Solar / Hybrid Pump Controller ACIM & PMSM Pumps

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Overview

Solar / hybrid pump controller that allows existing 230 Vac 1Ø and 3Ø pump sets (ACIM or PMSM) to run directly from a solar PV array, with the option to use grid power as backup. It is intended for OEMs and system integrators who want to convert installed AC pumps to solar or hybrid operation without changing the pump or motor.

The controller takes DC from the PV array (and optionally AC from the grid in hybrid configurations), performs MPPT on the solar input and generates a regulated 230 Vac output for the pump. Panel voltage can be lower than the motor voltage; the controller boosts and regulates the output to match the 230 Vac pump, reducing the required panel wattage and overall system cost.

This makes it suitable for both new solar water pumping systems based on standard 230 Vac pumps and for retrofits of existing borewell, surface or booster pumps where replacing the pump and motor is not practical.

Key Features

  • Hybrid solar pump controller for existing 230 Vac pumps – designed to run standard 230 Vac 1Ø and 3Ø ACIM or PMSM pump sets from solar PV, with optional grid backup.
  • Pure solar and hybrid operating modes – supports solar-only operation, as well as solar + grid hybrid where grid power can be used as backup or for extended runtime.
  • Reuse existing pump and motor – existing 230 Vac pump and motor can be retained; only the controller and PV array are added, lowering changeover cost and simplifying field implementation.
  • DC-to-AC conversion with voltage boost – controller tracks the maximum power point of the PV array and boosts/regulates the output to 230 Vac for the pump, even when the panel DC voltage is below the motor’s equivalent voltage.
  • ACIM and PMSM compatibility – compatible with 1Ø and 3Ø AC induction motors and permanent magnet synchronous motors, allowing OEMs to support multiple pump technologies with a single controller family.
  • MPPT and high efficiency – integrated MPPT for the PV input coupled with high-efficiency inverter operation to maximise delivered water per kW of installed solar.
  • Pump protection and reliability – built-in protections for dry run / low water, overload, overcurrent, over- and under-voltage, reverse polarity (DC), phase loss and drive over-temperature.
  • Water level and pressure control options – digital and/or analog inputs for tank-level or pressure feedback allow automatic start/stop based on tank full/empty or pressure thresholds (variant-dependent).
  • Monitoring and communication – local indication of operating status and faults, with options for RS485 / MODBUS or OEM monitoring interfaces for integration and remote diagnostics.
  • IP-rated controller for outdoor use – supplied as an IP-rated controller suitable for pump houses and outdoor installations; PCBA options for OEM integration into custom enclosures can be supported in OEM projects.

Applications

  • Solar retrofit of existing 230 Vac borewell and surface pump installations in farms and rural areas.
  • New solar water pumping systems using standard off-the-shelf 230 Vac pump sets.
  • Hybrid (solar + grid) agricultural water pumping where reliable supply is needed through the day.
  • Village and community drinking-water schemes based on existing AC pump infrastructure.
  • Small building or community booster systems where solar can offset grid energy use for water pumping.
  • Any water pumping application where reuse of 230 Vac pump sets and reduction of operating cost are key.

Technical Specifications

Typical values; model-dependent. Refer to the datasheet for exact ratings.

Supported pump types 230 Vac 1Ø and 3Ø AC induction motors and PMSM pump motors
Pump power range ~0.5 to 5 HP (family dependent; other ranges possible under OEM programmes)
PV / DC input
  • Solar PV array DC input with MPPT
  • Wide-range DC input suitable for typical solar strings used with 230 Vac pumps (exact range model dependent)
  • Reverse polarity, over-voltage and under-voltage protection on DC input
AC input (hybrid mode)
  • 230 Vac nominal, 1-phase, 50 Hz (for hybrid/grid-backup variants)
  • Solar-only, AC-only (where permitted) and solar + AC hybrid modes depending on wiring and configuration
Motor / pump output
  • 0–230 Vac output (1Ø or 3Ø, model dependent)
  • Variable frequency output for soft start and speed control
  • Overcurrent, overload and short-circuit protection (model dependent)
MPPT & efficiency
  • Integrated maximum power point tracking (MPPT) on PV input
  • High static and dynamic MPPT efficiency
  • High inverter efficiency to minimise conversion losses and heating
Control & interfaces
  • Digital inputs for start/stop, tank-level / float switch and other logic (variant dependent)
  • Analog input for pressure or level transmitter where closed-loop control is needed
  • RS485 / MODBUS or equivalent serial interface options for OEM monitoring and integration (model dependent)
  • Local status and fault indication via LEDs / basic display depending on variant
Environmental & mechanical
  • IP-rated controller suitable for pump house / outdoor installation (typical IP65 or higher)
  • Ambient temperature typically −10 °C to 50 °C (as per datasheet)
  • Humidity up to 95% RH, non-condensing (max.)
  • Designed in line with relevant IEC standards for EMC, safety and drive efficiency for solar pump controllers

Downloads & Contact

Download solar / hybrid pump controller datasheet for 230 Vac pumps

Request a sample controller for trial with your existing pump models

Discuss OEM integration of the solar / hybrid controller into your pump range

Enquiry Information

For a focused response on the solar / hybrid pump controller, please include:

  • Pump details (borewell / surface / booster, ACIM or PMSM, 1Ø or 3Ø, rated HP, rated voltage, rated flow and head).
  • Existing system details (grid-only pump, existing starter or VFD, any protections currently used).
  • Planned operating mode (pure solar, solar with grid backup, AC-priority hybrid, other).
  • Solar PV details if known (array power, array voltage range, panel configuration).
  • Required daily water output and typical run-time (hours per day, seasonal variation).
  • Control requirements (tank-level control, pressure control, remote start/stop, monitoring interface).
  • Installation environment (pump house vs open, ambient temperature range, dust and moisture exposure).
  • Project status and expected annual quantities (concept, prototype, field trial, production).

We will use this information to recommend a suitable configuration of the solar / hybrid pump controller for your 230 Vac pump sets and discuss any required customisation or OEM integration support.