Lorentz - Pvdisconnect 1000 40 5 Manual - en PDF

PV Disconnect 1000-40-5
Connection Box with DC Disconnect Switch

Item no.: 19-000115
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
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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

• This LORENTZ product is supplied from the factory in proper packing
6 Product Description .................................................. 3
in which it should remain until it is to be installed.
6.1 Technical Data ...................................................... 3
• Handle the product with care and avoid unnecessary impacts and
6.2 Related Products ................................................... 4
shocks.
6.2.1 PV Combiner 1000-125-4 (Item no.: 19-000116) 4
6.2.2 PV Protect 1000-125 (Item no.: 19-000117) ..... 4 • Prolonged intermediate storage in an environment of high humidity
and fluctuating temperatures must be avoided. Moisture condensation
7 PV wiring scheme for PSk pump systems ............... 5 may damage metal parts. Non-compliance will void any warranty. It is
recommended storing the parts in a closed and dry room.
8 Installation ................................................................. 6
• The product can be stored in the range of –30 °C to 50 °C (-22 °F to
8.1 Mounting & Dimensions......................................... 6 120 °F). It should be avoided to expose the product to direct sunlight.
8.2 Wiring.................................................................... 6
8.2.1 General .............................................................. 6
8.2.2 Connecting the PV Strings ................................. 6
3 Operating Conditions
The permitted ambient temperatures for use are:
9 Trouble Shooting....................................................... 8 -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
Meets the requirements for CE
4 Declaration of Conformity
We, BERNT LORENTZ GMBH & Co. KG Germany, declare under our
sole responsibility that the product
PV Disconnect 1000-40-5
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
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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
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6 Product Description
Figure 1: PV Disconnect 1000-40-5
The LORENTZ PV Disconnect 1000-40-5 is a PV connection box with

an integrated disconnect switch designed to be used with our PSk pump
systems. The product is able to combine up to 5 PV module strings in
parallel and connect them through the enclosed DC disconnect switch to
the pump controller.
This is done by using the spring-loaded terminal clamps located inside

the box. The DC-rated disconnect switch is used as a manual circuit
breaker between the solar array and the controller. This switch is easily
accessible by unlatching the bottom spring lock and opening the hinged
lid.
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
6.1 Technical Data
• Wiring for 5 PV strings

• DC rated disconnect switch enclosed
• Enclosure class IP 54 (covers NEMA 3, 3X, 3S, 3SX)
• Meets the requirements for CE
1,000 V DC (Uoc)
Max. voltage
880 V DC (Ump)
Max. current per string 40 A
Max. total current 40 A
Max. no. of strings 5
String cable size 4 - 10mm²
Output cable size 4 - 16mm²
Figure 2: Wiring scheme for PV Disconnect 1000-40-5
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6.2 Related Products
Some large installations may require additional accessories to connect
the PV wiring of the system in a proper way. Therefore the following
accessories are available; please also refer to “7 PV wiring scheme for
PSk pump systems.
6.2.1 PV Combiner 1000-125-4 (Item no.: 19-000116)
In case:
• More than 5 PV module strings have to be connected to the

pump controller
• The maximum rated current of the enclosed disconnect switch
is exceeded by the total short circuit current (Isc) of the PV
generator
Then two or more PV Disconnect 1000-40-5 units must be used to

operate the switch within its specification.
The product “PV Combiner 1000-125-4” can be used to combine the

output of up to 4 “PV Disconnect 1000-40-5” to one single string that
finally connects to the pump controller.
Figure 3: Wiring scheme for PV Combiner 1000-125-4
6.2.2 PV Protect 1000-125 (Item no.: 19-000117)
The PV Protect 1000-125 is installed on the DC input line close to the

pump controller. The PV Protect 1000-125 will provide an enhanced
level of protection from electrical surges (for example indirect lightning
strikes). For effective operation it requires a reliable ground connection.
Figure 4: Wiring scheme for PV Protect 1000-125
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7 PV wiring scheme for PSk pump systems
PV String 1 - 5 PV String 6 - 10
1 2 3 4 5 6 7 8 9 10
PV Disconnect PV Disconnect
1000-40-5 1000-40-5
PV Combiner
1000-125-4
PV Protect
1000-125
PSk Controller Pump
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8 Installation
8.1 Mounting & Dimensions 8.2 Wiring
WARNING – All electrical connections should be per- 8.2.1 General

formed by qualified experts only!
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 voltage is present
The PV Disconnect must be mounted vertically to a wall or a pole using during wiring of the system. Only reconnect the PV plugs and switch on
appropriate fixings. the system when all work is finished.
The distances between the four mounting holes of the box are: CAUTION – Loose connections are the most common cause
PV Disconnect 1000-40-5 254x164mm, Ø7mm. 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
For optimal protection against water ingress the cable glands must point clamping range of the cable gland to ensure a proper seal. If necessary
downwards. 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
CAUTION – Make sure the housing is not distorted after
Wiring Diagram which is provided by COMPASS and to the module
mounting; otherwise the lid may not close properly.
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.
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.
8.2.2 Connecting the PV Strings
To access the clamping terminals open the lid of the housing and un-
screw the touch protection panel (3x Philips screw):
PG cable glands PG cable glands

(10x M16) (2x PG11)
Net. Weight:
2,5kg / 5,5lbs
Figure 5: Installation dimensions for PV Disconnect 1000-40-5
Figure 6: Touch protection panel
WARNING – Do not commission the PV Disconnect with-

out re-installing the touch protection panel to avoid an
electric shock hazard.
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Only use the cable entries provided to bring the PV string cables into the Connect all PV string cables with positive (+) pole to the left terminals
housing. Remove the plastic sealing cap from the cable gland in ad- labeled with “Positive (+) Input” and all cables with negative (-) pole to
vance. The cable conduits have to be tightened properly to provide an the right terminals labeled with “Negative (-) Input”.
effective seal:
Connect the two cables leaving the box and going to the pump controller
to the output of the DC disconnect switch labeled with “(+) Output (-)”.
Figure 7: Left tightened – Right not tightened
Weidmüller terminal clamps
The terminal system used in PV Disconnect 1000-40-5 boxes is provided

by Weidmüller. These terminals use tension clamp technology which
allows for faster and more reliable termination of system wiring. A stain-
less steel spring is used to securely connect the wire to the current bar.
The cable entries are on the top of the terminal. This has the advantage
that it is easier to see where the wires are inserted and so reduces wiring
errors. (Cf. below “Figure 8: Operation of Weidmüller terminals”)
To install the wires:
Strip the insulation from the end of the cable to be terminated. Figure 9: Wiring terminals of PV Disconnect 1000-40-5
For a 16 mm² cable strip 10 mm of insulation.
1. Push a flat screw driver downward into the terminal block. WARNING – Make sure that all terminal connections are
(Figure 8: 1) conducted properly to avoid damage and abnormal opera-
2. The clamp for the cable is now open tion. All terminal clamps have to be checked after installa-
(Figure 8: 2) tion!
3. Push the stripped cable into the terminal.
(Figure 8: 3) WARNING – Make sure that all PV strings are connected
with the correct polarity or the PV modules will get dam-
4. Remove the screwdriver. A high contact force is supplied by
aged immediately.
the stainless steel clamp.
(Figure 8: 4)
WARNING – Before connecting the PV modules to each
Gently pull the cable to check it is clamped properly. other make sure that the installation is complete and the
touch protection panel has been re-installed.
Figure 8: Operation of Weidmüller terminals
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9 Trouble Shooting
Please read this section before calling for help.
If you call for help, please refer to the model and serial numbers. The
serial number can be found on a small label with a barcode on the inner
side of the lid.
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:
• All cables are fitted properly by the clamp terminal.

• 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).
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PV Disconnect 1000-40-5

Connection Box with DC Disconnect Switch

Manual for Installation and Operation

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

Humidity and air salinity:

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

Bernt Lorentz, CEO

observed at all times. Any danger to per-

 Safety-oriented operation – The safety

Figure 1: PV Disconnect 1000-40-5

The LORENTZ PV Disconnect 1000-40-5 is a PV connection box with

This is done by using the spring-loaded terminal clamps located inside

The use of a properly sized DC disconnect switch is an important safety

6.1 Technical Data

• Wiring for 5 PV strings

Figure 2: Wiring scheme for PV Disconnect 1000-40-5

6.2.1 PV Combiner 1000-125-4 (Item no.: 19-000116)

• More than 5 PV module strings have to be connected to the

Then two or more PV Disconnect 1000-40-5 units must be used to

The product “PV Combiner 1000-125-4” can be used to combine the

Figure 3: Wiring scheme for PV Combiner 1000-125-4

6.2.2 PV Protect 1000-125 (Item no.: 19-000117)

The PV Protect 1000-125 is installed on the DC input line close to the

Figure 4: Wiring scheme for PV Protect 1000-125

PSk Controller Pump

WARNING – All electrical connections should be per- 8.2.1 General

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

WARNING – SOLAR-DIRECT systems only - do not con-

8.2.2 Connecting the PV Strings

PG cable glands PG cable glands

Figure 5: Installation dimensions for PV Disconnect 1000-40-5

Figure 6: Touch protection panel

WARNING – Do not commission the PV Disconnect with-

Figure 7: Left tightened – Right not tightened

Weidmüller terminal clamps

The terminal system used in PV Disconnect 1000-40-5 boxes is provided

To install the wires:

Figure 8: Operation of Weidmüller terminals

Please read this section before calling for help.

If The Pump Does Not Run

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

• All cables are fitted properly by the clamp terminal.

Inspect all wires and connections

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

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