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Solar Water Pump

By Jonathanrjpereira (/member/Jonathanrjpereira/)
in Workshop (/workshop/) > Solar (/workshop/solar/projects/) 145,138 593 45 Featured

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By Jonathanrjpereira
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About: I'm an Electronics Engineer who likes to make Doze Lamps, Lumen Powered Thingamajigs, Almighty Brainy Buttons,
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This Instructable will help you to setup a fully functional Solar Water Pumping System. The Solar
Water Pump System can be used for residential water requirements and also for commercial
uses. This system can also be used for irrigation of Agricultural Land. The Solar Panel Array can
also be used without the water pump and can power your house or apartment. The Instructable
will act as a guide in helping you understand the principles required to pump water using solar
energy.

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Solar Power

Photovoltaic(Solar) systems do not use any Fuel. They last for 20+ years. They are cost effective
and are independent from a countries electricity grid. The cost of installation is almost the only
cost. Solar Power is a Green Renewable energy 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 for survival. Inorder to
obtain their daily water requirements we pump our water from wells, dams, rivers, ponds,etc.
Since the system is OFF-Grid, it can always pump water even in an apocalypse.

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Step 1: Economics, Viability & Applications

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

Agriculture

Agriculture in developing nations isn't as efficient as it really should be. One of the main
problems of agriculture is water management. Even developing nations which receive a good
amount of water through rainfall fail to be efficient in the field of agriculture.

The initial investment of solar energy is high. Buts lets put it in a developing nation's
agriculturists/farmers perspective. I have chosen my country India as the 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 an electrical
connection to his/her farm depending on how far the nearest village transformer/power
distributor is from the farm. The farmer then has to buy a pump 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 carried out and there is high variation in the supplied voltage. This causes the pumps
coil and windings to get damaged. This can lead to loss of efficiency or even total damage to the
pump. Farmers who have batteries and inverters for their farms also suffer losses from the
damage caused by voltage fluctuations to the inverters,etc. Therefore the farmer has to also
spend additional revenue in buying 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 of agricultural output. Consider a 10 acre
Cucumber crop plantation which should ideally yield a harvest of approximately 1000kg/day.
Lets say due to a power outage, there is no power supplied to the farm for an entire day. This
would lead to the crop not being watered for a day and could result in significant weight loss of
the cucumbers. In country's such as India, farmers sell vegetables based on weight and hence
any weight loss would result in significant losses. But all these problems can be solved by the
implementation of a Solar Water Pump System.
 In Jonathanrjpereira
Solar Water Pump by India, there are mainly two crops: Kharif(Monsoon
(/member/Jonathanrjpereira/) Follow Crops) & Rabi(Winter Crops).
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of solar energy, I have been able to plant 4 different crops. i.e. 2 additional crops excluding the
Kharif and Rabi crops. I have been able to irrigate a cucumber and watermelon crop in the
middle of summer which also has significantly increased my profits from agriculture, something
I wouldn'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 energy for their sprinkler
systems in their greenhouses. You can check out the graphs above to get an overview of the
efficiency of solar water pump systems. They can also use for artificial lighting to grow saplings. I
have also seen a Solar water pump systems being used in poultry(chicken) applications to cool
the sheds and provide drinking water to the poultry birds.

Household/Domestic Applications

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

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

DIY Solar+Wind House (https://www.instructables.com/id/WindSolar-Powered-House/)

Apartment Solar System (https://www.instructables.com/id/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 Preparedness Contest :)

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Step 2: Parts & Skill List

Standard System

The specifications of the Metal Stand (Angle), Solar Capacity, Pump output have been optimised
to my desired requirements and location. Hence depending on your purpose (Residential,
Commercial or Agricultural) you can either change the output of the system by adding or
subtracting the solar panels inorder to increase or decrease the production of electricity.
Depending on the requirement and capacity of the system, the specifications and quantity of
each part could defer. This Instructable will act as a standard guide which help you in
understanding how to build the Solar Panel Stand, Estimating the Number of Panels & Other
Parts required, Electrical Connections,etc. Hence you may have to buy parts according to your
specific requirements. The main factors involved in choosing parts are: Solar Output, Cable Size,
Pump: Power,voltage,current,speed,flow rate,efficiency and Pipe: Length, Diameter.
 Parts
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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
9. 280W
10. 35V
11. 1960X990X42 (mm)

12. Solar Pump System Controller

13. Max Input Voltage: 238V
14. Output: 3-phase(60-240V0, 3kW)

15. Solar Pump

16. Submersible
17. 3-phase
18. Output:22m^3/hr

19. Cable (Depending on depth of well,etc)

20. 6X Circuit Breakers.
21. 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.

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Step 3: Solar Panel Stand

 The
Solar Water Pump by Solar Panel (/member/Jonathanrjpereira/)
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Follow of I-beams and C-channel that help
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solar panel and keep them inclined at the required angle. In the next couple of steps, the
Instructable will teach you how too setup the metal framework.

Solar Angle

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

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

Inorder to calculate the optimum angle I have used an online calculator which uses the location
of the Solar Panel Array. Solar Panel Angle Calculator (http://solarelectricityhandbook.com/solar-
angle-calculator.html)

Anti-Corrosion Paint

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

3D Models/Layout Diagrams

Inorder to understand the design of the Solar Panel Stand, I have attached the 3D model and
Layout diagram files.

Layout Diagram.dwg
Download(https://content.instructables.com/ORIG/FJO/F9AE/I7MY36F1/FJOF9AEI7MY36F1.dwg)
(https://content.instructables.com/ORIG/FJO/F9AE/I7MY36F1/FJOF9AEI7MY36F1.dwg)

Layout 3D Model Diagram.skp

Download (https://content.instructables.com/ORIG/FTU/6NAN/I7MY36FN/FTU6NANI7MY36FN.skp)
(https://content.instructables.com/ORIG/FTU/6NAN/I7MY36FN/FTU6NANI7MY36FN.skp)

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Step 4: I-Beam Placement & Foundation

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Once you have determined the optimum angle at which the solar panels must be placed at, you
can start building the metal stand. In this step you will need to 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 24.46ft
6. The total height of each I-beam from the ground surface is 11ft.

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Step 5: Adding Lower C-channel

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(https://content instructables com/ORIG/FRM/2SAL/I6DZ0Q7L/FRM2SALI6DZ0Q7L png?

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

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

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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 is specified in the layout diagram. If you do
not wish to add an '11ft+7ft' I-beam design 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-plate of the 11ft I-
beam.
2. Make sure that the 7ft I-beam is perpendicular to the ground surface with the 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.

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Step 7: Adding the Remaining I-beams

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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 first two I-beams.
2. Ensure that the I-beams are perpendicular to the ground surface using a Level Bottle.

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Step 8: Adding Lower C-channel

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

1. Start by attaching either side of one 19.63ft C-channel to the top of the Lower 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.
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Step 9: Adding the Inclined C-channel

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

1. Start by placing one of the C-channel at each end as shown in the layout diagram.
2. Next place one of the C-channel at the centre as shown in the layout diagram.
3. Place one C-channel between the Centre and outermost C-channel on either side.
Weld all the joints using a Welding Machine. Use all necessary welding and safety 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 by bolting it to the
entire structure.

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Step 10: Additional Supporting C-channel

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auto=webp&frame=1&width=1024&fit=bounds&md=460ef28c4d144cabc367b2b44d6fb811)
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In this step you can either use C-channel or Aluminium Box Channel. In this step you will be
using 6x 20.18ft C-channel.

1. Start by placing the C-channel from one side of the structure horizontally such 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.
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Step 11: Adding the Solar Panels

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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 panel datasheet.

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.

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Step 12: Connecting the Solar Panels

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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. Form 3 such strings.

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Step 13: Electrical Connections

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Before connecting the Solar array to the Solar Pump System Controller we must 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 separate CB.(Input of CB)

3. Connect the Negative wire from each string to one end of a separate CB.(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 pump system controller to
the matching numbers on the pump leads. Note: Other combinations may cause reverse
rotation!

9. Some pumps come along with additional connections such as Low Water Probe, Float Switch,
Battery System,etc. Follow the manual instructions for more details.

10. Connect the Water output of the pump to a long pipe and ensure that it is secured properly.
Lower the pump into the water source and switch it on.3

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Step 14: Solar Pump System Controller

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The Solar Pump System controller is the brain of the entire project. It basically regulates 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. Given below are the
descriptions of the LED indicator functions of the controller that I have used.

System(green)

When the LED is Green, the controller is switched on and the power source is present. In low-
power conitions, the light may show even if there is not enough power 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. After the water level
recovers, the pump will restart, but this light will slowly flash until 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 previous off/on cycle.

Tank Full(red)
 Pump
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Step 15: Solar Water Pump

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

The pump basically uses the power supplied from the solar panel array inorder to pump water
from the source. Mostly the pumps come with four wires: 3 wires 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 a suitable pump depending on your
requirement.

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45 Comments

(/member/AmerC2/) AmerC2 (/member/AmerC2/) 2 years ago

Reply / Upvote
Thank you for sharing the knowledge...

 (/member/shivarajuns/)
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shivarajuns (/member/shivarajuns/) 6 years ago
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how much this cost.

can this system power a above ground pump with a well depth of 80-100
1
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deborah.stevenson.98 (/member/deborah.stevenson.98/)
(/member/deborah.stevenson.98/)
6 years ago
on Introduction
Reply / Upvote
Would like to no approximate costs
1
reply
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(/member/SitaraS/) SitaraS (/member/SitaraS/) 6 years ago

on Introduction
Reply / Upvote
By the way, whether this solar panels expensive?

I think solar panel will reduce waste also and good for third world countries, also good for remote
areas. Many of them are near the equator and have plenty of sunlight year round.
http://goo.gl/VH9JRv (http://goo.gl/VH9JRv)
1
reply
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(/member/daenergymon/) daenergymon (/member/daenergymon/) 6 years ago

on Introduction

Reply / Upvote
You could use a lot less solar if you used a made for solar DC direct powered pump like Grunfos,
Dankoff or SunCentric makes.

1
reply
F

(/member/DebRinger300/) DebRinger300 (/member/DebRinger300/) 6 years ago

on Introduction

Reply / Upvote
What Solar Panel Manufacturers, do you purchase from. They are usually expensive here in the USA.
I called a installer here in the Midwest and to solar power a small home starts around $65000, Those
panels are expensive. i.e. > The house isn't worth too much more than that and I could never sell the
home for the value. The cost of electric energy would only cost around half of that budgeted over 20
years.
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(/member/Mjtrinihobby/) Mjtrinihobby (/member/Mjtrinihobby/) 6 years ago

on Introduction

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this is impressive.
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(/member/bogie7129/) bogie7129 (/member/bogie7129/) 6 years ago

on Introduction

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DebRinger300 (https://www.instructables.com/member/DebRinger300/), thus being a DIY page, I
suggest you build your own solar panels. You can buy solar cells on eBay, they are extremely easy to
assemble and by following this instructable you really can do this sort of stuff yourself. If not, you can
find trades people on CraigsList very easily who will do a fine job for you. Good luck.
 (/member/indharachod73/)
Solar Water Pump by Jonathanrjpereira indharachod73
(/member/Jonathanrjpereira/) Follow (/member/indharachod73/) 6 years ago
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best DIY

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(/member/ldistler/) ldistler (/member/ldistler/) 6 years ago

on Introduction
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How close to the water source do the solar panels have to be?

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