENTZPUMP.We set a new standard for quality andeconomy in solar pumping. It incorporatesthe best solar pump technologies that werevery expensive until its introduction in 2002.

Before you beginCheck the model numbersof all the components of your system, andverify that they are the items that you ordered.

Also check against the PUMP specificationsand performance charts (end of this manual)to be sure the system is appropriate for yourapplication. If you expect to pump water thatis very cold or very warm, check the tempera-ture range specifications (Section 12). If youthink you may have the wrong pump for yourapplication, call your supplier immediately.

Please fill in the SYSTEM REPORT. This willbe essential information if any problemsoccur.

This manual covers two types of systems,

batteryand solar-direct.If you purchasedthe Pumpto connect to a battery system, youcan skip the sections about the solar arrayand solar-direct systems.

REFERENCE SECTION (Section 13) ManysInstallers are new to solar pumping, so we

provide helpful informationprinciples ofoperation, instructions for wellhead assem-bly, water storage, control and monitoring ofwater supply, pipe sizing, freeze protection,and a glossary of technical terms.

3 INTRODUCTION


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PHOTO GALLERY

A MODEL INSTALLATIONA PS600 300Wp solar-direct systemColorado, USA

This system was installed by students in asolar water pumping class.

- The array is set at summer tilt angle.

- The controller is mounted on the northside of the pole, directly under the array.This shades it from the hot mid-day sun.

- Mounting and ground-bonding details areshown in Section 5.1.

- Electrical conduit runs from the PUMPjunction box to the wellhead to protect thepump wires. The water pipe is all underground.

Courtesy of Dankoff Solar Products, NM, USA

This PV array was

assembled and

wired on the

ground, then lifted

with a crane.

Courtesy of Dankoff Solar

Products,NM, USA

PS600 HR04-

300Wp system in

Colorado, USA,installed by

students in a solar

pumping class.

The drop pipe is

0.75"

polyethylene.

Hand installation

requires caution

and is not alwaysrecommended

(see Section 7.3)

Courtesy of Dankoff SolarProducts NM, USA

PV array assembly. The mounting pole is short

enough to facilitate assembly without mechanical

assistance.


Setting an array

pole in con-crete.

Courtesy of Dankoff SolarProducts, NM, USA


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A tracking solar array

The mounting pipe was extended to 11 feet (3m), by welding it to a larger pipe. Wire is typeUSE (outdoor rated). The wire is looped to

help it to shed water and to flex. Wires enter

the conduit through a weather head.


Owners of a domestic water system watch asthe pumpfills their polyethylene storage tank.The tank was buried later.

Photo courtesy of Dankoff Solar Products, NM, USA


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4 INSTALLING THE SOLAR ARRAY

Sunlight is the fuel that drives a solar pump.Full solar exposure of the solar array is criticalfor full performance of a solar-direct system.

Choose a location for the solar array that hasunrestricted sun exposure through the dayand through the year. The array can be placedseveral hundred feet (100 m) or more from thewellhead. There will be no loss of perform-ance if the electrical wire is sized properly, butnaturally, the cost of wire will increase signifi-cantly. The System Sizing Table specifieswire size requirements for both normal and

extended wire lengths.CAUTION Shading a smallportion of a PV array may causethe pump to stop completely.

Each PV module (panel) containsa series of solar cells (typically

36 or 72 cells). Every cell that is shaded actslike a resistor, reducing the output of theENTIRE ARRAY. Shading just a few cells willreduce the power disproportionately, and maystop the pump. Consider this when decidingwhere to install the array.

To determine where shadows may be cast at

any time of the year, you can survey the sitewith a Solar Pathfinder.This device isespecially useful in forested areas or wher-ever there are obstructions nearby. It isavailable directly from Solar Pathfinder (USA)tel. (317) 501-2529, fax (931) 590-5400,www.solarpathfinder.com.

Place the bottom edge of the array at least 2feet (.6 m) above ground to clear rain spatter,growing vegetation and snow. Keep in mindthat trees and perennial plants will grow tallerin the coming years.

There are two ways to install the solar array.

1. Assemble the array on the ground, wiringand all, then lift the entire assembly onto thepole or roof. A system of 300 watts or moremay require the assistance of a backhoe,boom truck or crane to lift it over the pole.

2. Assemble the array piece-by-piece on thepole. If the pole is higher than about 6 feet(2m), it is best to construct a temporaryplatform, like a scaffold assembly commonlyused in building construction). A scaffoldsystem can be rented from a local supplier.

4.3 Solar Array Mounting

Rack

WARNING Your mounting

structure must be engineeredfor wind resistance and safety.

Follow the rack (or tracker)

manufacturers instructions

that are packed with your rack.

Solar TrackingA solar tracker is a specialpole-mounted solar array rack that tiltsautomatically to follow the daily path of thesun. In clear summer weather, it can in-crease your daily water yield by 40-50%. (It ismuch less effective in winter and in cloudyweather.)

4.1 Location of the Solar Array 4.2 Solar Array Assembly

Methods


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8

9

1011 1

2

4

3

6

7 5

6

1996 by John VeltmanSouth

North

AM PM

West East

Jun

Aug

Sep

Oct

Nov

Dec

May

Apr

Mar

Feb

Jan

Jul

40o

50o

30o

Sun Compass Instructions

1. Draw an arrow from Month dot to intersec-tion of your StandardTime and LatitudeNorthern (50 N to 70 N)The gray line is an example: August, 2 PM at40 N lat.

2. Stand and face your shadow.

3. Hold this page horizontally.

4.Point the arrow that you drew to center ofyour shadow.

5. Sun Compass now points to the fourdirections.

SUN COMPASS

4.4 Orienting the Solar Array to Solar South

Sun Compass is available for the followinglatitudes:

1. U.S.A. (25 to 55) shown here

2. Northern (50 N to 70 N)

3. Equatorial (20 N to 20 S)

4. Southern (10 S to 40 S)

To obtain reproduction rights, contact: JohnVeltman PO Box 23533, Santa Fe, NM 87502

USA

For the USA

(lower 48 states)

and other 25 to

55 North latitude

regions.

Find True South

quickly andaccurately using

only your shadow.

No magnetic

compass needed!

For full performance, your solar array mustbe oriented within 10 of true (solar) south.Depending on your location, a compassreading may show an error of as much as 20.To correct this discrepancy, apply the mag-netic declination for your region. Manyregional maps indicate the magnetic declina-tion. If you dont have a compass but can seeyour shadow and know the time of day, usethe Sun Compass.


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Solar Array TiltAngles by

Latitude

0-25 latitudes: Apply a minimum tilt angle of

10, or dust and debris will accumulate.

4.5 Setting the Solar Array Tilt Angle

CAUTION People often forget to make

seasonal adjustments.

Ideal angles (from horizontal) are:

Summer optimum = latitude - 15Winter optimum = latitude + 15

Maximum performance is obtained from asolar pump when its photovoltaic array is tilted(elevated) to face the sun. The solar arrayracks that are supplied with the PumpSystemsare adjustable to the desired tiltangle. It is the responsibility of the installer toperform this adjustment.

Some systemsinclude a solar tracker, andothers with a fixed (non-tracking) rack. Bothtypes of array have a manual tilt-angleadjustment. (The tracker follows the dailypath of the sun, but not the seasonal tiltvariation.)

The optimum tilt angle is determined by thelocation (latitude). It also varies with the timeof the year. This data is presented in the tablebelow.

Should the tilt angle be adjusted periodicallythrough the year? This depends on theseasonal water-use pattern, and also onhuman factors. There are three options tochose from.

Select one of these options for seasonal

management:

1. Year-round compromise(no seasonaladjustment) Set the angle equal to the latitude

of the location and forget it. This is practicalbecause people often forget to adjust thearray. The performance displayed in theSystem Sizing Tableis based on this fixedcompromise setting of the tilt-angle.

2. Seasonally adjustedIt is sufficient toperform the adjustment only twice per year, atthe spring and autumn equinoxes, to thesummer and winter angles indicated below.For central USA, this will increase the dailywater production by about 8% in summer, 5%in winter compared to option 1.

3. Seasonal use onlyIf the pump is to be

used no more than half of the year, set thearray to the appropriate seasonal angleshown below, and forget it.

If you use the pump all year but do not wantseasonal adjustment to be required, set theangle to year-round compromise(equal tolatitude).

noitacoL

)selpmaxe( edutitaL

remmuS

tliT

retniW

tliT

dnuoR-raeYesimorpmoC

eliT

nrehtuoS

adanaC 05 53 56 05

drihTreppU

ASUfo 54 03 06 54

drihTelddiM

ASUfo 04 52 55 04

drihTrewoL

ASUfo 53 02 05 53

lartneC

ocixeM 02 5 53 02


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5 ELECTRICAL INSTALLATION

5.1 Controller, Junction Box, and Conduit

WARNING To be

installed, con-

nected and

serviced by

qualified person-

nel only. Ensureall power

sources are

disconnected

when makingconnections to

the controller.

Follow all

appropriateelectrical codes.

There are no

user serviceable

parts inside the

motor or the

controller.

CAUTION Loose connections are the most

common cause of system failures.

Pull on each connection to confirm that it issecure.

LocationPlace the controller close to thesolar array, not the pump. This will reduce therisk of lightning damage.

Explanation The controllers input circuitryis more sensitive to surges than its output. Itis safest to minimize the length of the inputwiring.

Protection from solar heatElectronicdevices are most reliable when they areprotected from heat. Mount the controller inthe shade of the mid-day sun. An ideallocation is directly under the solar array, onthe north side of the mounting pole. If shade

is not available, cut a piece of sheet metaland bolt it behind the top of the controller.Bend it over the controller to provide shade.This is especially important in extremely hotlocations. Extreme heat may trigger a thermalswitch in the controller and cause it to turn off.

Location of controller Mount the controllervertically to keep out rainwater. It is preferableto mount it ON THE NORTH SIDE of a pole orother structure, to help reduce solar heating.This may also allow easiest access withouthitting your head on the lower (south) edge ofthe array.

Junction Box (optionally)A pre-wiredjunction box is available for your system. Thejunction box terminals will handle pump wiresas large as #6 (13 sq. mm). If large wirescannot be accommodated easily in the box,you can join them to smaller wires in the

junction box. #12 (4 sq. mm) or larger isacceptable for this very short length. Do NOTremove terminal screws. If the key to the

junction box gets lost, it can be opened with ascrewdriver.

Mounting the controller and junction box

to a pole See photos on the following page.The controller can be mounted onto the solararray support pole using materials availablefrom your local electric supply store. The bestmounting hardware is slotted strut (Unistrut

or equivalent) with matching conduit clamps tofit around the mounting pole. This makes avery strong assembly that is easy to adjust. InNorth America, these materials are commonlyavailable from electric suppliers.

Electrical conduit is recommendedWe urgeyou to use electrical conduit (pipe) to protectoutdoor wiring from the weather, from humanactivities, and from chewing animals. Seephotos on the following pages. If you dontuse conduit, use strong, high-quality outdoorcable. Where cables enter the junction box,install sealed strain-relief cable clamps.

Keep the controller and junction box sealed

Unused holes must be sealed to keep outanimals, insects, water and dirt. Each hole issupplied with a rubber plug that can be keptin place for this purpose.

Battery systemBatteries must be in a coollocation for best longevity, and in a protectiveenclosure for cleanliness and safety. Placethe controller near the batteries but NOT inthe same enclosure. They must be safelyisolated from the battery terminals and fromcorrosive gasses.


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Typical assemblyof controller and junctionbox on the solar array mounting pole. Boxesare secured using slotted strut and conduitclamps.

Mount the

controller on the

north side of the

pole to reduce

solar heating.

Bare ground wires bond the PV modules tothe controller enclosure, and continue down tothe ground rod. Flat braid is flexible andeliminates the need for terminal lugs.

slotted strut (Unistrut or equivalent), cut tothe width of the box.

conduit clamp to fit slotted strut

hose clamp

Conduit holes

3 holes for 3/4" conduit (28mm)

1 hole for 1 1/4" conduit (45mm)

Holes are in a removable plate that can bereversed.

Rubber plugs are included for unused holes.

Controller, Junction Box, and Conduit continued


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5.2 Grounding and Lightning Protection

Surges induced by lightning are one of themost common causes of electronic controllerfailures in solar water pumps. Damagingsurges can be induced from lightning thatstrikes a long distance from the system, oreven between clouds. The risk of damage isgreatly reduced if these instructions arefollowed.

Location of the pump controllerPlace thecontroller close to the solar array, not thepump. This will reduce the risk of lightningdamage. Explanation: The controllers inputcircuitry is more sensitive to surges than itsoutput. It is safest to minimize the length ofthe input wiring.

Construct a discharge path to groundAproperly made discharge path to ground(earth) will discharge static electricity thataccumulates in the above-ground structure.This helps prevent the attraction of lightning. Ifa lightning strike occurs at close proximity, awell-grounded conductive structure can divertthe surge AROUND the electrical circuitry,greatly reducing the potential for damage.The controller has built-in surge protectors,but they help ONLY if the system is effectivelygrounded.

Earth connection Create an effective

discharge path It helps to picture this as adrain field for electrons. Here are sugges-tions for grounding, in order of their efficacy:

1. The best possible ground rod is a steel wellcasing located near the array. Drill and tap ahole to make a strong bolted connection tothe casing with good metallic contact. Bolt ona brass terminal lug. After the connection ismade, seal the connection with siliconesealant or other waterproof compound toprevent corrosion. Protect the ground wire(s)from physical damage so they arent stressed

by being stepped on, etc.

2. Install a copper plate or other specializedgrounding devices designed for the purpose.Some systems use salts to improve theconductivity of the surrounding soil.

3. Install one or more copper-plated groundrods at least 8 feet (2.5m) long, preferably inmoist earth. Where the ground gets very dry(poorly conductive), install more than one rod,spaced at least 10 feet (3m) apart.

4. If the soil is rocky and doesnt allow groundrods to be driven, bury BARE copper wire in atrench at least 100 feet (30m) long. If a trenchis to be dug for burial of water pipes, groundwire can be run along the bottom of thetrench. The wire size must be minimum #6 (16sq. mm) or double #8 (10 sq. mm). Connectone end to the array structure and controller.Or, cut the ground wire shorter and spread itin more than one direction.

Dry or rocky locationsTo achieve goodgrounding at a dry or rocky site, consult alocal contractor who specializes in lightningprotection. It is best to plan the procedure inadvance, and to coordinate the effort withother earth-excavating procedures that needto be done. Reference: www.lightning.org

Bond (interconnect) all the metal structural

components and electrical enclosures

Interconnect the PV module (solar panel)frames, the mounting rack, and the groundterminals of the disconnect switch and thecontroller, using wire of minimum size #8(6mm2), and run the wire to an earth connec-tion.

Ground connections at the controller Thecontroller and junction box have redundantground terminals inside. They are all con-nected in common with the metal enclosuresof both the controller and the junction box.Ground connections can be made to any ofthese points.

Ground connections to aluminumThisapplies to connections at the solar arrayframework, and at the controllers enclosurebox. Connections to aluminum must be madeusing terminal lugs that have an aluminum-to-copper rating (labeled AL/CU) and stainlesssteel fasteners. This will reduce the potentialfor corrosion.

WARNING

Failure to install

and connect an

effective ground-ing system will

greatly increase

the risk of

lightning dam-

age and will void

your warranty.We suggest you

wire the ground-

ing system FIRST

so it is not

overlooked. The

concrete footer of

a ground-

mounted array willNOT provide

adequate electri-

cal grounding.


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17

CAUTION

Ground the

cable shield at

the controller

end only, not at

the float switch.

WARNING

Isolate solar

pump wiring

from electricfence systems.

Do not connect

the pump system

to the same

ground rod as an

electric fence. Donot run power or

float switch cablesclose to an

electric fence.

DO NOT GROUND the positive or the nega-tive of the power circuit.The best lightningprotection results from grounding the metal-lic structure only, and leaving the powersystem ungrounded. This is called a floatingsystem.

Explanation:With a floating system and agood structural ground, lightning inducedsurges tend to reach ground through thestructure, instead of the power circuit. Whenhigh voltage is induced in the power circuit,the voltage in negative and the positive sidestend to be nearly equal, thus the voltageBETWEEN the two is not so high, and notusually destructive. This method has beenfavored for many decades by most engineersin the remote power and telecommunicationsfields.

Exception for battery systems:You canconnect the pump to a battery-based homepower system that has a negative ground. Ifthe wiring distance to the pump exceeds 100feet (particularly in a high lightning area), DC-rated surge protection devices are recom-mended.

Legal exception:If the local electricalauthority requires grounding of the powercircuit, ground the PV ARRAY NEGATIVEwire. This may increase the risk of lightningdamage.

Solar array wiringBind the array wires closetogether, or use multi-wire cable. Avoidforming loops. This helps induced voltages ineach side of the circuit to equalize and canceleach other out.

Wire twisting for long runsTwisting wirestogether tends to equalize the voltage inducedby lightning. It reduces the voltage differentialbetween the wires. This reduces the probabil-ity of damage. This method is employed intelephone cable, and in many other applica-tions. Some power cables are made withtwisted conductors. To twist wires yourself,you can alternate the direction of the twistabout every 30 feet (10 m). This makes the

job much easier.

Float switch cableA long run of control cableto a float switch in the storage tank can pickup damaging surges from nearby lightning.The best protection is to use shielded,twisted-pair cable . Shielded cable has ametallic foil or braid surrounding the twowires. Ground the cable shield as illustrated

in Section 5.10.

Low water probe cableA long horizontal runof wire to the low-water probe at the pumpcan pick up damaging surges from nearbylightning. Wire twisting is helpful. The bestprotection is to use shielded, twisted-paircable, same as recommended for a remotefloat switch. This product is suitable for directburial, but not for submersion in the well. Atthe wellhead, make a transition to submers-ible probe wires.

Additional lightning protectionThe controllerhas built-in surge protection devices. How-ever, additional grounding measures orsurge protection devices are recommendedunder any of the following conditions:

1. Isolated location on high ground in asevere lightning area

2. Dry, rocky, or otherwise poorly conductivesoil

3. Long wire run (more than 100 feet / 30m)from the controller to the wellhead, or to thefloat switch.

Additional lightning protection devices (surgearrestors) can be obtained from your pumpsupplier. The device(s) for the controllers PVinput, float switch and probe connections,

must be rated for DC. The device(s) for thecontrollers AC output to the motor must berated for 3-phase AC. In each case, theclamping (bypass) voltage should be 90V orhigher, but not much higher.

In extreme cases, it is best to employ theservice of a local lightning protection contrac-tor.

Referencewww.lightning.org

Grounding and Lightning Protection continued


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18

WARNING: The

photovoltaic

array generateshazardous

voltages. A 48

Volt (nominal)

array can

generate nearly

100 volts when

disconnectedfrom load. A

short circuit or

loose connec-

tion will produce

an arc that can

cause serious

burns. All wiringmust be done by

qualified person-

nel, in compli-

ance with local,

state, and

national electri-

cal codes.

5.3 Solar Array Wiring

2 types of PV module junction systems

TOPQuick-connect system using MCconnectors.

BOTTOMJunction box with screw terminals

and conduit holes

The solar array can produce hazardousvoltage even under low light exposure. Toprevent shock hazard while wiring the array,leave one or more wires disconnected orcover it with opaque material.

Solar-direct (non-battery) systems use avariety of array configurations. Some use 12V(nominal) modules, and some use 24Vmodules. Modules are connected in seriesfor 24 - 36 - 48V and up to 96V (for PS1200Systems), and sometimes also in parallel toincrease the current. Refer to the SystemWiring Diagramfor your system, attached atthe end of this manual. Be sure the modules(panels) match the description on yourSystem Wiring Diagram.

Solar module connectionsThe terminals inthe module junction boxes can be confusing.Refer to the module manufacturers instruc-tions that are packed with the modules. Makestrong connections that will hold for manyyears. Most array failures are caused byloose, corroded, or shorted connections.

Type of wireUse either electrical conduit oroutdoor UV-resistant wire. The solar array hasa life expectancy beyond twenty years. Dontdegrade it with inferior materials! Use mini-mum wire size #12 (4 sq. mm) for the connec-tions between modules and for short dis-tances to the controller. Some appropriatetypes of wire are: USE, UF, SE and SOOW.

Solar tracker wiringIf you are installing asolar tracker, pay careful attention to the wiresection that leads from the moving rack downto the stationary mounting pipe. Use a highlyflexible wiring assembly. Form a drip loop toshed water and to minimize stress. SEETRACKER PHOTO and caption in the PHOTOGALLERY. Secure the assembly mechanicallyat each end so the insulation and the connec-

tions are not stressed by the trackers motion.Swing the tracker fully in each direction, atvarious seasonal tilt angles, to verify that thecable will not rub or restrict the trackingmotion.

MC connectorsSome PV modules havethese quick connectors. If the connector is notappropriate at some junctions, you can cut thewire and make a conventional connection.


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5.4 Solar Array Disconnect Switch in the Junction Box

CAUTION Looseconnections are a

comon cause of

failure. Pull each

connection to

confirm.

CAUTION If you

are not using a

low-water probe,connect a small

wire between

terminals 1 and 2.

Note: Overload protection (fuses or circuitbreaker) is NOT required in the solar arraycircuit.

Explanation:

1. Short circuit current from the solar array

can never reach the ampacity (maximum safe

amps capacity) of the recommended wire.

2. The PS- controller has internal overload

protection.

Disconnect Scwitch

The disconnect switch satisfies NationalElectrical Code requirements for a safetydisconnect between the solar array and thecontroller. During installation and mainte-nance, switch off the disconnect switch toprevent shock and arc burn hazard.


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5.5 Junction Box (Controller Input) Wiring

WARNING TEST THE VOLTAGE before

connecting power to the controller. Voltage

(open circuit) must not exceed 100V for

PS200-, 150V for PS600 and 200V forPS1200 systems. (Even in cloudy weather,

the open circuit voltage will be near maxi-

mum.)

WARNING Do not apply a direct connectionor an amp meter between + and when the

controller is connected. A short circuit

here will cause a strong discharge.

WARNING SOLAR-DIRECT systems only

Do not connect any electrical load to the

solar array if it is not part of the LORENTZ

Pumpsystem.Connection of a batterycharger, active solar tracker controller, electricfence charger, or other load simultaneouslywith LORENTZ PS systemsmay confusethe controller and prevent proper operation.

CAUTION If you

are not using a

low-water probe,

connect a small

wire betweenterminals 1 and 2.

System DiagramFor solar-direct systems,refer to the System Diagram at the end of thismanual.

Ground connections The two groundterminals in the junction box are bondedtogether and are also bonded to the metallicenclosures of both the junction box and thecontroller. See Section 5.2

POWER INEnsure that the solar arrayDISCONNECT SWITCH (or battery fuse orcircuit breaker)- is OFF. Connect the powerfrom the solar array to the input terminals inthe junction box. Observe polarity. If your

wires are not clearly marked +/, test themusing a DC voltmeter or multitester.

PUMP See Section 5.8.

Low Water Probe See Section 5.9

Float SwitchSee Section 5.10, AutomaticControl for Full-Tank Shutoff. A connection ismade at the factory between terminals 4 and5. If you are NOT using a float switch, leavethis connection in place.


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5.6 Maximum RPM Setting

All PSXXX controller offer the option ofreducing the maximum speed of the pump.

This RPM control reduces the maximumspeed (RPM limit) to as low as about 30%. Itwill NOT reduce the starting or low-lightperformance. The pump uses less powerwhen it pumps less water.

Reasons to reduce the maximum RPM

1. To prevent over-pumping a limited watersource (see Section 6.7)

2. To improve energy and water-sourcemanagement in a battery system where slow

pumping is adequate to meet the demand3. To limit the back-pressure (and preventpossible pump overload) when pumping into adirect-pumped irrigation system, a filtrationsystem, or an undersized pipeline

How to reset the Maximum RPMsetting

CAUTION If you

perform this

adjustment,

record thesetting on the

System Report

Form (Section 2).

If flow testing isdone in the future,

the result may

lead to a wrongconclusion if this

adjustment is not

accounted for.

1. Remove the bottom end of the PS-XXXcontroller enclosure (the end with the conduitopenings)

2. Locate the adjustment knob shown in thephoto below (circled)

3. In most cases, the knob will be at thestandard factory setting full clockwise asindicated by setting #1 illustrated below.Turn it counter-clockwise to the desiredsetting. The exact positions may vary fromthis illustration. Follow the ink marks on thecontroller.

Terminals inside the PS-XXX controller.Max. RPM setting is at right.

Maximum RPM Setting Knob

12

Original Factory Setting (#1)


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5.7 Submersible Pump Cable and Splice

Selection of cableUse only an approvedtype of submersible well pump cable, thesame type that is used for conventional ACpumps. It is available from yourpumpsupplier or installer, or a local water wellsupply distributor. You need 4-conductorcable. It is often called 3-wire-with-groundbecause it has 3 power wires plus a groundwire. To determine the minimum required wiresize, refer to the Systems Sizing Table.

Submersible SpliceA splice kit includescrimp connectors to join the copper wires,adhesive heat-shrink tubing, and instructions.If the drop cable is too large to fit in the crimpconnector, cut off some of the wire strands.Use a crimping tool, and observe that thewires are held very securely.

motor leadercable

wires spliced with adhesive

heat-shrink tubing

drop cable


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5.8 Wiring Order for Correct Rotation

WARNING If the

pump wires are

in the wrong

order, the motor

will run inreverse and the

pump will not

function. Dam-

age may result.

Check thedirection BE-

FORE installingthe pump. The

proper direction

is COUNTER-

CLOCKWISE

when viewed

from above.

The power wires on the pump are black withwhite lettering to indicate L1, L2 and L3.WRITE DOWN the colors that you splice toL1/ L2 / L3 so you can match them with theL1/ L2 / L3 terminals in the pump controller.

If your pump cable has the standard RED,

BLACK and YELLOW colors, use this

sequence:

The power wires on the pump may also be

broun-black-grey for Motors delivered Q2

2005. Then use broun as L1, black as L2

and grey as L3

Testing the pump for directionHelical rotorpumps will produce water flow only if they arerotating in the right direction. If you place it ina water tank or a bucket, you will observe flowif the rotation is correct. (Submerge at least75% to observe full flow).

Alternative, dry testIf you dont have a watervessel to test the pump in, you can test it dryby watching the pump shaft and running it foronly a few seconds. The metal label on thepump has an arrow to indicate the properdirection of rotation. If the pump is new fromthe factory, it is lubricated so it can run dry forabout 90 seconds without risk. If the pump isnot new, it can be run dry safely for about 15seconds. Either way, this is more than enoughtime to observe the direction of the shaft.

If you did not write down the color match (orthe wind blew your note away) connect thethree power wires to the controller in ANYrandom order. Apply power. Observe thepump shaft rotation, then turn the power off. If

WARNING When

testing for

direction, do notrun the pump

dry for more

than 15 seconds.

the direction is wrong, exchange ANY TWO ofthe power wires at the controller. In any case,when you are finished connecting the pumpto the controller, test it to assure the properdirection.

Did you install the pump in the well without

checking the wiring order or the direction?

OR Is it running but not pumping?

HELICAL ROTOR pump (model number

does NOT contain C)Turn the pump on.Observe if air is rising from the pipe. If it isnt,reverse any two motor wires and observeagain. If you cannot observe air rise, chose

whichever direction is quieter (less vibration).There is risk of dry-run damage if it runs toolong in reverse. If the pump is new from thefactory, it is lubricated so it can run dry forabout 90 seconds without risk. If the pumphas been used, it must not be run for morethan about 15 seconds. In many cases, apump that is reversed will turn off due tooverload.

CENTRIFUGAL pump (model with C in the

name)In reverse, it will produce no flow (orvery little). This will NOT damage the pump. Ifthe flow is not normal, reverse any two motor

wires.QuestionThe motor shaft is hard to turn byhand, and moves in a bumpy manner. Is this

normal?

Answer YES. This is caused by permanentmagnets in the motor. It is especially hard toturn when it is connected to the controller, or ifthe pump wires are connected together.

DER KCALB WOLLEY NEERG

1L 2L 3L dnuorG


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5.9 Low-Water Probe for Dry-Run Protection

WARNING

Running com-pletely dry will

damage the

pump and void

the warranty.

The purpose of

the probe systemis to sense the

loss of water and

turn the pump off

before it can run

dry.

InstallationThe probe is packed with twostainless steel hose clamps. For a pump thatis to be installed in a vertical position, clamp itto the pipe just above the pump outlet, asshown in the photo. Splice the two probewires using the splice kit components that arepacked with the probe. The assembly proce-dure is the same as the main pump splice.

If you are NOT using the well probe, it mustbe bypassed.Connect a short wire betweenthe probe terminals in the junction box(terminals 1 and 2). Do this only if you feelcertain about the reliability of the watersource. Wire size: #18 AWG ( 1mm) orlarger.

Principle of operationThe probe contains amechanical float with a magnet inside. Whenthe probe is submerged, the float rises, andthe magnet actuates a switch. The switchcloses (makes contact) to indicate the pres-ence of water. The switch is sealed, so thecontacts never touch the water.

If the water level drops below the probe, thefloat drops, and the switch opens (breakscontact). The controller will stop the pump andthe Low-Water OFF light will indicate. Whenthe water level recovers and switch closesagain, the controller will delay the restart for20 minutes. This gives time for the water levelto recover. To force a quick restart, turn thecontroller off, then on again.

NOTE Pumps made before October 2003

may have a different type of probe, with

wet electrodes. Either type can be usedwith the PS-XXX series controllers.

The Low Water-OFF light flashes slowly forthe remainder of the day, even if the waterrecovers and the pump restarts automati-cally. This tells you that the water source ranlow at least once since the power wasdisrupted (or sun went down). To turn thelight off, reset the controller by turning it off/on.

CAUTION The

low-water probe

must be posi-

tioned vertically,within 10.If the

pump is NOT to

be installed

vertically, find an

alternative way to

mount or suspend

the probe, so thatit is higher than

the pump, and in

a vertical position.

CAUTION Do not use a

pressure switch with a lowwater cutout or loss of

prime feature as a method of

dry-run protection.A helical

rotor pumpwill maintainpressure as it runs dry, so this

method will not work reliably.For pressure switch information,see Section 5.12, Pressurizing

Systems.

Potential problems with the low-waterprobe in surface water The probe has amoving float. It is highly resistant to depositsand debris. However, it may stick under someextreme conditions, especially from algae orwater creatures (snails, etc.) that may bepresent in surface water. Possible solutionsare:

1. Hang the probe independently of the pumpand pipe (clamped to a weight, but not to thedrop pipe). This way, it can be pulled up forinspection or cleaning without the need to pullthe pump. (This may not be feasible if the wellcasing is smaller than 6".)

2. Pull the probe out periodically (with thepump if necessary) for testing and inspection.The pump should stop at the moment theprobe leaves the water.

3. Wrap the probe in a protective screen(fiberglass window screen, for example).

Substitute a different type of float switch. Youcan use any switch that makes contact on rise(normally open).

Low-water probe

installed in thestandard position,

for a pump that is

positioned vertically


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5.10 Automatic Control For Full-Tank Shutoff

We recommend the use of a float switch orother means to prevent overflow of your tank.This will stop the pump when the tank is full,then reset when the level drops. This con-serves ground water, prevents overflow, andeliminates unnecessary pump wear. PS-XXXcontrollers allow the use of small signalcable to a remote float switch, even if the tankis a long distance away.

Float switch requirements

1. A switch must be used, not wet electrodes.

2. The preferred system requires a floatswitch to MAKE contact on rise to turn the

pump OFF. This is called normally open(N.O.). It may be commercially labeled as apump down switch, but here it works inreverse, to allow pumping up.

sealedcable clamp

cableweight

pump off

pump on

pumpingrange

QUESTION Why do we use a

reverse-action (N.O.) float

switch? (a pump-down switch

for a pump-up application)

ANSWER If the cable con-

nection is broken, the pump

will continue to operate. Thewater supply will not be

disrupted (but of course, the

tank will overflow). This is the

general preference in the

industry. If you prefer the

pump to stop if the connectionis broken, use a normallyclosed (N.C.) float switch

instead.

Wiring to the controller

(junction box)The

controller (and junctionbox) offers two options forconnection of a remoteswitch. These allow theuse of either a normallyopen (N.O.) or a nor-mally closed (N.C.)switch. Normal refers tothe status of the contactswhen the switch is DOWNand calling for water.

Float switch cable require-ments

1. Two wires are needed.

2. Minimum wire size #18AWG ( 1mm). This is goodfor a distance as far as 2000feet (600 m).

3. The cable must be suitablefor its environment.

4. If it must run a longdistance, use twisted-pairshielded cable to reduce the

chance of damage from lightning-inducedsurge. (See Section 5.2 Grounding andLightning Protection).

Grounding shielded float switch cableIfyou use shielded cable, connect the shield toground AT THE CONTROLLER ONLY. DONOT ground the shield at the float switch. Thiswill reduce surges induced by nearby light-ning.

Wiring a normally open switchConnect the switch to terminals 3 and 4 (NO andcommon) and connect terminals 4 and 5 together, as illustrated.

Closing (connecting) the switch circuit turns the pump OFF

Wiring a normally closed/reverse action switch Connect the switch to termins 4

and 5. Closing (connecting) the switch turns the pump ON


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If you are not using a float switch,terminals4 and 5 must be connected. Terminal 3remains disconnected.

Operation of the float switch systemWhenthe water level is high, the float switch willstop the pump. The FULL-TANK OFF indica-tor on the controller will light up. When thewater level drops, the float switch will signalthe controller. The indicator light will go out,and the pump will restart if sufficient power isavailable.

Overriding the float switchYou may want tooverride the float switch to allow overflow for

irrigation purposes or to test or observe yoursystem. For a N.O. switch circuit, install aswitch to DISCONNECT ONE of the floatswitch wires. FOR A N.C. switch circuit, installa switch to CONNECT the two float switchwires together.

WIRELESS ALTERNATIVE, using a float

valve and pressure switch It may befeasible to use a FLOAT VALVE in the watertank (instead of a float switch) for remoteshutoff. This eliminates the need for a cable tothe tank when the tank is a long distance fromthe pump system. When the tank fills, thevalve shuts, causing pressure to rise at thepump. A pressure switch is installed at thewellhead (or at anywhere along the pipe). Thepressure switch is wired to the pumpcontrol-ler, and adjusted to respond to the rise andfall of pressure. The assembly is similar tothat of a normal pressurizing system. Referto Section 5.12.

CAUTIONS for the wireless alternative1. Thepumpsystem must be capable ofproducing at least 25 PSI (60 feet, 18m)more than the full lift pressure. (A conven-tional pressure switch may not functionreliably at a lower pressure differential.)

2. If the lift from the pressure switch up to thetank is to exceed 100 vertical feet (30m), theoff-pressure may exceed the pressure ratingsfor normal components, which is typically 150PSI (10 bar).

3. Pressure switch adjustments are critical. Besure to observe carefully to verify the perform-

ance.

4. Install a pressure gauge near the pressureswitch, to help you make adjustments.

5. Install a small pressure tank near thepressure switch. Without it, rapid start/stopcycling is likely to occur which is very undesir-able. Any captive-air pressure tank of 2gallons (8 ltr) or larger is sufficient.

6. Adjust the pressure tank pre-charge to apressure slightly lower than the workingpressure in the pipe. On level ground, theworking pressure may be nearly zero. In that

case, open the water-end of the pressure tankto the atmosphere and let out all the pre-charge air. (The air bladder must not collapseall the way.)

7. WARNING Install an appropriate pressurerelief valve for safety (see Section 5.12).

8. Be sure the tank has a safe way to overflowif the float valve leaks, wire breaks, etc.

9. To prevent slow action of the float valve,and lots of on/off cycling, we recommend aquick-acting float valve. Source: Tek Supply,www.teksupply.com(800) 835-7877, Item#WR-1300, or search Hudson Valve.

MANUAL REMOTE CONTROL SWITCH Thefloat switch circuit can be used with a manualswitch to turn the pump on and off from adistance. Use any simple on/off switchavailable from an electronic supply, electricalsupply, or hardware store (it only carries 12volts, very low current). Wire it according tothe illustration above, for a normally closedfloat switch.

Automatic Control For Full-Tank Shutoff continued


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5.11 Battery-Based Systems

PS-XXX pump systems can be operatedfrom batteries.

Install a jumper wire between terminals 6and 7 to set the controller to battery mode.

This will de-activate the MPP-Trackingfunction and activate the Low Voltage Discon-nect.

Overload protectionInstall a fuse or circuitbreaker near the power source. For either 24or 48V , use a 25 amp circuit breaker ( PS200

or PS600 Systems) or a time-delay (slowblow) fuse. The purpose of this protection isfor safety in case of a wiring fault, and toprovide a means of disconnect when install-ing or maintaining the system. PS-XXXcontrollers have electronic over-currentprotection against motor overload.

Wire Sizing for the DC circuit Wire must besized for no more than 5% voltage drop at 20amps (starting).

Refer to a wire sizing chart specifically for 24Vor 48V, or follow these examples:

24V SYSTEM:#10 wire to maximum distance of 30 ft.

CAUTION The

PS-XXXcontrol-

ler is NOT a

battery charge

controller.Acharge controller

prevents battery

overcharge. It is a

normal part of

any renewableenergy battery

charging system.

Be sure thecharge controller

is appropriate to

the type of

batteries used.

(Sealed batteries

use lower voltage

settings thanliquid-filled

batteries.)

Metric: 6 sq. mm to max. 10m48V SYSTEM:#12 wire to maximum distance of 22 ft.Metric: 4 sq. mm to max. 13m

GREATER LENGTHS For each 150% in-crease, use next larger wire size.

ON/OFF switchingYou can switch either theprimary power to the controller, or the remote(float switch) control circuit. For an explana-tion, see Section 5.12 (Pressurizing Sys-tems) Pressure switch connection.

Low-voltage disconnect function. Lead-acid

batteries can be permanently damaged byover-discharge when the voltage falls below acritical point. To prevent this, the PS battery-system controller will turn off at low voltage,and turn back on only after the battery hasrecovered significantly. The set points are:

24V SYSTEM: OFF at 22V ON at 24V48V SYSTEM: OFF at 44V ON at 48V

A controller in disconnect mode can be resetmanually by turning off/on, but it will quicklydisconnect again if the battery is not gaining asubstantial recharge.


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LORENTZ PS-XXX Pump Systemsareexcellent for automatic water pressurizingwhen powered by a battery system. If you areraising water vertically AND pressurizing, thepump must handle to total head. Note therelationship: 2.31 ft. = 1 PSI (1 Bar = 10vertical meters.) Example: A pump that lifts100 vertical feet (30m) and pressurizes to 60PSI (4 bar) must pump the equivalent of 240feet (70m). Be sure your pumpwas chosencorrectly for your application. The installationis similar to that of a conventional AC pump.

A typical pressurizing control assembly isillustrated in the following photo. These arestandard components, same as used forconventional AC water pressure systems. Theparts (from left to right) are:

1. check valve (prevents back-flow)

2. pressure gauge 0-100 PSI (0-7 bar)

3. pressure relief valve 75 PSI (5.3 bar)

4. tank tee (a bronze casting that holds all thecomponents)

5. pressure switch (turns the pump on/offaccording to pressure set-points, adjustable)

6. hose outlet (to drain the system or to

supply water when outlet is shut off)7. ball valve (to shut off the supply to theoutlets)

The components can be purchased from localsuppliers, or as a kit from your pump sup-plier

WARNING A

PRESSURE

RELIEF VALVEIS REQUIRED. If

the pressure

switch fails, this

will prevent

extreme pres-

sure from

bursting the tankor piping and

causing a flood.Install the valve

near the pressure

tank, before the

shutoff valve. Use

a 1/2" (or larger)valve set about

25-75% higher

than the cut-out

pressure. Run a

pipe or hose from

its outlet to a

drain or to theoutdoors where

water dischargewill not cause

damage.

5.12 Pressurizing Systems

Pressure tankA pressure tank is required.We recommend a captive-air pressure tankof 40 GALLONS (150 liters) OR MORE, toassure a steady supply of water pressure asthe pump cycles on and off and the waterdemand varies. A large tank is always best.Size and cost are the only practical limita-tions. More than one tank can be used toincrease the total capacity.

How to pre-charge a captive-air pressure

tank for PS-XXX Pump Systems

For the system to function properly, the airbladder in the tank must be pre-charged with

air according to these instructions.1. Make note of the cut-in setting of thepressure switch (either by observation orknowing the factory setting).

2. Turn off the pump and exhaust the waterfrom the tank if necessary, so the waterpressure is 0.

3. Find the air fitting on top of the tank.Measure the air pressure in the tank using atire gauge.

4. Adjust the pressure to about 3 PSI (.2 bar)LESS THAN THE CUT-IN PRESSURE.

Pressure switchPS-XXX Pumps Systemscan use an ordinary pressure switch sold forconventional AC pumps. Do not use apressure switch with low water cutout or

loss of prime feature (with a shutoff lever

ball valve

WATER IN

from pump

pressure switch

To PressureTank

pressure gauge

check valvetank tee

hose outlet

WATER OUT

to distributionsystem


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29

on the side). It is intended to prevent dry runof centrifugal pumps. The helical rotor pumptypes will maintain pressure even as it runsdry, so this device will not work reliably. It willalso shutoff if the pressure falls due to highwater demand.

Pressure switch connection There are twoways to connect the pressure switch:

1. primary power switching The switch isused to disconnect the DC power source.Wire the switch between the power sourcedistribution point and the controller, as youwould with a conventional pump.

2. remote switchingThis method uses theremote float switch terminals. Small wire

(minimum #18 AWG) can be run to thepressure switch from a long distance. Seeillustration below.Advantage: the controllerstays on all the time. If the water source runs

low (even if it recovers) the Source Low

indicator light will stay on to notify the user.Power draw of the controller in OFF mode is

only about 1 watt.

Pressure switch connected to the controller

(junction box) for remote switching

Pressurizing Systems continued


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6 PREPARING TO INSTALL THE PUMP

6.1 WARNINGS about Handling Helical Rotor Pumps

CAUTION (helical rotor mod-

els) BEFORE INSTALLATION,KEEP THE PUMP OUT OF THE

SUN.If the pump gets hot, therubber stator will expand and

may lock the rotor. No damage will result fromthis, but you may be unable to test thedirection of rotation. If the pump gets hot,allow it to cool in water for 20 minutes beforetesting.

WARNING (helical rotor mod-

els) DO NOT APPLY MACHINEGREASE TO THE PUMP.

Ordinary machine grease will

damage the stator (NBR

rubber) and void the warranty.Helical rotorpumps are lubricated at the factory with aclear, non-toxic grease. Its only purpose istemporary, to allow the pump to be run dry fora short time to test the direction of rotation.There is no normal reason to reapply lubricantbut if you do, use VASELINE(petroleum jelly,white petrolatum) or non-toxic silicone grease

approved for water valves and seals.

WARNING for SIPHON APPLI-

CATIONSIf a pump system hasa vertical lift LESS THAN 33FEET (10m) up from the surfaceof the water source, and then thewater flows downhill to a lower

point, a siphon effect may cause suction onthe pump. This will cause an upward thrust onthe motor shaft, resulting in damage to themotor. Prevent this by installing an air vent ora vacuum breaker at the high point on thepipe.


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6.2 Drop Pipe

PS-XXX Pump Systems can be installedusing the same pipe components that are

used for conventional submersible pumps.

Usepipe with a sufficient pressure rating,with coupling components that are designedto handle the weight of the entire assembly.

Torque arrestorIt is NOT REQUIRED. (soft-start motor system.)

Size of pipeA long line of undersized pipewill reduce the performance of the system.Proper selection of pipe size is based on themaximum flow rate and the total length ofpipe from the pump to the pipe outlet or tank.

Refer to the pump specifications at the end ofthis manual to determine the peak flow ratefor the system you are installing. For sizing ofa long pipe line, refer to Section 13.2 WaterPipe Sizing Chart. It is often wise to makeburied pipelines extra-large, in case a largerpump is desired in the future.

Reduced drop pipe size should be consid-ered in the following situations:

1. Sandy water conditions especially with asolar-direct system. The flow will be very slowon cloudy days. This may cause sediment toaccumulate in the drop pipe. Smaller pipe will

increase the flow velocity and helps exhaustthe sediment. (See Section 6.6 Coping withDirty Water Conditions.)

2. Hand installation to reduce the weight,especially for removal when the pipe is filledwith water.

Balance these advantages against theincreased friction loss in smaller pipe. You canuse a pipe size that is smaller than the pumpoutlet by using a reducer bushing. Horizontalpipes can be larger.

PS-XXX Pump Systemshave a stainlesssteel outlet fitting. It is compatible with iron,

steel, galvanized, bronze, brass, or anyplastic pipe components.

WARNING Do

not use a ropewinch to install

or remove a

pump in a drilled

well casing. Do

not use a vehicle

to install or

remove a pump.

See Section 7.3.

CAUTION Do not assemble iron,steel, or galvanized pipe

components in metallic contact

with brass or copper.This willcause rapid electro-chemicalcorrosion.

CAUTION If polyethylene (blackflexible) pipe is to be used, see

Section 7.3.

CAUTION Screwing a metal

pipe component into a plasticreducer bushing may cause

the bushing to crack, sooner

or later. If you use a plasticreducer bushing, reinforce it with a hoseclamp (all-stainless steel) as shown in thephoto. Tighten the clamp first, then hand-tighten the metal pipe component.

Hose clamp reinforcing a

plastic reducer bushing


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6.2 Safety Rope and Binding

Safety ropecan prevent loss of the pump. Ifthe drop pipe breaks, the rope will preventstrain on the electrical cable and can be usedto pull the pump out. Use 1/4" (6mm) waterwell safety rope. It can be purchased fromyour pumpsupplier or from a local pumpsupplier. Polypropylene marine rope is alsogood. DO NOT use nylon.

Secure the safety rope at the wellhead

Prepare to tie the rope inside the well casing.If your well cap does not have a place to tiethe rope, drill a hole in the casing and installan eye-bolt. Prepare this detail BEFORE youinstall the pump. (See Section 13.3 Wellhead

Assembly for Drilled Wells.)

Bind the drop pipe/cable/wires/rope with

tape Lay out the pipe, submersible cable,probe wires and rope on the ground. Do nottwist them together. Bind everything to thepipe about every 10 feet (3-4m) using vinyltape. Use either standard (UL-listed) electricaltape (about 6 to 8 turns) or pipe wrap tape,which is wider and requires fewer turns. Pipewrap tape is available from plumbing andelectric supply stores. Remember that thepipe will stretch, and the cable will not. Leavea slight excess length of cable between each

wrap as illustrated.

WARNING Do not use nylon

cable ties in water.Nylonabsorbs water and gets weakafter a few years. To bind thepump cable to the drop pipe, usevinyl electrical tape or pipe-wraptape.

WARNING when using flexible

POLYETHYLENE (PE) pipe,

allow for pipe stretch. Make thecable, probe wires and ropelonger than the pipe, to prevent

tension when the pipe stretches.

>> cable & wires 1.5% longer than pipe

>> rope 1 % longer than pipe

Distribute the excess length along the lengthof the pipe (as illustrated) and leave a littlemore excess length around the splice.

If the water is highly mineralized or has highbiological activity, you may choose to hangthe low-water probe separately from the pipe,cable and rope, so it can be pulled up sepa-rately for inspection or service. See Section5.9 Low Water Probe.

WARNING Safety

rope for well

pump installa-

tion is for

emergency

pump removal. Itmust not be a

primary means

of support. Make

it slightly longer

than the drop

pipe so it does

not bear anyweight.

WARNING Do

not use nylon

rope in water.

Nylon absorbs

water and

weakens after afew years. Failure

can cause

damage or loss of

your equipment.

Use

polypropylene

rope made forwater well or

marine applica-

tions

WARNING

Plastic rope will

weaken fromlong exposure to

sunlight. Secure

it INSIDE the well

casing to avoid

exposure. If sun

exposure cannot

be avoided, use

stainless steelwire rope.

motor

pumpe

nd

Bind the submersible cable,low-water probe wires and

safety rope to the pipe.

Pipe wrap tape or electrical

tape located at about every

10 feet (3 m) over the length

of the pipe

submersible cable splice

low water probe

(not shown)

Tie safety rope here


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33

6.4 Installation in a Surface Water Source

CAUTION Highwater tempera-

ture can cause

failure to start.

Low temperature

can reduce lift

and flow capac-

ity.This canoccur in surface

water during

weather ex-

tremes, due to

temporary

expansion or

contraction of therubber stator. The

product specifica-

tions say: Opti-mum water temp.is 46F to 72F(8C to 22C).Other ranges areavailable byspecial order.

These perform-ance problems

are temporary

and will NOT

damage the

pump.If you areuncertain about

using the pump

you received,

contact your

supplier before

you install it.

CAUTION The

pump must be

fully submerged.

A helical rotor

pump may

overheat and stop(temporarily) if the

pump end is not

fully submerged.

This refers to a surface well, spring, pond,lake, river or tank.

Positioning the pumpThe pumpmay be placed in an inclined orhorizontal position if desired. Toreduce the intake of sediment,do not place the intake veryclose to the bottom.

Models 03, 03H, 04 and04H have a small venthole near the top of thepump (photo). If the hole isnot submersed, it will suck air

and prevent the pump fromperforming fully. The purpose ofthis hole is to allow water to fillan internal gap, to conduct heataway from the rubber stator.

River or streamSecure thepump from logs and debris thatmay float downstream. Usestainless steel wire rope or chaininstead of plastic safety rope(plastic rope will weaken insunlight). Consider digging ashallow well near the stream. This will allowfiltration of the water through the earth, andwill protect the pump from floating debris orhuman tampering.

Position of the low-water probeCAUTIONThe low-water probe must be positioned

vertically, within 10.Normally, it is to beinstalled on the pipe above the pump outlet,as shown in Section 5.9. This will only work ifthe pump is installed vertically. If the pump iswill NOT be vertical, find an alternative way tomount or suspend the probe, so that it ishigher than the pump, and in a verticalposition.

Is a flow sleeve required?NO, not within thenormal temperature range.The PS-Pumpshigh-efficiency motor generates very littleheat. A conventional submersible pumprequires a flow sleeve to assist motorcooling when installed in open water (notconfined by a narrow casing). It is a piece of4-6" pipe that surrounds the pump to in-crease flow around the motor.

Depth of submersionPS-Pumpsmay besubmersed as deep as necessary to ensurereliable water supply. The lift load on thepump is determined by the vertical head ofwater starting at the SURFACE of the water inthe source. Increasing the submergence ofthe pump (placing it lower in the source) willNOT cause it to work harder or to pump lesswater. Avoid placing the pump close to thebottom where it will pick up sediment.

Filtration at the pump intakePS-Pumpswilltolerate small amounts of sand, but you mayneed to filter out larger debris that is normallyfound in a pond or stream. You can constructa simple coarse screen to protect the pumpand to reduce the nuisance of debris in yourwater system. One method is to wrap thepump with about 6-8 layers of loosely-wovenfabric or screen, of a material that will notdecay or rust. Some suggestions arefiberglass window screen, agricultural shadecloth, or weed-barrier fabric (available fromnursery and landscaping suppliers). Bind thefabric or screen with all-stainless hoseclamps, rubber, or polypropylene rope. Do notuse nylon; it softens with submersion in water.

An improved method is to construct a sealed

pump enclosure from 4-6" plastic pipe, withmany holes or slots to let water in. Then, wrapthe screen around that enclosure. This willdistribute the flow through a much larger areaof screen. After cutting holes or slots in theplastic pipe, wipe the inside carefully toremove plastic shavings and dust.

WARNING for SIPHON APPLI-

CATIONSIf a pump system hasa vertical lift of less than 33 feetup from the surface of the watersource, and then the water flowsdownhill to a lower point, a

siphon effect may cause suction at the pump

outlet. This will cause an upward thrust on themotor shaft, resulting in damage to the motor.Prevent this by installing an air vent or avacuum breaker at the high point on the pipe.

>


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34

6.5 Deep Well Setting How

Deep?

PS-Pumpsmay be submersed as deep asnecessary to ensure reliable water supply.The lift load on the pump is determined bythe vertical head of water starting at theSURFACE of the water in the source. Increas-ing the submergence of the pump (placing itlower in the well) will NOT cause it to workharder or to pump less water, nor will itincrease the stress or wear on the pump.

There are reasons NOT to set the pump nearthe bottom of the well, if it isnt necessary:

1. A deep setting will increase the sizerequirements, costs and weight of pipe and

cable.2. A deep setting may increase the chance ofsand or sediment being drawn into the pump.

To make an informed decision, it is helpful tohave accurate data for your water source. Inmost places, drillers are required to report thedetails and the performance of wells that theydrill. If you do not have the drillers wellrecord, you may be able to obtain a copy fromyour regional government office that overseesground water resources and issues drillingpermits. In USA, it is a state office, typicallycalled Department of Natural Resources or

State Engineers Office. However, the datamay be missing or inaccurate, and conditionscan change over the years. In critical cases, itis wise to have the well re-tested by a waterwell contractor.

6.6 Coping with Dirty Water

Conditions

PS-Pumpshave good resistance to quanti-ties of sand and fine sediment that cannormally occur in a well. However, anyamount of abrasive material will reduce thelife of this pump, like any other pump.Extreme sediment can cause the pump tostick. Sediment can also settle inside thedrop pipe each time the pump stops, andblock the flow. For water sources that containhigh amounts of sand, clay, or other solids,consider the following suggestions.

To avoid pumping dirty water

1. Have your well purged, developed, or

otherwise improved by a water well contractorbefore installing the pump.

2. Temporarily install a more powerful pumpto draw at a high flow rate until the waterlooks clean.

3. Set the pump as high as possible in thewell. If the pump can be placed higher thanthe perforations in the well casing, it willprobably avoid all but the finest suspendedsilt.

4. After lowering the pump in a well, wait atleast 15 minutes for sediment or debris tosettle down.

5. If the water source is at the surface, dig ashallow well next to the water source to obtainclean water.

6. If the water source is at the surface, use afabric screen to protect the pump (see Section6.4).

If dirty water cannot be avoided

1. Use a reduced size of drop pipe. This willmaximize the velocity of water flow in order toexhaust sand particles. Refer to Section 13.2Water Pipe Sizing Chart. Select the smallestsize pipe that does not impose excessive

friction loss. Use a reducer bushing on thepump if necessary, to adapt it to a smallerpipe size (see the caution about plasticbushings in Section 6.2).

2. Monitor the situation regularly by observingthe volume of water pumped and/or thecurrent draw of the pump (AC amps seeSection 9.3 and 13.7). As a pump wears, itsflow rate (and current draw) will decreasegradually. Replace the pump end whenreduced performance is observed, or beforeyour season of greatest water demand.Increased current draw may indicate debris

stuck in the pump and/or pipe.

QuestionWhat

effect does hard,

mineralized,

alkaline or saltywater have?

Answer Gener-

ally, none.Dissolved miner-

als and salts are

not abrasive.


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35

6.7 Utilizing a Low-Production

Water Source

6.8 Installing the Pump Under a

Windmill or Hand Pump

Cylinder

PS-Pumpscan make the best of a limitedwater source, even if the pumping rate canexceed the recovery rate. You want to drawthe most water possible, without running dry.PS-Pumpscan handle this in two ways.

The low-water probe The low-water probeallows the pump to work to its full potentialuntil the water level drops (see Section 5.9).This is a good strategy because you get allthe water you can while the sun shines.Place the pump near the bottom of the well toutilize the storage of water in the well. Whenthe pump is stopped by the low-water probe,it re-starts after a 20 minute delay. The LowWater OFF light will slowly flash even afterthe water recovers and the pump restarts, toindicate that the level got low at some timeduring the day. See Section 5.9, Low WaterProbe. It may be feasible to hang the probeindependently and use it to locate the waterlevel at any moment. See Section 6.3, SafetyRope and Binding.

Reduce the Maximum RPM settingIf thewell has little storage capacity, the supply mayrecover before the 20-minute restart delay. Inthis case, reduce the Maximum RPM settingin the controller. See Section 5.6.

WARNING Do not use a valve

as a means of reducing the

flow. With a helical rotor pump,excessive pressure may result.Use the Maximum RPM settinginstead.

PS-Pumpscan be combined with a classicwater-pumping windmill or hand pump, toutilize both energy sources automatically. Thefollowing system is often used with a conven-tional AC pump, so a generator can be usedfor backup. The AC pump is placed immedi-ately below the cylinder, and connected to thecylinders threaded intake. When power isapplied to the AC pump, it pushes water upthrough the cylinder, pushing its valves open.When the windmill draws water, it sucks it upthrough the AC pump with little resistance.(The centrifugal pump end of the standard ACpump allows water to flow through it when it is

stopped.) When both pumps operate, eachone is relieved of its load, more or less.

This system can be employed with PS-Pumps.A centrifugal model (one with a C inthe model number) will allow water to flowfreely through it and does NOT require anyspecial precautions. For helical rotor models,the following warning applies.

To use a helical rotor pumpunder a cylinder,you must build a bypass assembly with a Tfitting and a foot valve (a check valve withintake screen). When the cylinders flowexceeds that of the solar pump, water is

sucked in through the foot valve. When thesolar pumps flow exceeds that of thecylinder, the foot valve closes and allows thesolar pump to work normally and push upthrough the cylinder.

Question How is a pump damaged

from dry run?

AnswerIf the pump runs completely

dry, parts will overheat and be

damaged. However, if water is only

trickling into the pump, it will usuallyprovide enough lubrication and

cooling to prevent damage.

WARNING

helical rotor

models (those

without a C in

the model

number) will

NOT allow waterto flow freely

when stopped. A

bypass foot

valve must be

used. If it is notused, the result-

ing suction cancause an uplift

on the rotor

which will cause

damage and

void the war-

ranty.

Bypass foot valve assembly with offset

elbows to fit a drilled well casing

windmill or hand

pump cylinder

foot

valve

PUMP

To make this system for a casing6" (150 mm) or smaller, an offsetusing 45 elbows must becarefully constructed, as illus-trated. Copper fittings must beused for the bypass assemblydue to the limited space in thewell casing. Do not use any iron

fittings in this assembly.


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36

7 IN-WELL ASSEMBLY AND

INSTALLATION

SEE REFERENCE SECTIONAt the end ofthis manual (Section 13) you will find instruc-tions for wellhead assembly, water storage,control and monitoring of water supply, pipesizing, freeze protection, and more.

7.1 Rubber Spacers (Models -07, -10, -14, -20 only)

This applies ONLY to models HR-07, 10, 14and 20 (HR-07, 14 and 20 pump ends)

Helical rotor pumps vibrate due to the eccen-tric rotation of the helical rotor. This is normal.Rubber spacers reduce the vibration that maybe transferred to the well casing. Models 03and 04 vibrate very slightly so they are notsupplied with rubber spacers.

Clearance for drilled well casingsRubberspacers fit a 6" (150 mm) inside-diameter orlarger well casing.

Cut the rubber spacer legs to fit smaller

casing If you are installing the pump in a wellcasing smaller than 6", cut the spacer legs.Grooves indicate where to cut for a 4" (100mm) casing. Use a fine-tooth saw to cut therubber.

CAUTION The

threads in the

check valverequire an

adhesive seal-

ant. They are not

tapered pipe

thread. Normally,

there is no reason

to remove thecheck valve. If

you do remove it,

use a hardening

adhesive sealantor epoxy glue

when you replace

it. See CAUTIONin Section 9.1.

These helical rotor models doNOT have rubber spacers:

HR-03HR-04HR-04H

These modelshave rubberspacers:

(HR-07)

(HR-10)

(HR-14)(HR-20)


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37

7.2 Machine Installation

Water well pumps can be installed by hand inshallow water sources and in remote areasthat are not accessible to a pump servicetruck. Hand installation is generally perf

lorentz pump manual

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