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User Manual: PDS23 Solar Pump Controller
User Manual: PDS23 Solar Pump Controller
User Manual
Version code:PDS23-EN-602000561-1702
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PDS23 Series
Preface
Thank you for using PDS23 series products. This manual provides you with relevant
operation instructions and detailed description of parameters. Please read this
manual carefully before installation, running, maintenance or inspection.
Please make sure the wiring and the pump’s rotation direction is correct before use.
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Content
Preface ............................................................................................................... - 1 -
1.1 Features.................................................................................................................... - 8 -
- 2 -
- 3 -
■ Before Installation
WARNING
Do not install or operate the controller that is damaged or has missing parts. Otherwise, it
may result in equipment damage or harm life.
■ Installation
CAUTION
◎ Hold the bottom of the controller when installing or moving the controller, can not just
hold the shell to prevent the injured or broken controller.
◎ Install the controller on nonflammable material like metal. Otherwise it may cause a
fire.
◎ When the controller is mounted in a protective cabinet, the cabinet need to set vents to
ensure ambient temperature is below 40℃, otherwise it may be damaged because of high
temperature.
◎ When install the controller, you should avoid direct sunlight, can be installed under the
PV array.
WARNING
◎ Ensure only qualified personnel to operate. Otherwise it can cause an electrical shock or
damage of the controller.
◎ Make sure the controller is isolated from power supply by the circuit breaker. Otherwise it
may cause a fire.
◎ Make sure that the ground terminal is grounded correctly.
◎ Do not touch the power input terminals of the controller and the pump’s terminals .
Otherwise it may cause an electrical shock.
- 4 -
■ Operation
CAUTION
◎ Do not open or remove the front cover when operation. Otherwise it may cause an
electrical shock.
◎ Before testing the pump must be installed; can not make the pump dry-run for a long time.
In order to test the pump, the maximum dry-run time is not more than 15s
◎ If the pump turning is reversed, it can change any two lines of the pump’s three power
lines.
◎ When the water pump is due to the light shadow, it will restart the operation after 120s.
◎ If a water level probe is installed in the well, when the water level is below the level of
water shortage, the water pump will stop. If there is no water level probe, it will need to be
short. If a water level probe is not used, the controller terminal must be short.
WARNING
◎ Only qualified or authorized professional personnel can maintain, replace and inspect the
controller. Otherwise it may cause damage and injury.
◎ Wait at least 10 minutes after the power failure, or make sure that is no residual voltage
before carry out maintenance and inspection, otherwise it may cause damage.
■ Others
WARNING
◎ If failing to follow these instructions, resulting in damage to the machine, can not enjoy
the warranty service.
- 5 -
The PDS23 solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable. The controller can
convert DC from the PV array to AC,and drive kinds of pumps. In sunny days, the
PDS23 solar pumping system can continuously pump water. The system without
batteries and other energy storage devices, it is recommended to take water pumped
to a reservoir for later use and water sources are those natural or special such as river,
lake, well or waterway, etc. A float switch can be installed in the water tower to
control the pump operation. And install a low-level probe in well to detect the well
water so that when the water shortage pump is stopped. Figure 1 shows a typical
diagram of a PDS23 solar pumping system. The major parts and components in the
system are listed after the diagram.
A. PV Array
B. DC Breaker
E. Well
Level Switch
D. Pump
- 6 -
The PDS23 solar pump controller runs at variable speed while match the changing
power provided by the solar array. Variable speed operation means there is no
in-rush or surge of energy during the pump/motor start-up, helping to eliminate wear
on the motor and pumping system.
- 7 -
1.1 Features
System Diagnostics
The PDS23 solar pump controller continuously monitors system performance and
detects a variety of abnormal conditions. In many cases, the controller will
compensate as needed to maintain continuous system operation; however, if there
is high risk of equipment damage, the controller will protect the system and display
the fault condition. If possible, the controller will try to restart itself when the fault
condition subsides. See Diagnostics and Troubleshooting section for a list of Fault
Codes and corrective actions.
Motor Soft-Start
Normally, when there is a demand for water and power is available, the PDS23
solar pump controller will be operating. Whenever the PDS23 solar pump
controller detects a need for water, the controller always “ramps up” the motor
speed while gradually increasing motor voltage, resulting in a cooler motor and
lower start-up current compared to conventional water systems. Due to the
controller’s soft-start feature this will not harm the motor.
The PDS23 solar pump controller is designed for full power operation from a solar
array in ambient temperatures up to 45 °C. In excess of 45 ℃ temperature
conditions,the controller will reduce output power in an attempt to avoid shutdown.
Full pump output is restored when the controller temperature cools to a safe level.
- 8 -
The PDS23 solar pump controller’s input power terminal may be switched manually
to a backup AC power source.
Note: Depending on the model number, PDS23 solar pump controllers support
power input either 220VAC single phase, or 380VAC three phase, Please contact
controller manufacturer or authorized agencies for details.
When the system is running on back-up AC power, please check for sufficient DC
primary source power every 30 minutes. If the primary DC power is available, shut
down the controller, switch back to primary power and attempt to run on DC
power supply.
NOTICE : A DC circuit switch and a generator power switch must be installed, and
these two switches must be mechanically interlocked each other to prevent
switching on together resulting the solar PV and the generator being connected to
the solar PDS23 solar pump controller simultaneously! Please check if the design is
in accordance with all applicable national and local electrical codes.
- 9 -
The PDS23 solar pump controller is a variable speed motor drive designed to run
any IEC three-phase asynchronous motor. The PDS23 solar pumping system
provides water to remote locations by converting high voltage, direct current from a
solar array into alternating current to run a standard three-phase asynchronous motor.
When solar power is not available, the controller can be switched manually to an
alternate single-phase or three-phase AC input such as a generator or inverter from
battery, if available. The controller provides fault detection, motor soft start, and
speed control. The PDS23 solar pump controller is designed to provide these
features with the plug and play ease of installation.
The PDS23 solar pump controller is designed with the high standard of reliability
expected of products. The controller attempts to drive the pump and motor to deliver
water even under adverse conditions, reducing output as necessary to protect the
system components from damage, and only shutting down in extreme cases. Full
operation is restored automatically whenever abnormal conditions subside.
2.1 Inspection
Before you begin, receive and inspect the PDS23 solar pump controller unit. Verify
that the part number is correct and that no damage has occurred during transit.
NOTE: PDS23 solar pump controller is one component of a PDS23 solar pumping
system which has other two optional components, solar array and AC pump with
motor.
- 10 -
The PDS23 solar pump controller continuously monitors system performance and
incorporates a number of features for pumping system protection. In the event of a
fault, the PDS23 solar pump controller will indicate the type of fault through the
LED display mounted on the front cover of controller.
The PDS23 solar pumping system is optimized for pumping under adverse input
power conditions unique to solar arrays:
- 11 -
- 12 -
- 13 -
- 14 -
- 15 -
- 16 -
B
H
ø1
W D A
ø1
ø2
B
H
A
ø1
Figure 3 18.5~55kW Outline &installation dimensions diagram
- 17 -
W D A ø1
ø2
B
H
H1 ø1 A
W
D A2 A3 A3 A2
A1 A1 ø1
ø2
H
B
H1
ø1 A3 A3
- 18 -
- 19 -
- 20 -
The PDS23 solar pump controller must be installed into a control box which has a
tight enclosure to avoid direct sunshine, rain, dust, moisture, animals, plants, etc.
The control box should have a bottom gland plate for installing wire cord or conduit.
To decide the size of control box, Please refer to the following Figure 6.
100mm
Ventilation
or above
Hot Air Ventilation
PDS Solar
Pump
Controller
50mm or above
Dust Filter
Air Flo PDS Solar
100mm w Pump
or above
Controller
Control
Terminals
Main
Terminals
- 21 -
+ - R S T PB U V W
NO FUNCTION
AC INPUT Pump
GROUND
GROUND
Power In
The DC and AC ca n't To reverse direc tion,
input at the sam e time. reverse any two wires.
Figure 9 Main terminals (The sequence may be different from actual product)
M1 M2 M3 COM M4 M5 M6 COM
N0
No Function
NC
Low-water Remote Float Sw itch
sensor probe
Figure 10 Control terminals (The sequence may be different from actual product)
Connect the cables which comes from the two-pole DC disconnect Switch
downstream terminals marked with “+” and “-” (positive and negative poles of
Solar panel output), to PDS23 solar pump controller’s terminals block labeled as
“+”, “-” .
Note: The R, S, T terminals are with anti reverse connection protection; DC power
supply can be connected in the R, S, T terminals, can not consider the phase
sequence.
- 22 -
WARNING
Before connect DC wiring, following the steps below to prevent hazardous electric shock
resulting in serious injury or device burning.
• Make sure that the external DC disconnect switch is off.
•To ensure that the polarity of the solar array cable must be properly connected to the
controller's +, - pole, otherwise possible damage the controller.
•Make sure that AC power is disconnected (If AC power supply is wired as backup power,
AC and DC power supply can not simultaneously put into the controller, otherwise it will
damage the controller.)
- 23 -
position
pump off
cable pumping
weight range
position
pump on
- 24 -
If the float switch is not used, the M6 and COM are kept short.
N0
M5 M6 COM
N0
Remote NC
NC
Float Float Switch
Switch
COM
COM
UP: closed
if cable is shielde d, DOWN: open
ground this end onl y normal: open
- 25 -
NO FUNCTION
AC INPUT
GROUND
GROUND
Power In The DC and AC To reverse direction,
can't input at reverse any two wires
the same time. Remote Float
Low-water Switch
sensor probe NC
N0
+ - R S T PB U V W COM M4 M5 M6 COM
Float Switch
(optional)
Submersible
Cable Splice
Low Water
Level Probe
(optional)
NOTE:
1. The float switch is optional; if not use, please keep the terminal M6 and COM
short.
2. Low water level probe is optional; if not use, please keep the terminal M4 and
COM short.
The PDS23-2S series controller is connected in series with the serial number of the
input components of the 10 ~12 block, and the 250W 280 ~360VDC (MPPT) is
satisfied.
The PDS23-4T series controller is connected in series with the serial number of the
input components of the 18 ~20 block, and the 250W 500 ~600VDC (MPPT) is
satisfied.
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A
N o F u n ctio n
V
U p In crease K ey
D o w n D ecrease K ey
STOP S to p /F au lt R eset K ey
R u n K ey RUN RESET
- 27 -
- 28 -
After the controller has failed, the controller will display the relevant fault code
information. The conventional fault code (E002/3/4/5/6/7/8/9/10/11/12/18) can
automatically reset after 10s operation, and can also choose to reset the
STOP/RESET on the keyboard. If the conventional failure persists, the controller
will reset once every 10s. Special fault code (E001/13/14) requires the user through
the STOP/RESET key on the keyboard to reset the fault; the controller can continue
to run after the reset.
For Example, if the motor which rated frequency is 60Hz, these parameters need
modification:
High limit of running frequency F0.12=60;
Other related parameters are: motor rated power F2.01, motor rated frequency
F2.02=60, motor rated speed F2.03, motor rated voltage F2.04, motor rated current
F2.05.
If the pump is in dry-run state, the maximum operating time can not exceed 15s,
otherwise it may cause damage to the pump.
- 29 -
If the pump is in dry-run, the maximum operating time can not exceed 15 seconds;
otherwise it may cause damage to the pump. If the pump steering error, close the DC
switch, according to the pump / motor wiring to change the wiring of the motor
section of the two leads.
After the above parts are complete, you can try to run the system.
Let the system work for an hour, check the water supply capacity.
Commissioning finish
When the light is insufficient, the solar power module output power will be
reduced, and the pump operation speed will be very slow until stop. The controller
will attempt to start every 120s, and during the trial run, the running indicator is
always on.
When a shadow suddenly passes through the battery array, the controller will lose
track of the input voltage, and the pump will stop working. But the controller does
not show the fault, the controller will try to restart the pump.
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Function Modifica
Function Descriptions Unit Factory Setting
Code tion Type
Max. output
F0.10 10.00~600.00 Hz 50.00 〇
frequency
High limit of
F0.12 30.00 ~60.00 Hz 50.00 〇
running frequency
Low limit of
F0.14 0.00 ~F0.12 Hz 20.00
running frequency
F0.18 Acceleration time 0.1 ~3600 s 10.0 〇
Different
F2.01 Motor rated power 0.4 ~400.0 kW according to ●
inverter model
Motor rated
F2.02 10.00 ~F0.10 Hz 50.00 ●
frequency
1500(Different
F2.03 Motor rated speed 0 ~36000 rpm according to 〇
inverter model)
- 31 -
Function Modifica
Function Descriptions Unit Factory Setting
Code tion Type
Different
Motor rated
F2.04 0 ~480 V according to ●
voltage
inverter model
Different
Motor rated
F2.05 0.8 ~2000 A according to ●
current
inverter model
FA.02
Threshold of 70.0~110.0(standard bus
% 85.0 〇
trip-free voltage)
FA.03
Decrease rate 0.00~F0.10 Hz 3.00 〇
of trip-free
FA.08
Auto current 0:Enable
0 〇
limit selection 1:Disable
FA.11
Mppt sample 0~8 2 〇
period
Phase-lack
0:Disable
FA.13 protection of 1 〇
1:Enable
output
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Function Modifica
Function Descriptions Unit Factory Setting
Code tion Type
0: No fault
1: Inverter module protection
(E001)
2. Over-current when
Fault record of the
FA.14 accelerate (E002) ◎
one before last
3: Over-current when
decelerate (E003)
4: Over-current at constant
speed (E004)
5: Over-voltage when
accelerate (E005 )
6: Over-voltage when
decelerate (E006)
7: Over-voltage at constant
FA.15 Last fault record speed (E007) 〇
8:Hardware overvoltage
(E008)
9:Under voltage (E009)
10:Inverter overload (E010)
11:Motor overload (E011)
12:Phase-lack of input (E012)
13:Phase-lack of output
(E013)
14:Heatsink overheating
(E014)
15:External fault (E015)
16:Communication fault
Current fault
FA.16 (E016) 〇
record 17:Reserved
18:Current detection fault
(E018)
20:Well level fault(E020)
21:Tank level fault(E021)
22:EEPROM fault (E022)
26:Water shortage fault
(E026)
Running
FA.17 frequency when Hz ◎
fault occurs
- 33 -
Function Modifica
Function Descriptions Unit Factory Setting
Code tion Type
Output current
FA.18 A ◎
when fault occurs
DC bus voltage
FA.19 V ◎
when fault occurs
Water shortage
detection current
FD.12 ratio 80.0 ~300.0 % 150.00 〇
corresponding to
no-load current
Interval of water
FD.13 1 ~9000 min 20 〇
shortage detection
Upper limit of 250-FD.15
FD.14 VDC 275/500 〇
MPPT voltage 430-FD.15
Lower limit of FD.14-450
FD.15 VDC 350/600 〇
MPPT voltage FD.14-800
Parameter interpretation:
- 34 -
F0.14, Low limit of running frequency: this parameter defaults to 20Hz, when the
light becomes weak, and the controller output frequency is lower than F0.14, the
controller will be in standby mode. After the light becomes strong, the controller
will rerun. Can set this parameter artificially, in order to avoid pump at low speed
without water, reduce the pump abrasion at low speed.
F2.01-F2.05, Motor parameter: the user can be set according to the actual pump
motor nameplate parameters
F7.00 user password: the user can set a 5 digits password; after the password is set
up and confirmed, the password will be valid for a minute.
FD.07, Automatic start when power on: the factory defaults to 10 (disabled).It can
be set to 11 (enabled), then as long as the solar module power supply, the controller
will automatically start and achieve automatic operation of the whole day.
FD.10 water shortage detection time: when applied to a deep well pump, not using
the water level probe to detect the water shortage, the controller can use the built-in
water shortage detection function to complete the water shortage detection. When
this parameter is not 0, the software will start the function of water shortage.
Software shortage detection principle: If the water shortage happens, the controller
will still run FD.10 time, after that it will appear the water shortage fault E026. The
fault will be reset and the controller will restart automatically after 20 minutes. If
there is no water shortage but fails E026, it may appear false; then you can simply
reduce FD.12 value.
WARNING: DO NOT touch any other piece inside the PDS23 Solar pump
controller while power is applied. To service any other areas of the controller,
disconnect ALL power sources and wait 5 minutes before continuing.
For the selection of PDS23 solar pump controller, it can be matched with the power
of the pump. However, if the controller drives a submersible pump, please use a
higher-rated controller; if the length of cable is more than 100m, add an output
- 35 -
reactor. For example, to an application of 50m deep well, a 5.5kW controller should
be selected to control a 4kW motor.
- 36 -
The PDS23 solar pump controller will attempt to drive the pump to deliver water
even under adverse conditions. To ensure years of reliable service, it must also
protect the system components from conditions that might result in equipment
damage. When adverse conditions arise, the controller will continue to deliver as
much water as possible at reduced output if necessary, and will shut down only in
extreme cases. Full operation will resume automatically whenever abnormal
conditions subside.
If the controller has stopped to indicate a fault code on the display, the associated
time-out delay will vary depending on the nature of the fault. The number following
the “E” symbol corresponds to the error code for the offending condition.
- 37 -
Fault
Fault description Possible causes Remedy
code
Over-current during Too-heavy and large-inertia load Add proper braking units
E003
deceleration
Replace with higher-rating
lower-rating controller
controller
Over-voltage at
Install proper input AC
E007 constant running Abnormal input voltage
reactor
speed
- 38 -
Fault
Fault description Possible causes Remedy
code
Instantaneous over-current of
Refer to over-current remedy
controller
- 39 -
Fault
Fault description Possible causes Remedy
code
- 40 -
③ The motor shaft vibrates and can not rotate, it may be caused by the wiring errors;
Need to re check the motor wiring.
④ Pumps and pipes are clogged with mud and debris, and the pump can't run
② Because of the increase in operating current of the pump, which is caused by the
pump wire is too long, the controller will be protected, and the controller will be
enlarged to use.
- 41 -
② Check if the machine has a burning smell; if there is a burning smell, please
contact the agent to replace the controller
- 42 -
• pump
The pump’s motor is permanently sealed, no need to maintain. Pump head is a
mechanical device, may be used for a period of time, due to the sand in the water,
and other impurities cause a certain wear, the performance of the pump needs to be
regularly detected. If the flow of the pump is less than the normal value, may need to
be replaced.
6.3 Cable
Need to regularly check the power cable and ground wire to make sure all the wires
are reliably connected and without being corroded.
- 43 -
In order to ensure continuous water supply, solar water pump system can be
manually switched to standby AC power supply when the light is insufficient or wet
days. When switching, the need to ensure that the DC and AC power supply reliable
mutual lock. Backup AC power source can be a local power grid, or a diesel
generator (please refer to the 2.4.3 technical form).
Warning: at any time, only one power supply can be entered, otherwise it may cause
the controller to damage.
Take three phase 380VAC backup AC power supply for example, the wiring is
shown in the following diagram:
NO FUNCTION
AC INPUT Pump
GROUND
GROUND
Power In The DC and AC To reverse
can't input at direction,reverse
the same time . any two wires Remote Float
Switch
NC
N0
+ - R S T PB U V W COM M4 M5 M6 COM
Float Switch
(optional)
DC Switch AC Switch
Backup Submersible
Cable Splice
AC Power
Low Water
Level Probe
(optional)
PV Array
Earth Ground
Pump Motor
If the pump motor rated voltage is three-phase 220-240VAC, then the single-phase
220VAC standby power supply L/N power line, need to be connected to the main
terminal R/T of the controller
- 44 -
System Report
System and Components
Date of Purchase
Distributor
(Contact details)
System
Controller
Serial Number
Motor Serial
Number or
Power
Solar Power
Solar Module
Manufacturers
Type
Peak Voltage
(Vmp)
Open Circuit
Voltage (Voc)
Quantity
- 45 -
Installation
Installation Date
Installer
(contact details)
Submersible Pump Surface Pump
Type Type
Type Type
- 46 -
V1.0
Inverter
- 47 -