PV Disconnect 440-20-1

PV Disconnect 440-20-6
Connection Box with DC Disconnect Switch and optional lightning surge protection

Manual for Installation and Operation

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 Contents 1 Introduction
1 Introduction ............................................................... 2 Thank you for purchasing a LORENTZ product.
Before you begin - Check the product label to verify that this is the
2 Storage and Handling ............................................... 2 item that you ordered. Also check against the product specifications to be
sure the product is appropriate for your application.
3 Operating Conditions ................................................ 2
Read the manuals of pump end, controller, charger (optionally) and other
components used in your system.
4 Declaration of Conformity......................................... 2

5 Safety Instructions .................................................... 2 2 Storage and Handling

6 Product Description .................................................. 3
6.1 Technical Data ...................................................... 3
6.1.1 PV Disconnect 440-20-1..................................... 3
6.1.2 PV Disconnect 440-20-6..................................... 3
6.1.3 Optional surge protector ..................................... 3
7 Installation ................................................................. 4
7.1 Mounting & Dimensions......................................... 4
7.2 Wiring.................................................................... 4
7.2.1 General .............................................................. 4
7.2.2 Connecting the PV Strings ................................. 5
7.2.3 Installing the optional surge protector (SPD) ...... 5
7.2.4 Grounding .......................................................... 6
8 Trouble Shooting....................................................... 7
 This LORENTZ product is supplied from the factory in proper packing
in which it should remain until it is to be installed.
 Handle the product with care and avoid unnecessary impacts and
shocks.
 Prolonged intermediate storage in an environment of high humidity
and fluctuating temperatures must be avoided. Moisture condensation
may damage metal parts. Non-compliance will void any warranty. It is
recommended storing the parts in a closed and dry room.
 The product can be stored in the range of –30 °C to 50 °C (-22 °F to
120 °F). It should be avoided to expose the product to direct sunlight.
3 Operating Conditions
The permitted ambient temperatures for use are:
-30°C to 50˚C (-22 °F to 120 °F).
Humidity and air salinity:
The product must not be operated where day average humidity is above
80% or in saline air with more than 2µg/m³.

STANDARDS
4 Declaration of Conformity
Meets the requirements for CE We, BERNT LORENTZ GMBH & Co. KG Germany, declare under our
sole responsibility that the products

PV Disconnect 440-20-1
PV Disconnect 440-20-6

to which the declaration relates, are in conformity with the Council Direc-
tives on the approximation of the laws of the EC Member States relating
to:

 Low Voltage Directive: (2006/95/EC LVD)

 MD Electrical Equipment of Industrial Machines: (EN60204-
1:2006+A1:2009)

Henstedt-Ulzburg, Germany
1 January 2013

Bernt Lorentz, CEO

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 2
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 5 Safety Instructions
Safe operation of this product depends on its
correct transportation, installation, operation and
maintenance. Failure to follow these instructions
can be dangerous and/or void the warranty.

observed at all times. Any danger to per-

READ AND  The manual contains basic instructions
which must be observed during installation,
sons from electrical energy must be exclud-
ed by using good installation practices and
FOLLOW ALL operation and maintenance. The manual
should be carefully read before installation
working to local regulations. (For example
VDE in Germany).
and start-up by the person in charge of the
INSTRUCTIONS! installation. The manual should also be read
 Safety directions for maintenance, in-
by all other technical personnel/ operators
spection and assembly work – It is the
and should be available at the installation
When installing and using this electrical user’s responsibility to make sure that all
site at all times.
equipment, basic safety precautions maintenance, inspection and assembly work
should always be followed, including the is performed exclusively by authorized and
 Personnel qualification and training – All
following: qualified experts sufficiently informed
personnel for the operation, maintenance,
through careful perusal of the Operating In-
inspection and installation must be fully
WARNING – To reduce the risk of structions. The accident prevention regula-
qualified to perform that type of job. Re-
injury, do not permit children to tions must be observed. All work on the
sponsibility, competence and the supervi-
use this product. equipment should be done when it is not
sion of such personnel must be strictly regu-
operational and ideally electrically isolated.
lated by the user. Should the available per-
The sequence for shutting the equipment
sonnel be lacking the necessary qualifica-
WARNING – To reduce the risk of down is described in the manual and must
tion, they must be trained and instructed
electric shock, replace damaged be strictly observed. Immediately upon
accordingly. If necessary, the operator may
cords and cabling immediately. completion of the work, all safety and pro-
require the manufacturer/supplier to provide
tective equipment must be restored and ac-
such training. Furthermore the operator/user
tivated.
must make sure that the personnel fully un-
WARNING – It must be assured
derstand the contents of the manual.
that all grounding connections  Unauthorized changes and manufactur-
are properly made and that the ing of spare parts – Any conversion or
 Dangers of ignoring the safety symbols –
resistances meet local codes or changes of the equipment may only be un-
Ignoring the safety directions and symbols
requirements. dertaken after consulting the manufacturer.
may pose a danger to humans as well as to
Original spare parts and accessories author-
RETAIN THESE INSTRUCTIONS the environment and the equipment itself.
ized by the manufacturer guarantee opera-
Non-observance may void any warranties.
FOR FUTURE USE! Non-observance of safety directions and
tional safety. Using non-authorized parts
may void any liability on the part of the
symbols may for example entail the follow-
manufacturer.
ing: Failure of important functions of the
equipment/plant; failure of prescribed meth-
 Unauthorized operation – The operational
ods for maintenance and repair; endanger-
safety of the equipment delivered is only
ment of persons through electrical, mechan-
guaranteed if the equipment is used in ac-
ical and chemical effects; danger to the en-
cordance with the directions contained in
vironment because of leakage of hazardous
this manual. Limits stated in the data sheets
material; danger of damage to equipment
may not be exceeded under any circum-
and buildings.
stances.

 Safety-oriented operation – The safety

 Cited standards and other documenta-
directions contained in the manual, existing
tions – DIN 4844 Part 1 Safety marking;
national regulations for the prevention of
Safety symbols W 8, Supplement 13; DIN
accidents as well as internal guidelines and
4844 Part 1 Safety marking; Safety symbols
safety-regulations for the operator and user
W 9, Supplement 14
must be observed at all times.
Explanation of Warning Symbols
 General safety directions for the opera-
tor/user – If hot or cold equipment parts WARNING – Disregard might lead
pose a danger then they must be protected to injury or damage to the instal-
by the operator/user against contact with lation.
people. Protective covers for energized
Caution – Recommended to avoid
parts (e.g. terminal clamps) must not be re-
dysfunction or premature ageing
moved when the equipment is running. All
of the equipment etc.
government and local regulations must be

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 2
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 6 Product Description
6.1 Technical Data

6.1.1 PV Disconnect 440-20-1

 Wiring for 1 PV string

 DC rated disconnect switch enclosed
 Enclosure class IP 54 (covers NEMA 3, 3X, 3S, 3SX)
 Optional lightning protector available

Max. voltage 440 V DC

Max. total current 20 A
Max. no. of strings 1
Optional lightning String cable size 4 - 10mm²
protection device
Output cable size 4 - 10mm²
Figure 1: PV Disconnect 440-20-1 with installed SPD

6.1.2 PV Disconnect 440-20-6

 Wiring up to 6 PV strings in parallel

 DC rated disconnect switch enclosed
 Enclosure class IP 54 (covers NEMA 3, 3X, 3S, 3SX)
 Optional lightning protector available

Max. voltage 440 V DC

Max. current per string 10 A
Max. total current 20 A
Max. no. of strings 6
String cable size 2,5 - 4mm²
Output cable size 4 - 10mm²
Optional lightning
protection device

Figure 2: PV Disconnect 440-20-6 with installed SPD

6.1.3 Optional surge protector

 Connects through an existing mounting hole in the

The LORENTZ PV Disconnect series is a PV connection box with an PV Disconnect housing
integrated disconnect switch and optional integrated lightning surge  Proper grounding of the device is mandatory to achieve protection
protector. The box is designed to connect one PV module string ( 6
strings for the 440-20-6 ) with the pump controller by using the terminal Controller MidNite surge protector
clamps located inside the box. The DC-rated disconnect switch is used PS150 – PS200 MNSPD115
as a manual circuit breaker between the solar array and the load. This
switch is easily accessible by opening the hinged lid at the bottom spring PS600 – PS1800 MNSPD300
lock.
PS4000 MNSPD600
The use of a properly sized DC disconnect switch is an important safety
measure and obligatory for a professional installation of a solar pumping
system.
The switch must be installed between the solar generator and the pump
controller. It must meet the electrical requirements of the connected
devices.
The PV Disconnect has been designed to cover the range of PS pump
systems PS150 to PS4000

As an option a lightning surge protection device can be purchased from

LORENTZ that fits into a pre-built hole of the PV Disconnect. It requires
proper grounding to fulfill its protective function.
There are 3 different devices available to suit the voltage level of each
controller type.

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 3
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 7 Installation
7.1 Mounting & Dimensions

WARNING – All electrical connections should be per-

formed by qualified experts only!

The PV Disconnect must be mounted vertically to a wall or a pole using

appropriate fixings.

The distances between the four mounting holes of the box are:

PV Disconnect 440-20-1 164x164mm, Ø7mm.

PV Disconnect 440-20-6 254x164mm, Ø7mm.

For optimal resistance against water ingress the cable glands must point PG cable glands Optional lightning
downwards. (2x PG11 13x M16) protection

CAUTION – Make sure the housing is not distorted after

mounting; otherwise the lid may not close properly.

Net. Weight: Mounting hole

2,15kg (+0,35kg) (1x PG16 cap)

Figure 4: Installation dimensions for PV Disconnect 440-20-6

7.2 Wiring

7.2.1 General
Before starting to work on the electrical system make sure that all com-
ponents are disconnected from the power source. Make sure each PV
module string is disconnected at some point so that no current is present
during wiring of the system. Only reconnect the PV plugs and switch on
PG cable glands Optional lightning the system when you have finished all work.
(2x PG11 13x M16) protection
CAUTION – Loose connections are the most common cause
of system failures. Pull each wire connection SLIGHTLY to
confirm that it is tightened securely.

Make sure that the cable glands are tightened and that the cables fit the
clamping range of the cable gland to ensure a proper seal. If necessary
use some additional sealing material (e.g. silicone).

Solar-direct systems use a variety of array configurations. PV modules

can be connected in series and also in parallel. Refer to the System
Net. Weight: Mounting hole
1,4kg (+0,35kg) (1x PG16 cap) Wiring Diagram which is provided by COMPASS and to the module
manufacturer’s instructions that are packed with the modules. Make
good connections that will last for many years. Most system failures are
caused by loose, corroded or shorted connections.
Figure 3: Installation dimensions for PV Disconnect 440-20-1
WARNING – SOLAR-DIRECT systems only - do not con-
nect any electrical load to the solar array if it is not part of
the LORENTZ Pump system. Connection of a battery
charger, active solar tracker controller, electric fence
charger, or other load simultaneously with LORENTZ PS
systems may “confuse” the controller and prevent proper
operation.

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 4
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 7.2.2 Connecting the PV Strings

To access the clamping terminals open the lid of the housing and un-
screw the plastic “touch protection panel” (3x Philips screw):

Figure 7: Wiring terminals of PV Disconnect 440-20-1

Figure 5: “Touch Protection” panel

WARNING – Do not commission the PV Disconnect with-

out re-installing the touch protection panel to avoid an
electric shock hazard.

Only use the cable entries provided to bring the PV string cables into the
housing. Remove the plastic sealing cap from the cable gland in ad-
vance. The cable conduits have to be tightened properly to provide an
effective seal:

Figure 8: Wiring terminals of PV Disconnect 440-20-6

WARNING – Make sure that all terminal screws are tight-

ened properly to avoid damage and abnormal operation.
All terminal screws have to be checked again after instal-
lation for tightness!

WARNING – Make sure that all PV strings are connected

with the correct polarity or the PV modules will get dam-
aged immediately.

WARNING – Before connecting the PV modules to each

other make sure that the installation is complete and the
touch protection panel has been re-installed.

Figure 6: Left tightened – Right not tightened 7.2.3 Installing the optional surge protector (SPD)
Connect all PV string cables with positive (+) pole to the left terminals The device is available with different voltage levels to match our PS
labeled with “Positive (+) Input” and all cables with negative (-) pole to controller range (see chapter 0)
the right terminals labeled with “Negative (-) Input”.
Read the manual of the SPD completely to understand how it is installed
If the optional surge protector (SPD) is installed connect the grounding and operated before you start the installation. The manual is always
cable to the yellow/green earth-terminal on the right. shipped together with the SPD.
Please refer to chapter 7.2.3
The device is mounted to the right side of the housing by using the hole
Connect the two cables leaving the box and going to the pump controller provided. Apply the flat rubber sealing ring on the mounting thread,
to the output of the DC disconnect switch labeled with “Output (+) (-) to remove the sealing plug from the housing and insert the three cables
Controller” first.
Tighten the nut-ring to fit the SPD to the housing. Ensure that the metal
The correct torque for the terminal screws is 1,2Nm. claws of the nut are pointing to the inside.

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 5
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 Figure 9: SPD assembled to housing Figure 10: SPD - wires connected to the terminals

WARNING – The SPD must be connected to a proper

Connect the three wires of the SPD to the terminals of the PV Discon- ground source otherwise it will not provide ant protection.
nect.
Ensure that the wires are stripped correctly and that the terminal
Loosen the upper terminal screws of the following terminals:
clamps (screws) are tight!
For 440-20-1:
 Positive Input Terminal 7.2.4 Grounding
 Negative Input Terminal Grounding of the PV Disonnect is only mandatory when the optional
 GROUND lightning surge protector is installed. See chapter 7.2.3
For 440-20-6: The grounding cable should be a copper cable with a size of not less
 Positive Input No. 6 than 16mm² (AWG #6). The grounding profile rod should be located
 Negative Input No. 6 about 4-5m from the Box. The cable must not carry any mechanical
 GROUND loads.

The cables of the SPD will be connected to these terminals with the
existing cables.

For 440-20-1:
 Connect the red cable of the SPD to “Positive Input Terminal”
 Connect the black cable of the SPD to “Negative Input Termi-
nal”
 Connect the green cable to “GROUND”

For 440-20-6:
 Connect the red cable of the SPD to “Positive Input No. 6”
 Connect the black cable of the SPD to “Negative Input No. 6”
 Connect the green cable to “GROUND”

Avoid tight bends in the connection cables.

The cables can be cut to the required length.
Figure 11: Grounding rod (exemplary)

This is a possible example with a grounding rod.

The rod must be completely buried in the ground. Please refer to local
standards and requirements.

In general, grounding is mandatory to protect the users from potentially

fatal electrical shocks. It is meant for indirect lightning strikes and in-
duced electrical potential during operation of the pump system.

CAUTION – The wiring must be done by suitably qualified

staff. The grounding cable must have a reliable connection
to the ground.

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 6
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation
 8 Trouble Shooting

Please read this section before calling for help.

If you call for help, please refer to the model and serial numbers (if appli-
cable).

If The Pump Does Not Run

Most problems are caused by wrong connections (in a new installation)

or failed connections. Failed connects are normally a result of a terminal
/ clamp not being tightened properly or a wire slipping out of a terminal.

Please check:

 Screws of all terminal clamps are tight

 Polarity of connected cables
 Wire stripping is suitable for the terminals
 General condition of wires for signs of damage

Inspect all wires and connections

Look carefully for incorrect wiring (especially in a new installation).

BERNT LORENTZ GmbH & Co. KG Kroegerskoppel 7, 24558 Henstedt-Ulzburg, Germany, Tel. +49 (0) 4193 7548 - 0, Fax - 29, www.lorentz.de 7
V130830

All specifications are given with good intent, errors are possible and products may be subject to change without notice. Pictures may differ from actual
products depending on local market requirements and regulation