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Solar Water Pump by Jonathanrjpereira

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This Instructable will help you to setup a fully functional Solar Water PumpingSystem. The Solar Water Pump System can be used for residential waterrequirements and also for commercial uses. This system can also be used forirrigation of Agricultural Land. The Solar Panel Array can also be used withoutthe water pump and can power your house or apartment. The Instructable willact as a guide in helping you understand the principles required to pump waterusing solar energy.

Solar Power

Photovoltaic(Solar) systems do not use any Fuel. They last for 20+ years. Theyare cost effective and are independent from a countries electricity grid. Thecost of installation is almost the only cost. Solar Power is a Green Renewableenergy that will produce electricity as long as the Sun rises every morning.Solar systems require low maintenance.

Why go for a Solar Water Pump System?

Well sunlight is free and abundant. Humans are dependent on water forsurvival. Inorder to obtain their daily water requirements we pump our waterfrom wells, dams, rivers, ponds,etc. Since the system is OFF-Grid, it canalways pump water even in an apocalypse.

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About This Instructable

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I'm Jonathan Pereira, a electronicsenthusiast. I'm currently pursuing myUndergraduate/ Bachelor's in ElectronicsEngineering. I love to play around withelectronics especially hacking and makingcir...read more

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Step 1: Economics, Viability & Applications

Solar Energy is a giant leap in the field of science which has enabled humansto produce clean energy. In this step I am going to give you a brief introductioninto real economics, viability and applications of this Instructable.

Agriculture

Agriculture in developing nations isn't as efficient as it really should be. One of

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Apartment SolarSystemby Jonathanrjpereira

the main problems of agriculture is water management. Even developingnations which receive a good amount of water through rainfall fail to be efficientin the field of agriculture.

The initial investment of solar energy is high. Buts lets put it in a developingnation's agriculturists/farmers perspective. I have chosen my country India asthe perfect example of the best beneficiary from the use of solar energy.EXAMPLE based on past experience:

The common farmer over here has to pay approximately Rs 50,000 to setup anelectrical connection to his/her farm depending on how far the nearest villagetransformer/power distributor is from the farm. The farmer then has to buy apump to irrigate his land which could cost the farmer between Rs 5,000 -35,000. The problem is in such areas Maintenance of Power lines is not carriedout and there is high variation in the supplied voltage. This causes the pumpscoil and windings to get damaged. This can lead to loss of efficiency or eventotal damage to the pump. Farmers who have batteries and inverters for theirfarms also suffer losses from the damage caused by voltage fluctuations to theinverters,etc. Therefore the farmer has to also spend additional revenue inbuying replacement Pumps, inverters,etc.

Maintenance of the power lines has to be sometimes carried out by the farmer.Irregular power failures and power shortages causes major losses ofagricultural output. Consider a 10 acre Cucumber crop plantation which shouldideally yield a harvest of approximately 1000kg/day. Lets say due to a poweroutage, there is no power supplied to the farm for an entire day. This wouldlead to the crop not being watered for a day and could result in significantweight loss of the cucumbers. In country's such as India, farmers sellvegetables based on weight and hence any weight loss would result insignificant losses. But all these problems can be solved by the implementationof a Solar Water Pump System.

In India, there are mainly two crops: Kharif(Monsoon Crops) & Rabi(WinterCrops). With the help of solar energy, I have been able to plant 4 differentcrops. i.e. 2 additional crops excluding the Kharif and Rabi crops. I have beenable to irrigate a cucumber and watermelon crop in the middle of summerwhich also has significantly increased my profits from agriculture, something Iwouldn't have been able to do without solar energy.

What about farmers belonging to developed nations?

Well apart from the above, farmers in developed nations can use solar energyfor their sprinkler systems in their greenhouses. You can check out the graphsabove to get an overview of the efficiency of solar water pump systems. Theycan also use for artificial lighting to grow saplings. I have also seen a Solarwater pump systems being used in poultry(chicken) applications to cool thesheds and provide drinking water to the poultry birds.

Household/Domestic Applications

The solar water pump system can be used to pump drinking water in societiesand buildings. The concept of 'Green Buildings' includes the use of solar waterpump systems for the purpose of drinking water and other sanitary uses ofwater.

If you do not wish to use solar energy to pump water but instead to power yourhouse, check out some of my other Instructables:

DIY Solar+Wind House

Apartment Solar System

Apocalypse Preparedness

Imagine if their is an apocalypse & aliens attack all power stations! Protect

yourself from such events and install a Solar Water Pump System.

P.S: This application was included in view of the Apocalypse PreparednessContest :)

Step 2: Parts & Skill List

Standard System

The specifications of the Metal Stand (Angle), Solar Capacity, Pump outputhave been optimised to my desired requirements and location. Hencedepending on your purpose (Residential, Commercial or Agricultural) you caneither change the output of the system by adding or subtracting the solarpanels inorder to increase or decrease the production of electricity. Dependingon the requirement and capacity of the system, the specifications and quantityof each part could defer. This Instructable will act as a standard guide whichhelp you in understanding how to build the Solar Panel Stand, Estimating theNumber of Panels & Other Parts required, Electrical Connections,etc. Henceyou may have to buy parts according to your specific requirements. The mainfactors involved in choosing parts are: Solar Output, Cable Size, Pump:Power,voltage,current,speed,flow rate,efficiency and Pipe: Length, Diameter.

Parts

1. Anti-Corrosion Paint.2. 4X 11ft I-beams.3. 2X 7ft I-beams.4. 3X 24.46ft C-channels.5. 2X19.63ft C-channels.6. 5X 20.84ft C-channels.7. 6X20.18ft C-channels.8. 21X Solar Panels

280W35V1960X990X42 (mm)

9. Solar Pump System ControllerMax Input Voltage: 238VOutput: 3-phase(60-240V0, 3kW)

10. Solar PumpSubmersible3-phaseOutput:22m^3/hr

11. Cable (Depending on depth of well,etc)12. 6X Circuit Breakers.13. Concrete/Cement Mixture.

Tools

1. Welding machine and welding rods.2. Screwdrivers.3. Drills.4. Wire Cutters.5. Digital Multimeter.6. Spirit Level Bottle.

Skills

1. Basic Understanding of Electrical Wiring and Electronics.2. Basic Understanding of Structural Design.3. Basic Welding.

Step 3: Solar Panel Stand

The Solar Panel is a Metal framework consisting of I-beams and C-channelthat help support the solar panel and keep them inclined at the required angle.In the next couple of steps, the Instructable will teach you how too setup themetal framework.

Solar Angle

But before you start building the metal stand or framework you must determinethe optimum angle at which you must place you solar panels inorder to get themaximum efficiency from the solar system.

To get the best out of your photovoltaic panels, you need to angle themtowards the sun. The optimum angle varies throughout the year, depending onthe seasons and your location and this calculator shows the difference in sunheight on a month-by-month basis.

Inorder to calculate the optimum angle I have used an online calculator whichuses the location of the Solar Panel Array. Solar Panel Angle Calculator

Anti-Corrosion Paint

Before you start building the metal stand, you must paint all metal partsincluding I-beams, C-channel,etc with a layer of Anti-Corrosion/ Anti-RustPaint. After doing so, you can add a layer of coloured paint to enhance thelook of the Solar Panel Stand. By painting the metal stand you will prevent themetal from getting damaged due to corrosion.

3D Models/Layout Diagrams

Inorder to understand the design of the Solar Panel Stand, I have attached the3D model and Layout diagram files.

Layout Diagram.dwg 45 KB

Layout 3D Model Diagram.skp 474 KB

Step 4: I-Beam Placement & Foundation

Once you have determined the optimum angle at which the solar panels mustbe placed at, you can start building the metal stand. In this step you will needto mix concrete for the foundation.

1. Start by digging a hole into the ground of the dimensions: 2ft X 2ft X 2ft.2. Add some concrete into the hole and spread it evenly.3. Place the I-beam into the hole such that it is perpendicular to the surface.

Ensure that the I-beam is vertical by using a Level Bottle.4. Once 2ft of the I-beam is placed inside the hole vertically, fill the hole

completely with cement.5. Do the same for another I-beam separated from the first I-beam at a

distance of 24.46ft6. The total height of each I-beam from the ground surface is 11ft.

Step 5: Adding Lower C-channel

In this step, you will attach a 24.46ft C-channel to the two I-beams.

1. Ensure the C-channel is parallel to the ground surface with the help of aLevel Bottle.

2. Bolt each end of the C-channel to the I-beams.3. Make sure you use Stainless Steel nuts and bolts.

Step 6: Adding 7ft I-beam & Top C-channel

In this step you will add 2 X 7ft I-beams on top of the two 11ft I-beams.You will also attach a 24.46ft C-channel to the I-beams. The procedure isspecified in the layout diagram. If you do not wish to add an '11ft+7ft' I-beamdesign you can instead add an 18ft I-beam.

1. Place the lower Base-plate of the 7ft I-beam on top of the higher Base-plateof the 11ft I-beam.

2. Make sure that the 7ft I-beam is perpendicular to the ground surface withthe help of a Level Bottle.

3. Follow the same steps for the placement of the Second 7ft I-beam.4. Bolt the Base-plates of the I-beams with Stainless Steel nuts and bolts or

weld them together.5. Attach both sides of the 24.46ft C-channel to the top of the two 7ft I-beams

respectively with the help of Stainless Steel nuts and bolts.

Step 7: Adding the Remaining I-beams

In this step you will place 2 X 11ft I-beams at the remaining two corners.

1. The procedure for the placement and foundation is same as that of the firsttwo I-beams.

2. Ensure that the I-beams are perpendicular to the ground surface using a

Level Bottle.

Step 8: Adding Lower C-channel

In this step you will be using 2X 19.63ft C-channels and also 1X 24.46ftC-channel.

1. Start by attaching either side of one 19.63ft C-channel to the top of theLower I-beams by bolting them together. Refer to the Layout diagram.

2. Do this for the other 19.63ft C-channel.3. Next attach either side of the 24.46ft C-channel to the the top of the Lower

I-beams by bolting them together. Refer to the Layout Diagram.4. Ensure that the C-channel are parallel to the ground surface with the help

of a Level Bottle.

Step 9: Adding the Inclined C-channel

In this step you will be using 5X 20.84ft C-channel. This step also involveswelding.

1. Start by placing one of the C-channel at each end as shown in the layoutdiagram.

2. Next place one of the C-channel at the centre as shown in the layoutdiagram.

Show All 9 Items

3. Place one C-channel between the Centre and outermost C-channel oneither side.

Weld all the joints using a Welding Machine. Use all necessary welding andsafety equipment. Keep a fire extinguisher around incase of a fire.

Note: If you do not wish to weld, you can attach the inclined C-channel bybolting it to the entire structure.

Step 10: Additional Supporting C-channel

In this step you can either use C-channel or Aluminium Box Channel. In thisstep you will be using 6x 20.18ft C-channel.

1. Start by placing the C-channel from one side of the structure horizontallysuch that they are parallel to each other as shown in the layout diagram.

2. The spacing between two C-channel should be 3ft.3. One placed and aligned properly as shown in the layout diagram, weld or

bolt them to the structure.

Step 11: Adding the Solar Panels

In this step you will be using 21 solar panels.

Solar Panel Specifications: 1. Power: 280W. 2. Voltage at Pmax: 35V. 3. Length X Breadth X Height(mm): 1960 X 990 X 42.

Detailed specifications of the solar panels are given in the solar paneldatasheet.

1. Start by bolting the solar panels to the C-channel.

2. The distance between two panels on each side will be 0.25ft.

3. Refer to the Layout Diagram for more details.

Step 12: Connecting the Solar Panels

1. Start by opening the Solar Panel connector Box. 2. Use a multimeter to determine the polarity of the solar panel. 3. Form one string of solar panels by connecting 7 solar panels in series. Form3 such strings.

Step 13: Electrical Connections

Before connecting the Solar array to the Solar Pump System Controller wemust connect a Circuit Breaker(CB) between them.

1. Place 6 Circuit Breakers(CB) in a PVC Box.2. Connect the Positive wire from each string to one end of a separateCB.(Input of CB)3. Connect the Negative wire from each string to one end of a separateCB.(Input of CB)4. Connect the output of the 3 Positive CB's together.5. Connect the output of the 3 Negative CB's together.6. Now connect these to the inputs of a screw terminal.7. Connect additional wires from the output of the screw terminals to the input'Power IN' of the Solar Pump System Controller.8. Connect wires from the 'L1,L2,L3' & 'Ground' terminals of the solar pumpsystem controller to the matching numbers on the pump leads. Note: Othercombinations may cause reverse rotation!9. Some pumps come along with additional connections such as Low WaterProbe, Float Switch, Battery System,etc. Follow the manual instructions formore details.10. Connect the Water output of the pump to a long pipe and ensure that it issecured properly. Lower the pump into the water source and switch it on.3

Step 14: Solar Pump System Controller

The Solar Pump System controller is the brain of the entire project. It basicallyregulates the current supplied to the pump from the solar panels.

The Power IN,L1,L2,L3 and Ground connector terminals are in the controller.

Most Solar Pump System Controllers come along with LED indicators. Givenbelow are the descriptions of the LED indicator functions of the controller that Ihave used.

System(green)

When the LED is Green, the controller is switched on and the power source ispresent. In low-power conitions, the light may show even if there is not enoughpower to run the pump.

Pump ON(green)

Motor is turning. Sequence of flashing indicates pump speed. Pump speed(RPM) can be read of the flashing sequence of the Pump ON LED as follows:

LED ON > 900

1 flash > 1,200

2 flashes > 1,600

3 flashes > 2,000

4 flashes > 2,400

5 flashes > 2,800

If the Pump Overloads, the LED will change to red.

Source Low(red)

If the water source has dropped below the level of the low water probe. Afterthe water level recovers, the pump will restart, but this light will slowly flashuntil the sun goes down, power is interrupted, or the power switch is reset.This indicates that the water source ran low at least once since the previousoff/on cycle.

Tank Full(red)

Pump is turned off by action of the remote float switch.

Step 15: Solar Water Pump

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Pump Specifications:

1. Submersible Pump.2. 3-Phase.3. Flow Rate: 22m^3/hr

The pump basically uses the power supplied from the solar panel array inorderto pump water from the source. Mostly the pumps come with four wires: 3wires for each phase and one wire for Ground.

The Motor Power, Motor Voltage, Motor current, Motor Speed, Flow Rate,Efficiency, etc are vary from different pumps and manufacturers. Choose asuitable pump depending on your requirement.

We have a be nice comment policy. Please be positive and constructive. I Made it! Add Images

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ahorn8

agreenspan

JamesN6

Jonathanrjpereira (author) JamesN6

senseimitch Jonathanrjpereira

J2SARET

crgintx

Very cool. Solar pump projects are needed in developing countries.Many of the countries are near the equator and have plenty of sunlightyear round.

Aquaponics man! let's help the farmers maximize their time, space,and reduce waste!

What is the total cost of this project?

The total cost is variable from country to country. It depends onfactors such as cost of C-channel, Solar Panel Manufacturers,Government Subsidiaries on Solar Powered Water pumps,etc.

How about an example price? What did you pay where youare? Any suggestions on where to purchase the panels?

Very though. I am bookmarking your instructables for easy referenceduring our forthcoming remodel. On cavet. In areas like mine withplenty of lasting snow, one might to install at a bit steeper thanoptimum angle so snow slides off.

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Jonathanrjpereira (author) crgintx

lewisstreet2574

MrUmunhum

Jonathanrjpereira (author) MrUmunhum

esl401k

Jonathanrjpereira (author) esl401k

reyon.desouza2

Jonathanrjpereira (author) reyon.desouza2

Neat set up but... in terms of durability, simplicity and reliability, it'spretty hard to to beat windmills for pumping water. A dual powersystem using both wind and solar power in combination with a batterybank might be a better option.

I did try a Solar+Wind house:http://www.instructables.com/id/WindSolar-Powered-House/But so far I think a Solar Water Pump does serve its purpose.

nice idea really, I don't if I could afford this myself, good idea for thirdworld countries, for them getting clean water, like Africa, or india. alsogood for remote areas. thank you for your sharing your project online,steve bull

Where did you get the pump? What are the specs?

Submersible, 3-phase,5Hp,output: 22m^3L

Wow this is amazing

Thanks. Check out some of my other instructables too if youliked this one!

Cool!!

Thanks a lot.

5 days ago Reply

4 days ago Reply

seamster

Jonathanrjpereira (author) seamster

Very impressive project, as always! Nicely done!

Thanks a lot.

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