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STICHTING BAKENS VERZET

1018 AM AMSTERDAM, THE NETHERLANDS

Director,

T.E.(Terry) Manning,

Schoener 50,

1771 ED Wieringerwerf,

The Netherlands.

Tel: 0031-227-604128

Homepage: http://www.flowman.nl

E-mail: (nameatendofline)@xs4all.nl : bakensverzet

 


MODEL FOR SUSTAINABLE SELF-FINANCING INTEGRATED RURAL AND POOR URBAN DEVELOPMENT FOR THE WORLD'S POOR

Incorporating innovative social, financial, economic, local administrative and productive structures, numerous renewable energy applications, with an important role for women in poverty alleviation in rural and poor urban environments.

 


 

"Money is not the key that opens the gates of the market but the bolt that bars them"

 

Gesell, Silvio The Natural Economic Order

Revised English edition, Peter Owen, London 1958, page 228

 


 

Edition 5: 08 Diciembre, 2006

 


BOMBAS SOLARES SOLAR SPRING


INSTALACIÓN

Controlador de la Bomba

Un controlador de la bomba es requerido para cualquier sistema de bombeo sin baterías. Sin él, la bomba no arrancará apropiadamente, y se parará en condiciones de baja luz.

No intente hacer funcionar la bomba sin el controlador Sunprimer.
Una corriente inadecuada de arranque puede causar sobrecalentamiento del motor.

Montaje del Controlador SunPrimer Mark II

Coloque el controlador en la sombra, de tal manera que no se ponga muy caliente con el sol de medio dma. Montarlo abajo del arreglo AF es adecuado.

HIGH HAZARDOUS VOLTAGE WARNING

WARNING! If your PV array is left disconnected in the full sun in open circuit condition, voltage may rise to anything up to 100V even in cloudy weather, enough for a nasty shock. When working on the array output wiring you may leave one wire disconnected between two of the modules to break the circuit, or shade the array by turning it out of the sun or by covering it.

Switch de Desconexión Manual

Un switch on/off debe estar colocado entre el arreglo AF y el controlador, !NO sobre la línea que va a la bomba! Debe ser un switch de dos polos. Conictelo para desconectar el positivo de cada mitad del arreglo solar.

Sugerimos un modelo QO-200TR Square-D (marca), "Switch de caja moldeada cerrada", de su distribuidor elictréco, o de Graingers (modelo # 1H245). Es compacto y barato. O, puede usar un switch común AC de desconexión para lluvia intensa, de valores nominales "30 amps.,una fase".

Vea el diagrama de cableado del controlador. Si no está usando el switch de flotador, debe aislar el cable de tal manera que lo cables no entren en contacto, o de lo contrario.

FUNCTIONS OF THE SUNPRIMER CONTROLLER

The Sunprimer electronics unit incorporates five functions:

1) To interrupt current connection between the PV panels and the pump when insolation and, with Sunprimer MK II, the battery charge is such that voltage is so low (about 22V) that the pump slows down to the point where it stops. This stops the motor from being put under continuous load when stopped.

2) To start your Solar Spring pump as early as possible in the morning and keep it going as long as possible into the evening (thus extending running time), provided insolation or battery charge is sufficient to keep the pump running. If the pump cannot start, or is turning too slowly, function 1 enters into operation. If insolation is reasonable, function 2) will make another attempt to start the pump. A secondary timer unit attempts to start the pump at intervals of approximately two minutes. This timer also operates on initial starting up, so that the pump will start operating APPROXIMATELY TWO MINUTES) AFTER ELECTRICAL CONTACT HAS BEEN MADE.

3) To switch nominal voltage between 48V and 24V in relation to the available power from the PV panels and pump load, so as to optimise amperage absorbed by the pump motor and adjust motor speed as required to optimise pump capacity. The MK II Sunprimer controller always charges the capacitor to 60V even in 24V and battery applications. The Mk II controllers start in 24V mode, then switch to 48V if sufficient current supply is available.

4) To connect the Solar Spring pump to GOOD QUALITY external float switches and/or other devices such as presostates. This is the smallest cable which comes out of the Sunprimer. It has two wires which, when placed in contact with one another or in an electrical circuit, interrupt the electricity supply. When the two wires are not in contact with one another or in an electrical circuit, the controller feeds current to the pump motor and, assuming insolation is sufficient, the pump will start again after about three minutes. The external controls or switches used should be of high quality and such that on and off contacts be made cleanly, precisely and quickly. Uncertain or irregular contacts may damage the controller.

5) To save pump motor and system components where specifications are not complied with during installation and/or in the presence of particular extreme or unforeseen environmental events (including freezing or blocking of the feed pipe system for any other reason or excessive draw-down of water in the borehole) where a fail-safe system is needed. For instance this function intervenes to cut current where current is greater than 4.5 amps for more than half a second. Normal starting procedures will then be activated, so the pump will attempt to start again after approximately two minutes.

6)Another device will act to cut current to the contoller by putting the PV panels into short circuit when for any reason the main transistor in the controller is damaged so that the controller can no longer work properly. The pump will automatically start again once the damaged transistor has been repaired.

7) The Mk II controller does not have a minimum current control to switch the pump off where it is running dry. The pump can run dry for days or even weeks without suffering undue harm. It has been assumed that where dry running is not immediately obvious to users, those interested will carry out periodic checks to make sure the pump is in fact pumping water.

MOUNTING THE CONTROLLER

The Sunprimer unit is to be mounted VERTICALLY with CABLE OUTLETS TOWARDS THE BOTTOM on to the rear side of the lower panel support. Although the controller is hermetically sealed against water, sand, and weather conditions generally, it is good practice to place it in as protected an environment as possible, sheltered so far as possible against rain and the direct rays of the sun. Although the Sunprimer is equipped with internal protection mechanisms tending to avoid momentary faulty connections and inversions of polarity, electrical connections should be made very carefully. SHORT CIRCUITING SHOULD BE AVOIDED. NEVER put wires in short circuit to see whether they produce sparks as is sometimes done with motor vehicle batteries. Where the array is placed a long way away from the water source, it is preferable to site the controller separately, appropriately sheltered from heat and the sun's rays, closer to the water source. In case of doubt, please consult your supplier.

WARNING! DO NOT MOUNT THE CONTROLLER DIRECTLY AGAINST PV PANELS. PV panels become hot when exposed to the sun. If the controller is mounted in direct contact with PV panels, the heat from the panels can be transferred through the controller box to the electronics environment of the controller. This may damage the controller. Where the controller is to be placed next to PV panels suitable heat insulation material must be inserted between the PV panel and the controller to avoid passage of heat from the PV panel to the controller.

SELF DIAGNOSTIC CIRCUIT WITH LED LIGHTS - SUNPRIMER MK II

The controller incorporates a self-diagnostic circuit which helps detect faults during installation and maintenance. The LED lights can be seen when the back of the controller box is removed by undoing the four controller box screws. The LED lights are numbered in LOGICAL CIRCUIT ORDER, in order from the top 4,2,1,3

The LED at the top (marked no. 4 on the diagram) lights up when solar voltage greater than about 10V reaches the controller from the panels.

The second LED (marked no. 2 on the diagram) lights up when the main capacitor is charging. This phase lasts about two minutes.

The third LED (no. 3 on the diagram) lights up when the controller sends output voltage greater than about 10V to the pump motor.

The fourth LED (no. 4 on the diagram) lights up when the pump motor stops because the external (float) switch is in OFF mode.

For more information on the LED lights refer to USE OF CONTROLLER DIAGNOSTICS

WARNINGS!

Despite the presence of defence mechanisms built into the Sunprimer units, the manufacturer's guarantee is voided where voltages higher than those prescribed are used, even if such voltages are applied for a very short period of time. Nor does the manufacturer's warranty cover the use of the Sunprimer with power generators not being photovoltaic generators or, where Mk II units are used with batteries, nor does it cover infiltration of water or external overheating whether of solar or other origin. Consult your supplier BEFORE carrying out laboratory testing, for which instructions will be given to interested parties.

THE CONTROLLER ITSELF MAY BE DAMAGED IF VOLTAGES HIGHER THAN THOSE PRESCRIBED ARE USED.

THE PUMP MOTOR WILL BE DAMAGED IF CURRENT IS NOT CUT WHEN THE PUMP IS NOT WORKING.

The product guarantee for Solar Spring pumps and/or Sunprimer controllers does not cover use with generators, even for a very short time, other than PV panels and batteries, whether for testing purposes or otherwise. Nor does the warranty extend to use of the products with voltages and/or currents greater than those specified for normal conditions of use with 24V PV or battery systems or with 48V PV panels systems using 4 panels each of 12V nominal voltage as prescribed. Nor does the warranty cover loss or damage directly or indirectly caused by lightning, water infiltration or externally caused overheating whether of solar or other origin.

For information on lightning protection please return to INSTALLATION INDEX

AVOID leaving coils of surplus electric cable on-line at the well-head or elsewhere, as these have been known to cause secondary inductive current and on rare occasions confuse controller components.

INITIAL PRIMING OF THE PUMP

It is good practice to run the pump with an open head in a recipient for a few minutes to make sure the valves are not stuck, BEFORE proceeding with the installation of the pump. For a drawing, refer to:

1)THE BROWN OF THE SUNPRIMER IS CONNECTED WITH THE BROWN OF THE PUMP. Since the pump motor can run in either direction, the BROWN of the Sunprimer can also be connected to the BLACK of the pump.

2)THE BLUE OF THE SUNPRIMER IS CONNECTED WITH THE BLACK OF THE PUMP, Since the pump motor can run in either direction, the Blue of the Sunprimer can also be connected with the Brown of the pump.

3)THE BLUE OF THE PUMP IS THE EARTH WIRE AND IS TO BE CONNECTED TO EARTH OR WELL INSULATED AND NOT USED, ACCORDING TO APPLICABLE ELECTRICAL NORMS. The blue wire is supplied only to meet the requirements of eventually applicable electrical safety standards. We recommend the earth be used ONLY WHERE it's use cannot be avoided. We believe it INCREASES risk of damage and that it can cause electrogalvanic corrosion phenomena.

HOW TO CONNECT THE SUNPRIMER TO THE PANELS

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII FIRST, TO AVOID RISK OF SHOCK MAKE SURE YOUR ARRAY IS NOT IN OPEN CIRCUIT! Turn it away from the sun, and/or cover it and/or disconnect one wire between two modules.

THEN CONNECT THE SUNPRIMER TO THE MOTOR AS ALREADY DESCRIBED ABOVE.

CABLE IDENTIFICATION SUNPRIMER TO PANELS DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII The larger cable coming out of the bottom of the Sunprimer unit is the inlet cable and it has to be connected to the photovoltaic panels.

It has FOUR WIRES, brown, black, blue, and green-yellow.

WHERE YOU ARE USING FOUR STANDARD PANELS EACH WITH 36 CELLS WITH 12V NOMINAL VOLTAGE AND A WORKING VOLTAGE FROM 14-17V AND AN OPEN CIRCUIT VOLTAGE FROM 18V-21V open circuit voltages can reach 100V.

Panels with 72 cells are now commercialy available. These are usually made by mounting two standard panels each with its own electrical clips in the same frame. Extra attention should in such case be paid to the electrical contacts because of the risk of getting the electrical contacts of each of the two single panels mixed up. Panels with a nominal voltage of 6V can of course also be used provided they are grouped in lots of 24V as prescribed.

SOLAR SPRING IS A 48V NOMINAL SYSTEM!

The four photovoltaic panels are ideally divided into two pairs and the panels of each pair are connected in series with 24V nominal voltage.

Four panel 48V applications with the MK II controller

The POSITIVE of the first pair of panels is connected to the BROWN wire of the Sunprimer.
The NEGATIVE of the first pair of panels is connected to the BLACK wire of the Sunprimer.
The POSITIVE of the second pair of panels is connected to the BLUE wire of the Sunprimer unit. The NEGATIVE of the second pair of panels is connected to the YELLOW-GREEN wire of the Sunprimer.

If the connections are incorrectly made, or if the two pairs of panels are different from one another or exposed to the sun in a different way, the system MAY NOT WORK at all or may not work properly.

If the controllers are not new, it is good practice to check the positions of the internal switches BEFORE proceeding with the installation.

REMINDER

The Sunprimer will start the motor about two minutes after the circuit has been completed.

TWO PANEL 2 x 12V = 24V APPLICATIONS

WHERE YOU ARE USING TWO PANELS with a Mk II controller: DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII

Connect the pump to the controller as for 48V installations. Then first connect together the brown and blue wires of the largest cable coming out of the controller, then connect the two panels in series so as to obtain 24V nominal, then connect the positive of the pair of panels to the combined brown and blue controller wires. Then connect negative of the panels to the yellow/green controller wire.

Carefully insulate the black controller wire, which is not used.

The small float switch cable coming out of the controller is wired as for 48V installations.

General single- or two-pole on-off switches may if considered necessary be fitted on the positive wires (or on the positive and negative wires) of the panels. NEVER, NEVER insert any switch or other control device between the Sunprimer and the pump.

2 X 24V PANEL APPLICATIONS

Please consult the manufacturer

24V BATTERY APPLICATIONS

With the Mk II controller:

DRAWING OF CONNECTIONS FOR THE SUNPRIMER MKII

A general single- or two-pole switch must be fitted to the positive (or to the positive and the negative) of the battery set.

INSERT TWO GOOD QUALITY 3 AMP FUSES (they are not supplied with the pump) in series on the positive (combined brown and blue) wire between the battery set and the controller. Standard motor vehcle fuses are appropriate.

Connect the pump to the controller as for 48V installations.

Then first connect together the brown and blue wires of the largest cable coming out of the controller, then connect the two panels in series so as to obtain 24V nominal, then connect the positive of the pair of the battery set to the combined brown and blue controller wires. Then connect negative of the battery set to the yellow/green controller wire.

Carefully insulate the black controller wire, which is not used.

The small float switch cable coming out of the controller is wired as for 48V isntallations.

The product warranty does not cover damage caused by failure to install an on-off switch or a fuse or by the failure of such switch and fuse to work properly. For extra safety it is recommended that two identical fuses be mounted in series.

To ensure optimum battery duration a good quality automatic system for the control of battery charging and discharging cycles including LVD (Low Voltage Disconnect) should be installed, in particular to avoid excessive or long duration battery discharge conditions. The pump should work only when the battery set is appropriately charged and should be switched off when the set is discharged. The Mk II controller incorporates a device which switches the pump off should the input voltage go down to about 22V. This device should be considered a second line of defence and does not substitute correct manual or automatic management of battery use.

36V BATTERY APPLICATIONS

The Solar Spring pump may be connected WITHOUT CONTROLLER to 36V nominal battery sets in cases where special current surge for start up is not required.

Do not use pumps with 3mm or 2.6mm cams for battery applications without controller. This is because:

a) 3mm pumps need 56V on start up.

b) Commercial fuses are inaccurate and may take some time to react

TWO GOOD QUALITY 3 AMP SAFETY FUSES (they are not supplied with the pump) MUST BE FITTED in series on the positive (combined brown and blue) wire between the battery set and the controller. Standard motor vehcle fuses are appropriate.

The product warranty does not cover damage caused by failure to install an on-off switch or a fuse or by the failure of such switch and fuse to work properly.

Electric connection on start up MUST ALWAYS BE INSTANTANEOUS. If the connection is gradual and progressive, the pump may not start, and in this case high short circuit current conditions would occur with the pump stopped, and this would burn out the fuse.

ALWAYS test with general switch and safety fuse fitted.

Refer to comments under 24V battery systems concnering measures supporting optimum battery duration.

48V BATTERY APPLICATIONS

Do not use pumps with 3mm or 2.6mm cams for battery applications.

This is because:

a) 3mm pumps need 56V on start up.

b) Commercial fuses are inaccurate and may take some time to react

48V battery installations are potentially dangerous in that excessive surge current can be generated unless appropriate steps are taken to avoid risk of demagnetisation of the motor and rapid wear and tear of the motor brushes.

In addition to the general switch and the fuses mentioned for 36V battery installations, 48V battery systems must also have both in actual installations and during eventual tests an electrical resistance OF AT LEAST 0.68 Ohm to act as a limiter. This can be installed by inserting between THE BATTERY AND THE PUMP a 0.68 Ohm 25W resistor. The resistance of the electrical cable itself is sufficient for this purpose provided AT LEAST 50 meters of 2.5mm2 cable or AT LEAST 80 meters of 4.0mm2 cable or AT LEAST 120 meters of 6mm2 cable is installed.

Installation of systems with battery sets over 48V nominal voltage is PROHIBITED.

THREE PANEL APPLICATIONS

Although the system will work more effciently with 4 panels,three panels can also be used.

The panels have to be connected in series as for two panels.

The configuration uses the full power of all three panels, but (just as is the case for use with 2 panels) it does not use the series/parallel switching mechanism. The system used  will therefore operate for fewer hours per day, and the system will operate slightly less efficiently than it would with 4 panels. The starting power is the same as it would be if there were just two panels, but the normal working power is that of three panels.

Conditions of use lie between those for two panels and for four panels. In typical conditions you would use 3mm cam with 4 panels (with the Hyboost) and 2.2mm cam with 2 panels (without the Hyboost). So, you would use in this case a pump with a 2.6mm cam without the Hyboost unit with panels > 70Wp. If the panels were smaller it would be better to use a smaller cam. If you try to use a 3mm cam with Hyboost with 3 panels, you will not harm the pump, but the system is going to start later in the morning, finish earlier in the evening, and it may stop completely when clouds go over. It will therefore pump more water when insolation is good but less water over the whole day. It would therefore globally speaking operate less efficiently.

USE OF HIGH VOLTAGE MODULES IN VERY COLD AREAS

If certain types of high-voltage modules now being introduced to the market are used with the Sunprimer in very cold areas, there is a risk that AT CELL TEMPERATURES below -5 degrees C. it be advisable to install a voltage limiter between the panels and the Sunprimer unit.

Almacenaje del Agua

Capacidad del Tanque de Almacenamiento

Generalmente, se recomienda de 3 a 10 dmas de almacenaje. Esto depende del clima y su patrón de uso. Para uso doméstico en climas nublados, 10 días es lo mínimo. En un clima soleado, esto da un generoso margen de seguridad. Para irrigación profunda de árboles (donde la tierra permanece húmeda por una semana) 3 días pueden ser adecuados, porque la tierra misma provee almacenaje. Para irrigar un jardín, 5 dmas pueden ser lo adecuado. !No puede almacenar demasiada agua!

Ducto del Tanque de Almacenamiento

Coloque su punto normal de descarga mas alto que el fondo de su tanque de almacenamiento, manteniendo así una reserva y así el tanque no se quede completamente seco. Su tanque puede y se secará bajo cualquiera de estas condiciones: un período de poco sol y/o alta demanda de agua, cualquier fuga del ducto, cualquier falla eléctrica, falla de la bomba, descarga accidental del tanque. Coloque una segunda valvula de salida en el nivel inferior de su tanque de almacenamiento, pudiendo así descargar la reserva, en caso de emergencia. Vea la ilustración.

Prevención de Derrame del Tanque de Almacenamiento

Recomendamos el uso de un switch de flotador para evitar un derrame de su tanque. Este accesorio detendrá la bomba cuando el tanque se llene, y luego la reiniciará cuando el nivel baje. Esto conserva el nivel del agua, previene derrames y elimina trabajo de bombeo innecesario. Nuestro controlador permite el uso de un cable pequeño a un switch remoto de flotador.

Advertencia: El switch de flotador debe tener una acción opuesta. En otras palabras, tiene que HACER contacto al subir, de tal manera que APAGUE la bomba. Su distribuidor Solar Spring  puede proveer este accesorio.

Manteniendo la circulación en tanque de almacenamiento o poza

Para reducir el estancamiento (o prevenir congelamiento) con un mínimo desperdicio de agua, instale una válvula justo abajo del nivel de desactivación del switch de flotador, y ajústela para permitir una fuga lenta.

Limpieza de su Suministro de Agua

Es práctica común limpiar o depurar un pozo y el suministro de agua despúes que una instalación o servicio ha sido realizado. Esto se hace usualmente con una solución de cloro o una preparación de cloro seca, vertida sobre el pozo. La bomba distribuirá entonces la solución a través del agua del sistema. Pregunte a su distribuidor local o autoridad de cuidado del ambiente un procedimiento recomendado.

Solar Spring NO será dañada por un tratamiento con dosis normales de cloro.


Index instalación bombas Solar Spring.


Main menu Solar Spring pumps.


Some recommended technologies.


List of attachments to the Model.


Complete index of the Model.


Model Homepage.


Typical list of graphs and drawings.
List of abbreviations used.
List of key words.
Documents for funding applications.


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