Overall assembly instructions 1

SOLAR-PUMPED WATER SUPPLY FOR MON BOUTON, HAITI

File: overall assembly instructions-1.doc 11/5/12 - 1 -

Solar Water Pump for Haiti

Assembly and Operation Manual

Eric E. Sabelman, PhD Menlo Park, California, USA

© 2012 If Pigs Could Fly - Helping Hillside Haiti



The purpose of the solar water pump is to relieve women and children of some of the burden of carrying domestic water uphill. “If Pigs Could Fly-Helping Hillside Haiti” is providing two systems, each consisting of a solar panel, submersible pump, pump control box, electric cables, and components of a tripod or tower for supporting the solar panel (Figure 1). The systems should each raise 400 gallons (1500 liters) per day a height of 230 feet (70 meters). Components to be locally provided include PVC water pipe, galvanized steel EMT tubing to make the tripods, water storage tanks and concrete for footings and a basin at the water source. While each system can be used independently – drawing from separate sources and/or pumping water to different destinations – we assume the greater need is for water to be raised higher up the mountainside. Therefore, the two systems can be placed in series, with the lower system pumping halfway to the end of the water pipe, where it empties into a tank that serves as the source for the upper system (Figure 2). Both solar panels should be located so as to receive the same amount of sunlight. Since the solar panel can produce power when sunlight is low, even though not enough to run the pump, in one of the control boxes (designated “#1”) there is provision for a battery charger for cell phones and similar small electronic devices. While solar panels are often mounted on structures, there are none where these will be installed. To raise the panel above ground – which is needed to avoid shading by vegetation, prevent tampering and keep the panel clean – the panel is mounted on a tripod tower constructed on-site from steel tubing and plates pre-formed to fit around the tubing. U-bolts and threaded rod are provided to clamp the plates to the tubing. Tools are provided to bend the legs of U-bolts it they need adjusting to fit (always put a nut on each leg to protect the threads). In a toolbox are hacksaws for cutting steel tubing and PVC pipe, screwdrivers and wrenches, pliers and wire crimpers, a voltmeter, and general purpose tools. Also included are a 100 foot measuring tape and a Hoppy Split Image Transit, which are used for determining lengths and elevations, respectively, for laying out pipe. Spare parts for the pump are included, as well as spare bolts and wire. The solar panels are exposed to wind and weather. If footings are adequate, the panel and tripod should withstand winds of 50 miles per hour (22 m/sec) without difficulty. When higher winds are expected, the tripod can be unbolted from the footings and tilted forward so the panel lays flat on the ground (have enough people helping to keep the tripod from falling). The control box is water-tight; all connections and switches are on the bottom to keep water from entering. Where the panel is located higher than surrounding objects, a lightning rod – a separate vertical pipe higher than the panel set in the ground within a few feet of the base of the tripod – should be installed. The water systems will need maintenance. Leaves and dirt need to be cleaned out of the pump inlet screen. If circuit breakers blow, they need to be re-set after the cause is fixed. Pipes should be kept covered with soil to protect them from sunlight and damage. If leaks occur, they need to be patched. Water in storage tanks should be treated with chlorine (bleach) to prevent disease from drinking contaminated water.



“If Pigs Could Fly-Helping Hillside Haiti” does not intend the solar water pump systems to be the property of an individual, but to be operated as a common resource for the community. This model is appropriate to the scale and needs of the Mon Bouton region, as it is for similar regions around the world (see http://www.ourwatercommons.org/, http://www.waterculture.org/ ). Nonetheless, this resource needs oversight by one or more individuals who will take responsibility for its management; we encourage the community to establish a self-operated organization similar to the Acequia Associations of the New Mexico native peoples (see http://en.wikipedia.org/wiki/Commons/ ), which have long histories of wise allocation of that scarce resource, water.

FIGURE 1

Parts of the system:

1. solar panel & control box 2. pump 3. pipe 4. storage tank

The pump and control box are pre-assembled and ready to use. To test the system before final assembly:

1. place the pump in clear water at the bottom of a 5 gallon or larger pail 2. place the solar panel face up on the ground; cover with a black plastic bag to block

sunlight 3. connect the cables from the control box to the cables from the solar panel

(DO NOT connect the solar panel cables under load) 4. leave the wires from the small float switch cable disconnected 5. uncover the solar panel; green LED on control box will light if there is enough sun

to run the pump 6. turn the circuit breaker on the control box ON 7. water should come from the pump outlet 8. DO NOT let the pump run dry more than a minute or two

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2

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FIGURE 2: Solar Pump Systems in Series for Higher Elevation

vertical riseor pressure head = 460 ft = 140 meters

length of pipe = 600 - 1000+ ft = 180 - 300+ meters

diameter of PVC pipe = 3/4 inch = 18 mm

control box #2

float va lve

source with screened in let

solar panel #2

180 watt, 24 volt

size = 39.1 x 52.3 x 2.3 inch = 994 x 1328 x 57.5 mm

overflow to i r r igat ion

storage tank #2 =300 gal =1135 liters

EES 2/15/2011

PUMP# 2

PUMP# 1

solar panel #1same as #2

control box #1

storage tank #1 =300 gal =1135 liters

float va lve

capacity = 400 gal per 5 hours = 1500 liters

Control box #1 contains a charger for cell phone and similar batteries up to 12 volts. It operates in the morning when the solar panel output is between 15 and 24 volts, before the voltage is high enough to run the pump. It should be placed at an accessible location where cell phones can be plugged into the automobile “cigarette lighter” socket on the bottom of the control box. The charger can supply about 50 watts of power (a circuit breaker on the control box will trip at 5 amps). Settings indicating when a battery is fully charged can be adjusted internally. A yellow “ready” LED lights when the solar panel voltage is in the 15-24 volt range and a red “charging” LED indicates the battery is not fully charged. Both #1 and #2 control boxes have green “pump power” LEDs indicating that the controller is providing and regulating 24 volt power. The green LED will be off if the solar panel is not providing enough power or if the float switch indicates water level is low. Power is directed to the pump by turning the switch/circuit breaker ON. The green LED can be changed internally to light only when the switch is on and voltage is adequate.



FIGURE 3: Wiring and pipe connections

The pre-assembled cable assumes the control box is about 6 feet (2 m) from the solar panel, on one leg of the tripod. The pre-assembled underground-rated 12-gauge cable is 50 feet (15 m) long. If it is necessary to extend the cable, disconnect the solar panel cable from the controller inside the control box (terminals “PV+” and “PV-”) and add no more than 100 feet (30 m) of 10 gauge outdoor-rated 3-conductor (2 power conductors plus ground) cable between the solar panel cable and respective controller terminals at the alternate location shown above. Connect the extension and solar panel cables inside the weather-proof junction box provided; fasten this junction box with cable ties to the tripod leg where the control box would otherwise be attached. Clamp the ground conductor of the extension cable to the tripod leg at a “C” plate; tie the other end to the ground wires inside the control box. As described below, the solar panel should be grounded to the top of a tripod leg with a 12-gauge green wire (provided) and the bottom of this tripod leg should be grounded from an “A” plate to a metal post pounded at least 2 feet (60 cm) into the ground. Because the pump is selected for high pressure (elevation or “head”) and low volume output, the friction loss of water moving in the pipe is small. PVC plastic pipe ¾ inch (1.9 cm) in diameter will lose 2% of the nominal 230 foot elevation, or 4.6 feet, for every 1000 feet (305 m) of pipe. Bends and corners will add to the head loss. Pipe sections must be carefully joined to withstand 100 psi pressure (instructions provided). It is recommended to cement the lower 80% of the pipe length from each pump (allow joints to dry 24 hours) and temporarily install the upper 20% without cement. Then run the pump with typical sunlight on the solar panel to obtain reasonable flow at the outlet by adding or removing lengths of pipe at the top before cementing the final pipe sections. This method may not locate the outlet at a convenient site for drawing water from the storage tank, but insures that the pump and lower part of the pipe are not at excessive pressure.



Figure 4: Solar Panel & Tripod Parts:

1. Solar panel 2. Control box 3. Tripod:

EMT tubing Plates

4. Footings All plates and bolts are supplied. EMT tubing required per tripod (all 10 foot (3 m) lengths: 2 inch diameter 3 each for legs 1 inch 2 each, cut to 5 feet long for panel frame & tilt braces ¾ inch 6 each, cut to 7 feet & 3 feet for cross-braces & frame

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OVERALL ASSEMBLY INSTRUCTIONS

CONTENTS 1. Select site – see notes on horizontal and vertical angle of solar panel relative to sun 2. Install footings – see notes on wind resistance 3. Assemble tripod 4. Install solar panel & control box on tripod 5. Install tripod on footings 6. Install pump & float switch 7. Assemble delivery pipe & storage tanks 8. Turn control box breaker ON 9. Monitor water output and usage



OVERALL ASSEMBLY INSTRUCTIONS 1. Select site – see notes on horizontal and vertical angle of solar panel relative to sun 1.1 water source (with catchment basin or spring house as needed) 1.2 solar panel location 1.3 storage tank location 1.4 route for delivery pipe 2. Install footings – see notes on wind resistance 2.1 dig holes 2 feet diameter at corners of equilateral triangle 7 feet (2.1 m) on a side 2.2 place anchor bolts – if cement blocks are available, put anchor bolts in blocks so they

can be moved to position tripod for best sun angle 2.3 pour cement around blocks, if used. Otherwise, wait until tripod is in final position

before pouring cement 3. Assemble tripod 3.1 slide B & C plates on 3 legs 3.2 slide F plate on back leg 3.3 slide E plates on top of legs 3.4 place 2 cross-braces in B & C plates of front 2 legs 3.5 tilt on side and place 2 cross-braces in B & C plates of 1 front leg 3.6 place ends of cross-braces in B & C plates of back leg 3.7 tilt on other side and place 2 cross-braces in B & C plates of front & back legs 3.8 tilt so front legs are down; place left & right E plates with 1 top tube on top of front legs 3.9 place back E plate with 2 top tubes on back leg, so ends of tubes go into front E plates 3.10 construct solar panel frame from 2 horizontal and 2 vertical tubes and 4 D plates 3.11 attach frame to E plates 3.12 place 2 G plates on ends of top frame tube; place 2 angle tubes in G and F plates 4. Install solar panel & control box on tripod 4.1 attach control box to one tripod leg; circuit breaker should be OFF 4.2 attach solar panel to frame using U-bolts 4.3 plug solar panel into cables from control box. DO NOT connect while panel is in

sunlight; lower panel or cover with black plastic bag. 4.4 tie cables to tripod legs 5. Install tripod on footings 5.1 install L-brackets on footing anchor bolts 5.2 move tripod so bottom of front legs are next to south footings 5.3 raise tripod by walking it up from top toward footings 5.4 adjust position so legs are on base of L-brackets; attach with U-bolts 5.5 adjust F plate so solar panel is at desired angle 5.6 install long U-bolts (part H) where cross-braces meet at center 6. Install pump & float switch 6.1 assemble leaf trap using wire staples 6.2 place leaf trap in catchment basin so top is above waterline 6.3 place pump support beam over basin 6.4 tie pump support rope to beam and lower pump into leaf trap 6.5 connect wire from control box to float switch through hole in cap 6.6 attach float switch to pump support beam so float is above pump inlet 6.7 connect power cable from pump to control box 7. Assemble delivery pipe



7.1 place storage tank at its location 7.2 glue adaptor on first pipe section and attach output tubing from pump 7.3 glue pipe sections together using correct method for high pressure; let dry one day. See

notes on temporary pipe placement, above. 7.4 glue storage tank adaptor section to last pipe section, with outlet over tank 8. Turn control box breaker ON

Overall assembly instructions 1

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