Chapter 1

Introduction
to Solar Energy & Solar Water Pumping Systems
Established in 2008, Environment Conservation Society (SwitchON Foundation) is
a multiple award winner, registered non-governmental organisation dedicated to
work towards equitable and sustainable development. Over the past decade we
have completed multiple projects with bilateral organisations and government
agencies , incubated 3 social enterprises, 5 farmer producer companies and over
500 micro enterprises in pursuit of fulfilling our mission.

SwitchON Foundation has worked extensively across Eastern India. Our reach
ranges from West Bengal, Jharkhand, Maharashtra, Madhya Pradesh, Orissa to
North East Indian states. We have positively impacted more than 10,00,000 lives
of people in these regions and reached out to more than 5000 villages through
our work.

Environment Conservation Society (SwitchON Foundation) has prepared this

Handbook for Solar Water Pumping System Technical Training to promote
technical education in renewable energy sector.

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 TOPICS COVERED

Solar Energy

Solar Water Pumping Systems

Applications of Solar Pumps

Efficiency

Advantages and Limitations

Revolution of Solar Pumps over last

decade

Evaluation
Solar Energy

The energy from the sun can be Solar thermal has multiple applications
converted directly in the form of heat like water heating, drying vegetables
or converted into electrical energy and and agricultural products, cooking, etc.
then utilized. Accordingly the solar
energy is classified into solar
thermal and solar photovoltaic (PV).
Solar PV can be considered the only Water heating
form of electricity that can be
generated anytime and anywhere
provided sunshine is available.

Solar photovoltaic Drying

(PV) vegetables

Solar
thermal Agricultural
drying

The earth receives more energy from

the sun in just one hour than the world
uses in a whole year. Photovoltaic (PV)
Technology is a process of generating
electrical energy from solar radiation.
The principle of conversion of solar
energy into electrical energy is based
on the effect called photovoltaic
effect.
Solar Water Pumping Systems

The Solar Pumping System Spare parts and fuel can be difficult or
harnesses the abundantly available expensive to obtain, and the quality of
solar energy to power the pumps to fuel is often poor due to adulteration,
draw water from water bodies. The which leads to frequent maintenance
longer life span gives an edge to requirements.
promote use of this system. Solar water pumps are
The principal means of water cost-effective in the long run and
lifting in the developing world are dependable method for drawing
presently the hand pump for smaller water. It is a highly effective and
demands and the diesel or smarter solution in situations where
electric-driven pump for larger electric supply is unreliable or
quantities. Solar PV pumping can be unavailable; or fuel cost & maintenance
more appropriate than these costs are considerably high. A solar
technologies in many applications. pump is often the best option for
reducing the cost and labor which is
required in arranging the diesel.

Fig-A : Diagrammatic
representation of solar
water pumping system
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ABCDABCD AC ACBH ABCDA
Applications of Solar Pumps

The potential applications of solar pumps include:

Potable water
Irrigation
(individual farmers supply for
or cooperatives) institutions
(traditional niche
market for schools and
health clinics)

Community-sca
le water supply Livestock water
schemes supply
(larger village (individual or
schemes) communal)

Water pumped for irrigation can be used as drinking water also if it is free
from impurities and is potable. Therefore, PV systems for irrigation and drinking
water will be described together.

Access to a safe and clean water supply is one of the primary factors in
improving the health and quality of life in rural communities. In the developing
world, especially in Africa, Asia, and Latin America a lot of people do not have the
option of using clean water for drinking. These remote regions are not connected
to a centralized system for supplying drinking water.

A water pump does not necessary require batteries. To save costs, the
majority of solar powered water pumps can run directly from the solar panels.
Electricity aimed at running the water pump is not stored in batteries, but the
water is instead stored in a water tank or pond. This way the water is stored and
can be used anytime required.

In terms of automation, developed wireless technologies, researches

focused on automatic irrigation with sensors in agricultural systems. The
advantages of using wireless sensor is to reduce wiring and piping costs, and
easier to install and maintenance especially large areas.
Efficiency

The solar pump efficiency as we know is the ratio of output vs input and if
represented in percentage it is known as percentage efficiency. In the case of a
solar pump, the overall efficiency can be split into three parts

● The efficiency of conversion of solar energy into electrical energy.

● The efficiency of the motor drives the pump.
● The efficiency of a pump or the pumping efficiency.

A very narrow band in solar energy spectrum gets converted into electrical
energy, Therefore the efficiency of conversion is very low of order of 12 to 20%
which mainly depends upon the design of the solar panel and the ambient
conditions like temperature, etc.

The motor efficiency is of the order of 80 to 90% again mainly dependent upon
the design and rating of the motor. Finally, we come to pump efficiency which
normally is of the order of 50 to 65%. Adding up all the three efficiencies we come
to the overall efficiency of 47 to 58%.

Area Required and Lifespan of SWP

The area required by the solar The minimum lifespan of

pump depends on its size. For every solar panel is 25 years
1 HP of the solar pump size, the
area required is 100 square feet.
Therefore, a 2 HP solar pump Lifetime of pump is 10-15
required about 200 square feet area years.
to be installed and 5 HP solar pump
requires about 500 square feet area.
Relocation of a solar pump is not The Pump, solar modules
advisable. and pump controller have a
warranty for 5 years.
Advantages and Limitations

One of the major milestones in free water harvesting for a longer

solar water pumping is the elimination of period of time.
dependency on an external power source. Nevertheless, solar water
The solar panels in the pumping system pumps are a one-time investment
coalesce solar irradiation to provide the opportunity with guaranteed rich
electricity required to pump up dividends in store. One of the
groundwater from beneath the ground. major factors why it is promoted on
With a surge in the means of production, large scale India is because it
the prices of solar water pumps have significantly reduces the financial
gone down favorably for users in recent burden of electricity distribution
years. This has propelled users to recover companies who provide subsidized
their investments faster and use the pump power to its agriculture consumers.
for

The limitations of solar pumps and their

corresponding solutions are

Limitations Solutions

Government subsidies and easy bank

High initial investment cost finances are available

Use of VFD and battery can ensure a

constant supply without voltage
Output fluctuation due to varying fluctuations
solar isolation (weather Grid connected solar pumps use grid
dependent) energy to run the pump when solar
energy is not available

Anti-theft technology used in panels

Vandalism and theft and pump controller Bank insurance
is available at minimum premium

Excessive groundwater extraction

because operators face near zero Creation of groundwater recharging
structures and judicious use of solar
marginal-cost of pumping
pumps
groundwater
 The advantages of solar pumps are

1 Operation is independent of grid power and reduces dependency on electric grid

2 Negligible maintenance cost

3 Highly cost-effective in long run against diesel and electric

4 Environment Friendly - No Carbon emissions

5 No fuel cost - uses available free sunlight

6 Helps to increase in agricultural productivity due to consistent water supply

7 Ease of operation as it is highly automatic

Reduces the electricity distribution companies' (DISCOM) financial burden

8 in long term even after providing subsidized pump sets to farmers

Properly installed solar systems are safe and low risk due to low system
9 voltage

Solar pumping systems are modular so can be tailored to current power

10 needs and easily expanded by adding PV panels and accessories
Revolution of Solar Pumps over last decade

Solar water pumping systems

capacity and ability have expanded.
New pump and motor designs have
increased water outputs over the
entire pump range.

Prices of photovoltaic (PV) panels

have dropped exponentially: High
demand for PV modules for grid tied
applications has resulted in massive
economies of scale in production as
well as competition among vendors.
The commodity price of silicon, the
key material, has also dropped
substantially

The number of SWP manufacturers

and suppliers has increased: Old
monopolies have been broken, and
although the technology leaders
continue to innovate, competition is
fierce on price, performance, and
quality.

SWP is being mainstreamed and

awareness is growing: Further
opportunities are rising as intensive
awareness campaigns support and
elaborate on the details of system
performance and savings.

The investment costs associated with

buying solar water pumps has come
down in the past few years.
However, the factors which influence the deployment of a solar water pump are
numerous and include:
● Economic viability
● Access to capital subsidy
● Standardization and quality control of products and service
● Water management
● Environmental regulation at local level

Considering these factors, we can say that solar water pumping can provide
significant environmental and socio-economic benefits at the local and national
levels. At the local level, the technology can present a reliable source of energy in
remote areas, especially areas that are not connected to the electricity grid or
lacking a regular supply of costly liquid fuels. On a national level, solar water
pumping can help stabilize, increase and diversify agricultural production and
stabilize the electricity grid.

Many governments and institutions have realized that Solar Water Pumping
can act as a catalyst to increase farmers’ income and is an extremely viable way to
expand energy access across developing countries and communities. Additionally,
this creates a strong resistance to changes in rainfall patterns. This is the reason
many governments have opted to subsidize the cost of solar pumping, increasing
the pool of shared learning for this emerging technology.
Basic Definitions
Current (I): Power (P):
Current is the rate of flow of electric Power is the rate of electrical energy
charge particles. These charge particles transferred by an electric circuit per
are present in the current. It is defined unit time. It is the product of Current
as the number of charges per unit time and Voltage. Power is represented
passing through a point. Current is with the letter ‘P’.
represented with the letter ‘I’. Formula: P = V x I
SI Unit: Ampere (A) SI Unit: Watt (W)

Voltage (V): Solar Irradiance or Insolation:

Voltage is the potential energy Solar irradiance is the power per unit
difference between two points. It is the area received from the Sun in the
pressure that pushes the charged form of electromagnetic radiation as
particles from one point to another. measured in the wavelength range of
Voltage is represented with the letter the measuring instrument.
‘V’.
SI Unit: Watt per square metre
SI Unit: Volt (V) (W/m2)

Photovoltaic (PV) array:

Resistance (R):
An interconnected system of PV
Resistance is the measure of the modules that function as a single
difficulty of passing an electric current electricity-producing unit. The
through a substance. It explains the modules are assembled as a discrete
relationship between voltage and structure, with common support or
current. With more resistance, less mounting. In smaller systems, an
electricity will flow through the circuit. array can consist of a single module.
Formula: R = V/I
SI Unit: Ohm (Ω) Photovoltaic (PV) cell:
The smallest semiconductor element
Energy (E): within a PV module to perform the
immediate conversion of light into
The energy which is caused by the
electrical energy (direct current
movement of the electrons from one
voltage and current). Also called a
place to another such type of energy
solar cell.
is called electrical energy. In other
words, electrical energy is the work
Photovoltaic (PV)
done by the moving streams of the
electrons or charges. conversion efficiency: The ratio of the
SI Unit: Joule (J) electric power produced by a
photovoltaic device to the power of
the sunlight incident on the device.
Did you KNOW?
Evaluation

What is the drawback of diesel generators is

1
a. High capital cost
b. Availability of fuel
c. Pollution
d. Both b & c

2 Solar Pumps are

a. Eco-friendly
b. Releases pollution
c. High maintenance
d. Both a & c

3 ___________ requires high investment amount

a. Diesel
b. Solar
c. Grid Connected
d. Both a & c

What are the parts that require replacement in Solar PV

4
Pumping system before the end of 25 years?
a. Controller
b. Inverter
c. AC pump
d. Solar Panel
e. Both b & c

5 The life cycle cost of Diesel pumping system is _____________

than Solar PV Pumping system
a. more
b. less
c. Almost same

6 Maintenance cost of diesel pump is less as compared to

solar pump
a. True
b. False
Evaluation

The Solar PV is used to generate electricity anytime and

7
anywhere provided __________ is available.
a. Wind
b. Water
c. Sunshine
d. Silicon
8 The conversion of Solar Energy into Electrical Energy is
based on the principle of
a. Photosynthesis
b. Photovoltaic effect
c. Radiation
d. Heat

9 Thin Film Solar Panels have ________ efficiency than

crystalline modules.
a. More
b. Less
c. Almost equal
d. Cannot compare

10 Which silicon cells are made from an ingot of melted and

recrystallised silicon?
a. Thin film
b. Monocrystalline
c. Polycrystalline
d. None

The manufacturing process of __________ cells is complicated

11
compared to other technologies.
a. Polycrystalline
b. Monocrystalline
c. Thin film
d. None
Evaluation

The most commonly used material for manufacture solar

12
cells is
a. Silicon
b. Iron
c. Wood
d. Glass
13 Traditional solar panels produce __________ electricity as
output.
a. Alternating current
b. Direct current
c. Both a and b
d. None

When two cells are connected in series, _________ of the two

14
cells is added.
a. Power
b. Current
c. Voltage
d. Energy

The current of the two cells is added when they are

15
connected in
a. Series
b. Parallel
c. Combination of series and parallel
d. None

16 Higher power can be obtained using low power solar cells by

making ________ Connection of cells.
a. Parallel
b. Series
c. Combination of series and parallel both
d. None
Answers

1 d. 5 a. 9 b. 13 b.

2 a. 6 b. 10 b. 14 c.

3 b. 7 c. 11 c. 15 b.

4 e. 8 b. 12 a. 16 c.
 Chapter 2

Components of the Solar

Pumping System
TOPICS COVERED

Introduction

Solar PV Cells and Solar Array

Motor-Pump Set

Pump Controller

Inverters

Battery

Module Mounting Structure

Earthing Components

Lightning Arrester

Water Level Sensor

Water Storage Tank

Balance of System

System Configuration
 Introduction

A Solar pumping system consists mainly of Solar Panels, Motor-pump set and a
Controller, interconnected cables, earthing rod and lightning arrester. Sometimes
a water storage tank is also provided depending upon the requirement. This
chapter describes in more detail the major components used in solar pumping
systems.
Solar PV Cells and Solar Array

Solar Cells

The smallest part of the device that converts solar energy into electrical
energy is called a solar cell. Solar cells are in fact large area semiconductor diodes,
which are made by combining silicon material with different impurities. Sand, a base
material for semiconductors, is the most abundantly available raw material in the
world. The ordinary sand (SiO2) is the raw form of silicone.
All photovoltaic (PV) cells consist of two or more thin layers of semiconducting
material, most commonly silicon. When the semiconductor is exposed to light,
electrical charges are generated and these charges are conducted away by metal
contacts as Direct Current (DC). The electrical output from a single cell is small, so
multiple cells are connected together to form a 'string', which produces a higher
direct current.
Power generated by a solar cell depends on its efficiency.
The power generated per unit area is usually in the range of 10 milliWatt/cm 2
to 25 milliWatt/cm2 which corresponds to 10% to 25% cell efficiency.
The maximum area of a single, typical wafer based solar cell is 15 × 15 = 225
2
cm .
With 15% efficiency peak power generated by the solar cells would be
225 cm2 × 15 milliWatt/cm2 = 3.37 Watt.
Nowadays solar panels with efficiency of over 18% are also commercially
available.

Solar PV modules

It is not solar cells alone, but PV

modules that are installed in the field to
supply the power. Solar PV modules are
made of solar cells by connecting many
cells in series and/or parallel. The solar
PV modules are encapsulated properly
so that they can work in outdoor condi-
tions for a very long period of time. The module power output depends on the
power output of individual cells. By choosing appropriately sized cells, modules of
given power rating can be obtained. The power output of the module depends on
the condition under which module is working (radiation, temperature, etc).
Solar PV Modules can be considered as a big solar cell (array of several solar cells
connected in series and parallel) with larger voltage and current output than a single
solar cell.

In the first level of interconnection to increase the power output, cells are connected
to form solar PV modules. These days solar PV modules are available with power
ratings ranging from 3 Watts to 400 Watts. In the second level of interconnection
solar PV modules are connected together in the form of an array to get the power
which is more than a single PV module power output. A PV array can provide us with
power ranging from few Watts to several megawatts.

Higher power can be obtained using low power solar cells by making series and
parallel connections of cells. Series connection is done in order to increase the
output voltage while parallel connection is done in order to increase the current
output. While making a series and parallel connection of cells it is assumed that all
cells have the same characteristics, i.e. they are identical in all aspects like size,
material and efficiency.

PV modules are rated according to their power output, based on a solar irradiance of
1,000 W/m2 at a specified module temperature. Panel output data includes the peak
power (maximum power generated by the panel referred to as watt-peak or Wp),
voltage (volts or V), and current (amps or A). In addition to irradiance, PV module
temperature affects the amount of power produced, with higher temperatures
decreasing power output.

The main global standard for crystalline silicon modules is IEC 61215, which, like
similar standards, is awarded largely based on tests administered to samples of
modules produced. Since modules cannot be tested throughout their 25-year
lifetime, accelerated stress testing is performed. One of the main tests is the
verification of the nominal peak power that a PV module can deliver under standard
testing conditions (STC), which include 1 kW/m2 of solar irradiation perpendicular to
the panels and 25°C of PV cell temperature.

Quality of solar modules, and matching of solar module performance is especially

important in solar pumping systems consisting of large arrays of modules connected
in series, where array performance, hence system performance, depends on the
performance of the weakest module. Even one module with inferior output can have
a devastating effect.
 Classification of Solar Panels

Solar panels are broadly classified based on solar cell technology which is
being used. The ways in which interconnection of solar cells is obtained in the thin
film technology and in a wafer-based technology (Crystalline) are different. In thin
film technology, cells are interconnected during the process of manufacturing of
solar cells. While in wafer-based technology solar cells are manufactured first and
then interconnected to make PV modules.

Thin-film Wafer based

(Crystalline)

Monocrystalline silicon PV panels

These panels are made using cells sliced from a single

cylindrical crystal of silicon. This is the most efficient
photovoltaic technology, typically converting around 15%
of the sun's energy into electricity. The manufacturing
process required to produce monocrystalline silicon is
complicated, resulting in slightly higher costs than other
technologies.

Polycrystalline silicon PV panels

Also sometimes known as multicrystalline cells,

polycrystalline silicon cells are made from cells cut from an
ingot of melted and recrystallised silicon. The ingots are then
saw-cut into very thin wafers and assembled into complete
cells. They are generally cheaper to produce than
monocrystalline cells, due to the simpler manufacturing
process, but they tend to be slightly less efficient, with
average efficiencies of around 12%.
 Thin-film based solar panels

It basically uses less silicon, hence named thin film. It

tends to be less expensive but also has lower efficiency
than crystalline modules. A thin-film solar cell is a
second generation solar cell that is made by depositing
one or more thin layers, or thin film (TF)
of photovoltaic material on a substrate, such as glass,
plastic or metal.

Type Advantage Disadvantage

● Highest efficiency (upto 22% )

● Takes lesser space
Monocrystalline ● Higher durability Higher Cost
● More efficient in warm
weather

● Relatively easier to make

● Cost-effective as compared to
Monocrystalline panels
Efficiency of panels is
Polycrystalline ● Higher temperature
around 15%
coefficient, therefore impact of
temperature on power output
is less

● Lowest space
● Mass production is easier
Thin-film based efficiency
● High temperature and shading
solar panels ● Faster degradation as
have lesser impact on power
compare to mono &
output
poly panels
Solar PV system

Harnessing power from the sun, the PV system consists of a systematic

arrangement of components designed to supply usable electric power for a variety
of applications. Photovoltaic power capacity is measured in watts peak (Wp). When
the PV modules are exposed to sunlight, they generate direct current (DC). An
inverter then converts the DC into alternating current (AC). A small PV system has
capability to power a single home or even an isolated AC or DC based device.

Solar PV systems can be classified based on the end-use application of the

technology. There are two main types of solar PV systems:
● Grid-connected (or grid-tied) solar PV systems
● Off grid (or stand alone) solar PV systems

Off-grid solar PV systems are applicable for areas without a utility grid. Currently,
such solar PV systems are usually installed at isolated sites where the power grid is
far away, such as rural areas or off-shore islands. But they may also be installed
within the city in situations where it is inconvenient or too costly to tap electricity
from the utility grid.
Did you KNOW?
Module Mounting Structures

Various module mounting structure

solutions are available as per
requirement of site / project /
customer. They are designed in order
to maximize yield within a minimum
area. Tailor made structures are also
available to suit project requirements,
which maximize the generation from
solar modules. Most commonly used
are Galvanized Iron structures which
can withstand wind speed upto 150
kmph or as per requirement of site.
Aluminium structures are also seen,
however they are not as strong as GI
structures. Structure designed to
facilitate replacement of modules if
required. Common theft-prevention
measures include:
● use of lock tie nuts
● spraying the owner’s ID with non removable spray paint onto the back of
the panels;
● integrating the solar panels into the mounting structure (non detachable)
● placing the mounting structure out of easy reach by using elevated
structures, fences or floating PV systems.

There are two basic types of mounting structures

● Ground mounted structures which can be single pole mounting or multiple
leg mounted structures
● Rooftop mounting structures. These are installed where ground space is not
available
● Apart from this, floating structures are also noted in various location where
land area is inadequate
Additionally, tracker based mounting structures are installed that rotate the solar
modules in the direction of maximum solar irradiation
Common Features of Module Mounting Structure

Irrespective of various MMS designs, certain components are common in all

designs.

● There will be legs driven into the ground usually concreted to support the
weight of the entire mounting structure. They are called column posts
● There will be rafters which are tilted at an angle suitable to utilize solar
power in the most optimal manner as per design. Usually, the tilt is facing
the equator at an angle equal to the latitude.

Load Carrying Components of Module

Mounting Structure - Column and Rafter

● Rafter will be connected to column post either directly or using Front and
Rear bracings with cleats
● There will be purlins placed on the rafter perpendicular to it. Based on the
number of rows of modules, the number of purlins required are decided.
Modules are placed over the purlins and clamped to the purlins
● Long Bracings - These are supporting GI arms provided for strength and
stability of the structure at various places.

MMS are specified by the number of rows and columns. 4×3 MMS means there
are 4 modules in a row and 3 such rows

Purlin over rafter for module housing

 Ground Mounted Ground-mounted array can be positioned for best
structure exposure to sunlight. This option requires a suitable
ground area and type of soil, however. Typically,
ground-mounted arrays get high exposure to sun, and
they are a comparatively cheap option. The main
advantage of this structure is ease of installation. Also it is
easier to clean the panels.

Pole-mounted structure This is one of the most popular installation methods for
solar PV power in areas where ground- or roof mounting is
not suitable is to mount the array on poles. To increase the
number of panels, more poles shall be created adjacent to
the solar pump.
Installing a pole-mounted solar PV array is a more detailed
operation than other forms of mounting, and the
structural loading on a pole-mounted array must be
determined in advance. Every manufacturer has different
designs and sizes available.

Roof Mounted structure A roof-mounted array can be installed on a suitable

existing structure (such as a shed). This is the standard
mounting option for urban grid-connected solar PV
systems. The size of the array that’s possible is limited by
the available installation area on the roof.
This is not very popular in solar pumping systems, but can
save cost of mounting structures, if the roof is readily
available adjacent to the solar pump. Again, cleaning of
panels can become challenging if access to the roof is
difficult.

Overhead Tank This is popularly used in drinking water applications where

structure the fewer number of solar panels are available. Storage
tank is to be mounted on height to create water pressure.
Existing structure of overhead tanks can be utilized to
support the panels, this reduces the space requirement.
But it becomes challenging to clean the solar panels.

The fixed installation of solar panels on a rigid structure is the cheapest, most
reliable and most common method. Metal supports that are pile-driven into the
ground are generally recommended for larger systems. They make the utilization of
concrete foundations redundant and save labor and material cost. However, in
developing countries, simple concrete foundations are often used for smaller
installations and represent an appropriate solution, provided that static
requirements are met.
Fixed Tilt single column MMS
A single supporting column concreted to the
ground holds the entire MMS. Hence the
rafters need to be supported like a grid from
beneath and the entire rafter grid will have
to be fastened to the column post.

Seasonal Tilt single column MMS

In seasonal tilt the only difference is that

instead of fastening the rafter grid to column
post, a semi-circular GI plate with holes are
provided to fasten the rafter at multiple angles
with column based on seasons.

Usually, the seasonal tilting is done manually

Fixed Tilt multi column MMS

In multi-column MMS there is one column

leg to support each rafter (or two column
legs to support each rafter if the number of
rows are higher). Since legs support
individual rafters, rafters need not be
interconnected as a grid. Purlins can be
placed perpendicular to the rafters over it.

Seasonal tilt multi column MMS

In each rafter the seasonal tilt

option is provided with a GI
semi-circular plate with holes for
specific angles.
Single Axis Tracker

These rotate the array in the

east-west axis only, following the
sun at a fixed angle of elevation
from the time it rises in the east
until it sets in the west. Installing a
single-axis tracker for your solar PV
array results in higher power
output in the mornings and
evenings. Decision to install tracker
is purely economic based on the One of the single axis mechanisms
trade-off of additional energy
available Vs cost of tracker.

Double Axis Tracker

These rotate the array on an east-west axis

and also can tilt it on a second axis in south-
north direction, so that it is angled directly
towards the sun at all parts of the day. The
strength of dual-axis trackers is their ability to
maximize energy production. A motor
controlled by a programmed microcontroller,
which actuates a pneumatic actuator that can
move the entire rafter-purlin grid mounted on
a single column, in both axes.

Since they have a higher degree of mechanical complexity, they are expensive and
require more maintenance during their lifetime. Hence they are seldom used in
Solar pump installations.
Azimuth Angle
The angle between true south and the point on the horizon
directly below the sun. Azimuth angle of the solar module is
an indicator of alignment of the module with respect to
(true) south. For modules facing (true) south this angle is 0°
and for module facing (true) north this angle is +/- 180
The sun’s apparent location east and west of true south is
called azimuth, which is measured in degrees in east or
west of true south. Since there are 360° and 24 hours, sun
appears to move 15° in azimuth each hour. When the sun is
true south in the sky at 0 degrees azimuth, it will be at its
highest altitude for that day. This time is called solar noon.

On fall and spring equinoxes, the sun rises at the due east of south and sets at the
due west of south. Whereas in winter months it rises at the south of true east and
sets at the south of true west; in summer months it appears to rise north of true
east and set north of true west. In winter, the sun appears to be at its lowest in the
southern sky. So, they must be tilted up from horizontal at an angle 15° greater than
the latitude. Conversely, if a PV system is going to be used mostly in summer, where
the sun will be highest in the southern sky, it may be most advantageous to
optimize the performance of the panel by tilting it 15° less than the latitude.

Zenith Angle
Zenith Angle is the angle between the sun’s rays and the
vertical. The Zenith angle is calculated based on the angle of
incidence of the sun with the perpendicular line from the
round surface. The zenith angle varies throughout the day.

Tilt Angle
Tilt Angle is also known as Elevation Angle is the angle between the horizontal
ground and the solar panel. As the sun changes its position every hour due to the
rotation of earth, there is no exact direction towards which the panels can always be
faced. So, the system design should be in such a way that solar collection is
optimised by positioning the array to take full advantage of the maximum amount
of sunlight available at a particular region.
The panels need to be facing south since the installation is being done in the
northern hemisphere. In case of the southern hemisphere, the solar modules
should be installed facing the north direction.

Due to the rotation of earth about the tilted axis, the sun appears at different
altitudes above the horizon at solar-noon throughout the year. The latitude of the
location tells us about the altitude at which the sun appears above the horizon.
When the tilt angle or the angle at which the panels are elevated is equal to latitude,
the insolation is optimized. In the northern hemisphere, the sun travels towards the
southern sky.

In India, the tilt angle usually varies between 17° to 23°, based on the latitude of the
installation location.

Trackers for solar panels (Optional component)

A solar tracker is a device that orients solar panels toward the Sun. Trackers are
used to minimize the angle of incidence between the sunlight and a solar panel.
The purpose of a tracking mechanism is to follow the Sun as it moves across the
sky. The amount of solar energy available for collection from the direct beam is
the amount of light intercepted by the panel. Or to put it in another way, the
energy intercepted is equivalent to the area of the panel surface which receives
perpendicular direct beams of sunlight.
Motor-Pump Set

Water pumps are driven by electrical motors, which convert electrical

energy (produced, in the case of solar pumps, by PV panels) into mechanical
energy.

We can say that the pump is the heart of the Solar Pumping system. Primarily they
are classified based on their placement (underwater and above the water). These
pumps are surface and submersible pumps. These pumps can be further
classified into categories depending upon the type of motor used in the pump.
Most motors typically run on either direct current (DC), where the electrical flow
does not switch direction periodically in the wires; or alternating current (AC),
where it does. In solar pumping systems it is advisable to use the term
‘Motor-Pump set’ instead of calling it only pump or motor.

Based on various applications and parameters appropriate motor pump sets can
be selected for the solar pumping system. But before studying these
combinations it is important to understand the concepts which broadly classify
the pumps and motors to avoid any confusion.

Submersible Pumps

A solar submersible pump is located deep below the ground level;

whenever the suction head is beyond a depth of 10 metres. In a region where the
water table keeps on dipping radically, installation of the submersible pump
within the water table in a bore well is more practical. The pump remains
submerged under the water.
The installation of a submersible pump
often requires that a bore-well is dug
which can be a costly undertaking but
without which the water cannot be taken
out. Sometimes, a submersible pump can
also be located inside water bodies like
lakes, canals, etc.

● Submersible pumps as their name

portrays, are completely submerged in
the water source.
● One important thing is the efficiency
of submersible pumps as water
pressure naturally forces water into a
submerged pump rather than utilizing
energy to do so.
● Being submerged all the time, submersible pumps do not require manual
priming, which can easily become a very time consuming chore.
● Surface mounted pumps are also known to be much louder, and since it is on
the surface, it just looks out of place

When the pump is immersed into the water, air won’t be available around the
motor to provide cooling. Therefore, oil and water are used as coolants.

Oil filled Motors

● Oil is served as a coolant in oil filled motors.

● Oil filled submersible pumps are mostly used in water lifting in wells,
irrigation in farmland, hills, residential etc.
● These can be very advantageous if used in cool areas as oil cannot be frozen.
● They also have better lubricating conditions and give long service life.
● These are to be avoided where the quality of water pumped is important, as
the oil may leak sometimes.

Water Filled Motors

● Water filled motors use water as cooling material and is mostly used in
industrial, residential, farming etc.
● Water leaks do not pollute the water source and can be fixed for operating
beneath the water.
● The service life of water filled pumps is shorter than oil filled pumps.
Components of Submersible Pumps

1. Stator

In a submersible pump, the stator is a

stainless steel cylindrical metal tube with
stampings on the internal side acting as the outer
frame. The main function is to carry an alternating
magnetic field. Slots are punched on the inner side
of the stampings. The stator is wound with either
single phase or three phase coil windings. When
power is supplied through the stator, it generates a
magnetic field around the stator to drive the rotor.

2. Rotor

The rotor is the rotating electrical

component; consisting of a group of
electromagnets aligned around a
cylinder with the poles facing towards
the stator poles. The rotor is located
within the stator and is mounted to the
motor’s shaft, which is connected to the
pump shaft.
 3. Air gap

The space between the rotor magnets and stator magnets is called the air
gap. The air gap is an annular space to permit the magnetic lines of force to transmit
back and forth between the rotor and stator. The air gap is maintained on both ends
of the rotor by an inboard bearing and outboard bearing.

4. Bearings

The function of the bearing is to reduce

friction between the moving parts and allow
smoother rotation, reducing the energy
consumption. Submersible pumps use thrust
bearings instead of ball and roller bearings. There are
no moving parts within the bearing, so if the motor is
controlled correctly there are fewer risks of parts
failure. They transmit the rotating shaft’s axial load to
the frame of the motor.

5. Seals

Mechanical seals improve the efficiency

of submersible pumps. In a submersible pump, the
motor is hermetically sealed and close-coupled onto
the pump body. It protects the bearings and the motor
with a vertical shaft that is submerged in the pumped
liquid. Water and oil seals are also used for submersible
pumps.

6. Impellers

An impeller is a rotating iron or steel disc

with vanes that transfer energy from the motor
that drives the pump to the fluid being pumped
by accelerating the fluid radially outwards from
the centre of rotation. Submersible pumps are
multistage pumps, where a series of impellers
are connected to the rotating shaft which is
driven by the motor.
The water is pulled in through the intake, and as it enters the eye of the impeller,
they are thrown out due to the action due to centrifugal force. As a result, water
gains both kinetic and pressure energy. The water is carried to the next impeller
efficiently with the help of a stationary device called a diffuser, connected right
next to the impeller. The diffuser deflects the impeller water and makes it ready
for the next impeller stage. This series connection of impellers multiplies the
pressure. This is why submersible pumps can pump water to greater heights.

Surface Pumps

A surface pump is located in the open by the side of a water source, for example
an open well, lake or canal. The pump remains out of the water, and generally the
motor and the pump can be seen separately. Surface pumps are usually easy to
install and maintain.

Surface pumps can also be feasible options in cases where the water table is
within a depth of up to 10 meters and an open well is available.

These pumps are not they’re not situated in the water, meaning they are very
easily accessible if anything were to fail or need replacing. The pumps are usually
contained within a pump housing to protect them from the elements. The pumps
have filter baskets and an inspection cover.

Solar water pumping is becoming increasingly relevant in many applications,

especially for livestock watering, drip irrigation, remote houses and where water is
needed but no AC power is available. Pumping from remote bores or dams can
become very expensive using generators, and the cost of running power lines is
sometimes not feasible. In such situations, solar power is ideal comparing to
diesel generators.
● Allows easy access to the pump itself,
but because of the environment, they
may require access more often. Winter
storms can really affect the productivity
and results of a surface pump because
it is not below the freezing line, which
can cause trapped water to expand
inside the pump which could lead to
several problems like freezing.
● Flash floods, wildlife, and ● Another disadvantage is the
thunderstorms can also be a great risk amount of energy surface
because surface mounted pumps are pumps use; the water must first
not as shielded from their be moved up out of a water
surroundings, unlike submersible source by a suction force before
pumps. it can actually reach the pump,
this process requires a lot more
power than an apparatus that
already has the water readily
available.

Components of Surface Pumps

 1. Stator / Armature Coil

The stator is composed of iron plates

wrapped by copper winding located
around the main axis. This copper is
connected to a current source. The
function of the stator is to generate a
magnetic field around the rotor. When the
current is passed through the winding, a
magnetic force is induced in the stator. A
motor generally has three stator coils. The
more the number of coils, the greater the
magnetism generated, and faster the
pump rotates and faster water is pumped
out. For simple electric motors, the stator
is replaced using a permanent magnet.

2. Rotor Coil

Rotor resembles a stator, except that

the rotor is a dynamic copper wire as the
coil is attached with the main shaft or
main axle of the motor that will rotate.
The more the number of turns on the
rotor the greater the resulting spin.
Commonly, a chopper with a small
diameter. It aims to make the number of
windings more even if it requires a large
wire length. The wound end will be
connected to another rotor located at
the end of the main shaft.

3. Main Shaft

The main shaft is a rust-proof, durable

and temperature resistant aluminium rod
that extends to provide attachment for
the rotor coil and a drive pulley.
 4.Brush

A copper brush connects the current source with a coil

rotor. This brush is attached to a small rotor located at
the end of the main shaft. The flow of current is
maintained in the same direction using the brushes, even
though the rotor rotates, thus the rotation is synchronous
and continuous. The structure is supported by a spring
located behind the copper brush, which ensures it always
hits the brush even when spinning at high speed. A
simple electric motor should be equipped with two
brushes. The brushes need to be checked regularly for
wear and tear, and replaced during servicing if required.

5 . Bearing

The function of the bearing is to produce

rotation. A bearing between the shaft surface
and the motor housing reduces friction and
ensures free movement. Bearings are generally
made from aluminum, which has less friction
and does not inhibit motor rotation.

6 . Pulley Drive

The pulley drive is located at the outer end of the main

shaft, and transfers motor rotation to other
components. This acts like a gear, conducting the
rotation through the pump.

7 . Motor Housing

The electric motor is covered by an iron

plate that protects the parts of the electric
motor. In addition, motor housing also
controls the trembling effect of the motor
which is rotating at very high speed.
Classification of pump-motor set based on current

AC Pumps and Motors

An AC pump has a motor which operates on alternating current (AC). Direct current
generated by solar panels or batteries is converted to AC by an
inverter-cum-controller, and is then passed on to the AC pump motor. The
conversion from DC to AC leads to small losses in power between the points of
generation and consumption.

Advantages
● Low upfront cost compared to DC pumps.
● Easy to set up, installation and availability of maintenance and repair services
locally.

Disadvantages
● Low efficiency and water output compared with a DC pump.
● Additional inverter is required.
An AC electric motor is a type of electric motor operating with an alternating current
(AC) voltage source. This AC electric motor can be distinguished by its resources as
follows:

● Synchronous motor, is an AC motor working at a fixed speed at a certain

frequency system. This motor has a low initial torque, and therefore
synchronous motors are suitable for low-load initial use, such as air
compressors, frequency changes and motor generators. Synchronous motors
are able to improve the system power factor, so it is often used on systems that
use a lot of electricity.

● Induction motor is an AC powered motor that works based on induction

magnetic material between rotor and stator.
 DC Pumps and Motors

A DC Pump has a motor which operates on direct current (DC). Solar Panels
generate DC current, which is then passed on to the DC pump motor through a
controller. Since the current from solar panels or batteries is directly used, and no
conversion to AC is required, there is no/little loss of power between generation and
consumption. However, it should be noted that the current should not have to travel
a long distance before being fed to the pump in order to minimize the losses.

Advantages
● Approximately 10% higher water discharge as compared to an AC pump.
● No need for an inverter between the solar PV panels and the pump

Disadvantages
● High upfront costs.
● Lack of repair and maintenance services in rural and remote locations.

Direct current electric motor is a type of electric motor that operates with a direct
current DC voltage source (DC). DC motors can be distinguished again based on the
following resources.

● Separately Excited Motor is a type of DC motor where the field current source
is supplied from a separate source other than the electric motor coil, so the
DC electric motor is called a separate DC power source (separately excited).

● Self Excited motor is a type of DC motor where the field current source is
supplied from the same source as the electric motor coil, so the DC electric
motor is called a self-excited DC power motor.

DC motors are appealing for solar pumping because PV modules producing direct
current can be directly coupled to the motor with limited power conditioning. This
makes them an economical option for systems with low water demand and a short
cable distance between the PV panel array and the motor. For long-distance cabling,
however, low-voltage DC motors are not suitable because of power loss in the cable.
AC motors can be used in larger solar pumping systems, although they require a
DC/AC inverter.

The most suitable pump and motor type for any situation should be determined
based on manufacturers’ catalogues and motor pump manuals, and specifically on
pump/motor pair performance curves (characterized to the IEC 62253 standard) to
ensure that the pump/motor pair can deliver the required flow against the total
dynamic head
Standalone (off-grid) and Grid-connected
(on-grid) solar pumps

Standalone pumps are not connected to the main electrical grid, and the pump
completely runs on the energy harnessed from the solar panels connected to the
pump. A battery might be used to store the energy generated and pump out the
water when sunlight is not available.

Grid connected solar pumps are becoming popular gradually. Here, the pump can
switch it’s source of power from solar energy to grid connected electricity in the
absence of sunlight. Also, excess energy produced by the solar panels during the day
can be directed to the grid, which is sold and acts as a source of extra income for the
pump owners.
Pump Controller

Solar pump controller is a device installed between the panels and the pump that
allows the solar pump to regulate the intermittent sunshine to provide desired
output. The controller box contains the pump controller as well as various electronic
components, which provide electronic protection against dry run operation, over
and under voltage, short circuit and reverse polarity. The electronics normally
include an inverter, power conditioner or pump controller, controls/protections and
water sensors.

The main function of the pump controller are:

1. to match the output power that the pump receives with the input power
available from the solar panels.
2. to protect the pump against various faults which may damage the pump, thus
increasing its lifetime and reducing the need for maintenance.
3. to control the water level sensor and remote monitoring system.

Input voltage of the solar pump motors can be AC (alternating current) or DC

(direct current). If an AC pump is used, the direct current from the solar panels is
converted into alternating current using an inverter. The supported power range
of inverters can be adjusted according to size of irrigation systems. However, the
panel and inverters must be sized accordingly to accommodate the inrush
characteristic of an AC motor.

The “pump controller” in the DC powered pump system would typically include a
maximum power point tracker (MPPT) to ensure that the solar array is delivering
power at its peak power point. The “pump
 controller” in the AC powered pump system would include an MPPT as well as a
DC to AC inverter in order to operate the ac electric motor which is part of the
water pump. In larger systems these should be three-phase inverters to operate
three-phase motors.
A DC-DC Convertor is used to match the voltage output from the solar PV modules
with that of the voltage required for operating the pump, preventing overvoltage.

The inverter and controller must have IP54 protection or must be housed in a
cabinet having IP54 protection to protect the controller from dust and water.

Hybrid controllers are used sometimes too, when grid connected solar pumps are
used. These controllers switch between solar power and prid power intelligently.

The following Parameters are noted in the controller by the manufacturer

● Manufacturer's name, logo or trade-mark;
● Model and Serial Number;
● Voltage Range;
● Power Range in kW for Controller; and
● Current rating (A)
Maximum Power Point Tracker (MPPT)

The output of the Solar panel is variable as it depends on the temperature and
irradiance. The MPPT charge controller is a smart device that compares the panel
output with the pump voltage and then determines the most optimum panel output
in order to maximize the water output. The use of these solar charge controllers
increases the efficiency of the whole system. The MPPT tracks the I mpp and Vmpp every
5 seconds and forces the PV modules to operate at those voltages to get the
maximum power output.

The pump rotational speed can be regulated according to the variation of solar
irradiation: When the solar radiation intensity reaches the peak, the pump runs at
its rated speed, and the output power is close to the maximum power of the PV
array. When the solar radiation intensity is relatively weak, the pump runs with a
lower speed based on the MPPT algorithm. When the pump speed is so low that
no water flow can be available, the system stops working.
Variable Frequency Drive (VFD)

A solar pump controller matches the variable power provided by the solar array.
Variable speed control ensures there is no in-rush or surge of energy during the
pump/motor start-up, helping to eliminate wear on the motor and pumping system.

Normally, when there is a demand for water and when solar power is available.
Whenever the solar pump controller detects a need for water, the controller always
“ramps up” the motor speed while gradually increasing motor voltage, resulting in a
cooler motor and lower start-up current compared to conventional water systems.
Due to the controller’s soft-start feature this will not harm the motor. VFD provides
constant torque for a wide range of intensity of sunlight - morning till evening. So
water will be continuously pumped from morning till evening.

The VFD basically changes the frequency of the system. For a constant frequency,
the voltage is also constant. So, if the frequency of the system reduces then the
voltage needs to be reduced subsequently as well. The frequency is generally noted
in Rotations per Minute or RPM.

In case 3 phase connection is used, VFD is needed as the starting torque is high and
the initial voltage needs to be controlled. For single phase connection (for 1 or 2 HP
pumps), VFD is not required, instead capacitor is used. In a single phase connection,
all the connections need to be disconnected together to prevent oversupply.
Advantages of using a VFD

Reduce energy consumption

A VFD with variable torque load can be used in water pumps to reduce the
input energy requirement. As described by the affinity law, the power
consumption of the pump can drop significantly with a small drop in the speed of
the motor. Provided that the flowrate is acceptable, running a pump at a lower
speed over a long period of time can deliver considerable energy saving. The VFD
can reduce the operating speed of the motor, allowing a smaller PV array to be
installed to deliver the pumping requirement.
The ability of the VFD to control pump operation also means that in case of cloudy
conditions or times of reduced solar irradiation, the motor could still run to
deliver pumping work.

Reducing surge current at motor start-up

VFD can provide a reduced starting voltage to the motor windings, thus reducing
the starting current of the motor and giving it time to gain momentum before the
full load is supplied with power. The VFD also allows the user to start and stop the
pump at a controlled, programmable rate (e.g. accelerate or decelerate over a
time period) while putting minimum strain on the motor. This reduces the
mechanical wear of the motor as well as the startup loads on the PV array .

Remote Monitoring System

Remote monitoring system or RMS is installed in the pump controller to record

the electricity generated by the solar modules etc and sends it directly online,
which is used to monitor the system performance of the solar modules and the
pump.

The RMS is placed in the controller box and connected to the pump controller
through the wires.

The data can be collected through various methods:

● A recharged SIM card inserted in the RMS
● USB drive inserted in the RMS
● SD Card installed in the RMS
Inverter

Solar generators always provide DC

current. Most electric motors of solar
water pumps are powered by direct
current (DC). Since DC motors usually
have a higher efficiency than AC motors
of a similar size, they tend to be preferred
by solar pump manufacturers

A power inverter or inverter is a system

that converts Direct Current (or DC) to an
alternating current (or AC). A solar panel
produces DC current, batteries also
generate DC current, but most systems
we use in our daily lives use AC current.
Inverters also have transformers to
convert DC output voltage to any AC
output voltage. Depending on the type of
system (grid or off-grid) various types of
inverters are available.

Water-filled brushless DC motors in particular are gaining importance because

they are maintenance-free and are not affected by frequent starts/stops that are
typical of solar-powered systems. Some solar pumps are still equipped with
comparably cheap brushed DC motors. The main disadvantage of brushed motors
is that brushes are subject to wear and tear and need to be replaced at regular
intervals (approximately every two years). DC motors are mainly used for small to
medium-sized irrigation schemes, while AC motors are gaining importance in
applications where higher output/head combinations are required.

The controller has to have an inverter if the pump is AC. Innovations in DC/AC
inverter technology have led to the development of specially designed pump
inverters that can drive conventional AC motors. Non-compatible inverter/motor
combinations may reduce the expected lifetime of the conventional AC motor.
Therefore, well matched and tested controller/motor combinations are
recommended to increase system reliability.
Types of Solar Pump Inverters

String Inverters

Solar panels are installed in rows, each on a string.

And multiple strings are connected to one string
inverter. Each string carries the DC power the solar
panels produce to the string inverter where it is
converted into usable AC power consumed as
electricity. And based on the size of the installation,
you may have several string inverters each receiving
DC from a few strings.

Central Inverters

They are similar to string inverters but they are much

larger and are able to support more strings of panels.
Instead of string running directly to the inverter, as with
string models, the string is connected together in a
common combiner box, which runs the DC power to the
central inverter where it is the converter to AC power. It
requires fewer component connections, but requires a pad
and combiner box. And central inverters are also best
suited for large installations with consistent production
across the array.

Micro Inverters

They have also become a popular choice for residential

and commercial installations. Like power optimizers, they
are module-level electronics so one is installed on each
panel. And while, unlike power optimizers which don’t
convert, micro inverters convert DC power to AC right at
the panel and so don’t require a string inverter. It also
monitors the performance of each individual panel,
although string inverters show the performance of each
string. It makes micro inverters good for installations with
shading issues or with panels on multiple panels facing
various directions.
 Battery Based Inverter

With the growth of solar and storage, battery-based inverters are becoming
increasingly imperative. They are basically directional in nature, including both a
battery charger and an inverter. It requires a battery to operate. They may be ground
interactive, standalone grid-tied or off-grid, based on their UL rating and design. The
main benefit of the inverter is that they provide for continuous operation or critical
loads irrespective of the presence or condition of the grid.

1. Stand-alone inverters, used in isolated systems where the inverter draws its
DC energy from batteries charged by photovoltaic arrays. Many stand-alone
inverters also incorporate integral battery chargers to replenish the battery
from an AC source, when available. Normally these do not interface in any way
with the utility grid, and as such, are not required to have anti-islanding
protection.
2. Grid-tie inverters, which match phase with a utility-supplied sine wave. Grid-tie
inverters are designed to shut down automatically upon loss of utility supply, for
safety reasons. They do not provide backup power during utility outages.
3. Battery backup inverters are special inverters which are designed to draw
energy from a battery, manage the battery charge via an onboard charger, and
export excess energy to the utility grid. These inverters are capable of supplying
AC energy to selected loads during a utility outage, and are required to have
anti-islanding protection.
4. Intelligent hybrid inverters, manage photovoltaic arrays, battery storage and
utility grid, which are all coupled directly to the unit. These modern all-in-one
systems are usually highly versatile and can be used for grid-tie, stand-alone or
backup applications but their primary function is self-consumption with the use
of storage.
Sizing of Inverter

Sizing of the inverter depends on the wattage of appliances connected to it. The
input rating of the inverter should never be lower than the total wattages of the
appliances. Also it should have the same nominal input voltage as that of the
battery setup. It is always better to have inverter wattage about 20-25% more than
that of the appliances connected. This is specifically essential if the appliances
connected have compressors or motors (like AC, refrigerator, pumps, etc), which
draw high starting current. The minimum continuous watt rating of a solar water
pump inverter is required to start off a submersible water pump without
additional loads.

Most inverters available in the market are rated in Kilo Volt Ampere/Volt Ampere
or kVA/VA.

In ideal situations, (power factor of 1) 1 VA = 1 Watt.

But in real power factor it varies from 0.85 to 0.99.
So one can assume 1.18 VA = 1 Watt.
So if you have a setup where the total wattage of the system = 1000 Watts

It means your inverter size required is more than 1180 VA or 1.18 kVA (add some
extra to be on a safer side).

The higher the VA of an inverter, more is the number of appliances it can support,
but more costly it would be. So it is important to size it right while buying. Also for
a grid-tied system, as there are no batteries connected, the size or VA of the
inverter should match the wattage of the PV panel for efficient and safe operation.
 Battery

During optimum sunlight periods

(late morning to late afternoon on
bright sunny days) the pump
operates at or near 100 percent
efficiency with maximum water
flow. However, during early
morning and late afternoon,
pump efficiency may drop by as
much as 25% or more under these
low-light conditions. During
cloudy days, pump efficiency will
drop off even more.

Batteries can be used to store excess electrical energy produced during the peak
sunlight hours and used during the non-peak hours and night to pump out water.
The excess energy from the solar panels can be used to charge the battery, and
used for running a small appliance like light or charging.

In a battery, two or more electrochemical cells enclosed in a container and

electrically interconnected in an appropriate series/parallel arrangement to provide
the required operating voltage and current levels. The battery capacity is the
maximum total electrical charge, expressed in ampere-hours, which a battery can
deliver to a load under a specific set of conditions. The battery available capacity is
defined as the total maximum charge, expressed in ampere-hours, that can be
withdrawn from a cell or battery under a specific set of operating conditions
including discharge rate, temperature, initial state of charge, age, and cut-off
voltage. The period during which a cell or battery is capable of operating above a
specified capacity or efficiency performance level is known as battery life. Life may
be measured in cycles and/or years, depending on the type of service for which the
cell or battery is intended.

DC produced by solar panels can be connected either directly to batteries or

through solar hybrid inverters. This system includes solar modules, inverters and
batteries.
Types of Batteries used in Solar Pump

Lead Acid

The common automobile batteries in which the

electrodes are grids of metallic lead-containing lead
oxides that change in composition during charging and
discharging. The electrolyte is diluted sulfuric acid. The
new AGM Battery technology has made a huge impact
on lead-acid batteries, making it one of the best
batteries to use in solar electric systems.

Industrial-type batteries can last as long as 20 years

with moderate care, and even standard deep cycle
batteries, such as the golf car type, should last 3-5
years. Intermediate batteries, such as the S460 and
other batteries made by Surrette should last 7 to 12
years.

Lithium Ion Based

Lithium batteries have many advantages over

traditional battery types. They have an extremely long
cycle life and high discharge and recharge rates.

Nickel Cadmium

They are alkaline storage batteries in which the

positive active material is nickel oxide and the negative
contains cadmium. They are very expensive, and even
more expensive to dispose of. Their efficiency is
65-80%.

Nickel Iron

Alkaline-type electric cells using potassium hydroxide

as the electrolyte and anodes of steel wool substrate
with active iron material and cathodes of nickel plated
steel wool substrate with active nickel material. They
have a very long life, over 10 years, however, their
efficiency is low, as much as 50%.
Sizing of PV System Batteries

If you are not going for a grid connected system or a direct connected system, you
need batteries to store the energy generated using PV panels. Along with sizing of
the PV panel, it is important to size the batteries as well. Because if you purchase
more batteries then they will not get fully charged, if you buy fewer batteries, you
may not be able to get the maximum benefit out of the solar panel.

Most big PV systems use deep cycle (or deep discharge) batteries that are designed
to discharge to low energy levels and also to recharge rapidly. These are typically
lead acid batteries that may or may not require maintenance.

Batteries have energy storage ratings mentioned in Amp-hour (Ah) or

milli-Amp-hour (mAh). They also have a nominal voltage that they generate (typically
deep discharge batteries are 12V batteries). To calculate the total energy a battery
can store you can use following formula:

Units or kWh = (Volt x Ah) ÷1000 or (Volt x mAh) ÷1000000

Batteries should be sized in such a way that the units of energy generated by the PV
system should be equal to the number we have calculated above.

Now, you want the battery bank to last three days without recharging and that you
use 0.6 kWh per day.

Energy we need from the batteries = 0.6 x 3 = 1.8 kWh

Converting this to Ah we have to divide by the voltage of your system, which can be
12, 24 or 48 V for commercial application.

If we choose to use 48V,

the minimum AH capacity = 1800/48 = 37.5 Ah

Now if you divide by your battery's rating you find the number of batteries you must
use.

Batteries are usually not recommended for solar-powered livestock watering

systems because they reduce the overall efficiency of the system and add to the
maintenance and cost. Instead of storing electricity in batteries, it is generally
simpler and more economical to install 3 to 10 days’ worth of water storage.
C10 Solar Battery

Let us just take an example of 150 Ah battery

● A 150 Ah battery at C20, will last for 20 hours on a load of 7.5 A.
● A 150 Ah battery at C10 will last for 10 hours on a load of 15 A.
● A 150 Ah battery at C5 will last for 5 hours at a load of 30 A.

C5, C10, C20 all mean the same meaning if it is rated as 150Ah. All batteries are able
to supply 150 Amps for 1 hour or 1 Ampere for 150 hours. It should follow the
simple rule:
x(hours) × y(Amperes) = 150 if it is mentioned as 150Ah.

The difference is only in the state of charge.

1. A C5 battery means it should not be discharged within 5 hours otherwise the
battery life decreases
2. A C10 battery means it should not be discharged within 10 hours otherwise the
battery life decreases
3. A C20 battery means it should not be discharged within 20 hours otherwise the
battery life decreases

Simply, it means capacity of battery if any battery is rated 12V, 40Ah and C10, it
means 10 hours of 4A charging and discharging rate. If the rating changes to C20,
then 20 hours of 2A charging and discharging rate is being followed.
Earthing components

Earthing is to ensure safety or protection of electrical equipment

and humans by discharging the excess or leaking electrical
energy to the earth. The purpose of earthing is to minimize risk
of receiving an electric shock if touching metal parts when a fault
is present.
The earth rods are inter-connected to structure and lightning
arrestor via earth plates. Earthing can be accomplished through
bonding of a metallic system to earth. It is normally achieved by
inserting ground rods or other electrodes deep inside earth.
Normally charcoal and salt are added in earth pits with the rods
to improve conductivity. To achieve the required driving depth –
the rod couplers provide permanent electrical conductivity and
the longer copper earth rods access lower resistivity soils at
lower depths.
The earthing rod is a 17 cm long structure of 1.5 mm diameter,
made generally of copper. In case of a pipe earthing, the earthing
rod is a GI rod of 30 mm diameter and 2.5 m length.

Earthing Compound
Earthing compound is a mixture of water retaining clay
used to fill around the earthing pit with electrodes to help
lower the soil resistivity for the easy conductivity of the
electric current. Conventionally, earthing compound is a
mixture of wood, coal powder, salt and sand in equal parts.
Coal Powder is a good conductor of electricity,
anti-corrosive and minimizes the resistivity. Salt is used as
electrolyte to form conductivity between the electrode, coal
and earth with humidity. Sand lets water flow easily and
maintains humidity around the mixture. Coal and salt keep
the soil wet as coal absorbs water keeping the soil wet.
Moisture is the controlling factor of earth resistivity. With
more than 20% of moisture content, the resistivity is very
little but when it is less than 20%, the resistivity increases
rapidly. Water also is used to increase the conduction of
electricity in soil.
Now-a-days, we have pre-made mixtures like bentonite and
marconite in the market. They serve the same purpose but
rather more effectively.

10
Earth meter
Earth meter is the instrument used to test the resistivity of the
earth. If resistance of the earth is very low, the fault current
through the earth electrode passes to the earth. Thus, protects
the system from damage. The Earth meter helps us to keep a
check on the resistivity of the earth. Resistivity of the total earthing
system should be less than 1 Ohm.

Lightning Arrestor

A lightning arrester is a device used on solar power systems to protect

the insulation and conductors of the system from the damaging
effects of lightning. The typical lightning arrester has a high-voltage
terminal and a ground terminal. Ground terminal is connected to the
earthing rod. Necessary foundation for holding the Lightning Arrestors
is to be arranged keeping in view the wind speed of the site and
flexibility in maintenance in future.

The lightning arrester has 4 copper spikes which attract the lightning,
and therefore a separate earthing connection is required for the same.

Water-level sensor (Optional Component)

Most commonly used water level sensor is a float switch type, which is suspended
in the tank at a particular level. When water level rises it floats on the surface and
gives a signal to the controller to stop the pump.
Water storage tank (Optional component)

Water pumped from the well can be stored in the storage

tank. Usually this is used in drinking water applications for
communities. These tanks are mostly made up of poly vinyl
chloride (PVC) and are available in various shapes and sizes.
Sometimes water tanks are made up of cement materials.

Open reservoirs
Open reservoirs are inexpensive and relatively easy to
construct, but the big disadvantages are the high
evaporation losses of water and easy accumulation of debris
and sediments as well as algae growth. These effects can be
significantly reduced by covering the tank, e.g. with a plastic
foil. Evaporation and algae growth can be reduced when the
solar panels are installed on floating mounting structures.

Elevated water tanks

This is the classic configuration of a Solar Powered Irrigation System. The pumped
water is stored in an elevated water tank and irrigation functions by gravity. The
elevated tank serves as a battery where energy is stored in the form of water. The
irrigation system pressure depends on the height of the water level in the storage
tank. It also allows for pre-sunrise irrigation. Ready-to-use plastic tanks are
available in different sizes, easy to install and do not corrode as metal or cement
reservoirs do.

In order to secure a safe system operation, a water level sensor should be installed
in the water tank that switches off the pump to avoid overflow. If a submersible
pump is installed in a well, a second water level sensor is required to protect the
pump from dry running. Such sensors are often integrated into the motor pump by
default. As water tanks usually store huge amounts of water, it is important that
the foundation and support structure of the water tank meets the static
requirements.
Balance of System

Electrical Equipments
Electrical Equipment including cables and wires that are used for networking in the
system. It also includes MC4 connectors, circuit breakers and inverters used in
current and voltage management.

MC4 Connectors
MC4 Connectors are single contact electrical connectors
used for connecting solar panels. MC stands for
manufacturer Multi-Contact and 4 for the 4 mm diameter
contact pin. They are used because they make wiring solar
arrays much simpler and faster. The connectors come in
both male and female types which are designed to be put
together. They have a special locking mechanism and need
a MC4 unlocking tool to separate the connectors.

For connecting solar modules in series, a female MC4 connector with positive lead
of one solar module is connected to a male MC4 connector with negative lead of
adjacent solar module.

For connecting solar modules in parallel, we need additional equipment called MC4
multi branch connectors. There are two different types of multi branch connectors
for both positive and negative leads. When connecting, two male MC4 connectors
are connected to a MC4 multi branch connector that suits and has male MC4
connector for its output and two female MC4 connectors are connected to MC4
multi branch connector that takes female MC4 connectors as input and has a
female MC4 connector for its output.

Miniature Circuit Breakers

Automatic Circuit Breakers are used in the pump controller to protect from
overload or short circuit. The regulated current of the circuit breakers are chosen
based on the power and size of the pump.
Distribution Board
A distribution board (also known as panel board, breaker panel, or electric panel)
is a component of an electricity supply system that divides an electrical power feed
into subsidiary circuits. ACDB / DCDB are an important part of the Solar PV system
to provide extra electrical protection to the system during failures.
● Solar DCDB (Direct Current Distribution Box), is used to protect the
system if there is any fault during failure on the DC side. Here the electricity
supply system divides an electrical power feed into subsidiary circuits. It
contains a protective fuse or circuit breaker to switch the system off during
fault. DCDB controls the DC power from Solar Panels and has a necessary
surge protection device (SPD) and fuses to protect the solar panels strings
and solar inverter from any type of damage.
● Solar ACDB (Alternative Current Distribution Box), receives the AC power
from the solar inverter and directs it to AC loads through the distribution
board. ACDB includes necessary surge protection devices (SPD), Voltage,
Current monitoring and MCCB to protect the solar inverter from any type of
damage or heavy voltage.
● Array junction box (AJB), is referred to as solar PV junction box or
combiner box. It collects DC power from PV strings and then transfers either
directly or through a main junction box (MJB) to the power inverter. The
power inverter converts the DC power to AC which after metering is used to
measure the power consumption in ON-Grid/OFF-Grid/Hybrid system.

Wires and Wiring Size

Solar water pumping systems are typically provided with all
wiring appropriate for the installation. This is why it is
important to determine the distances between the solar
array and water pump during the site visits. This is
particularly important for borehole/well pumps because of
the water-resistant cable that must be used to connect the
pump.
A properly designed wiring system should have a voltage
drop of not more than 5%, and, therefore, on a 12V system,
voltage loss should not be more than 0.6V.
The wire-sizing chart below should be used to select the
correct wire cross section for a given current and length of
wire. The voltage loss values given in the table are for 100m
length of wire at a given current. The table can be used for
lengths of wire that are less than 100m by first dividing the
selected length by 100 and multiplying by the corresponding
voltage drop given
It must be noted that voltage losses in the table are theoretical, calculated using
Ohm’s Law. As such the state of wires must be considered.

Generally insulated copper wires of 2 mm diameter are used for connections in the
solar arrays, pumps and controllers. Also, for long distance transmission 9in case
the pump is located far from the location of the solar array, aluminium wires are
used.

The pump controller is connected to the pump and solar array using a 3-phase
connection and lug. The lug is opened, wires are inserted in the live neutral and
earth wire positions on either side. The colour coding is followed, and crimped and
connected. The colour coding followed in 3-phase conductor is red, yellow and blue
wiring, along with black wire for neutral and green wire for earthing. Once
repacked, the connection is sealed with waterproof covering using a compound
rubber strip. Splice kit is used to waterproof the connection, for otherwise short
circuits can happen during heavy rains.
Mechanical Equipments

Mechanical equipment consists of pipes and other plumbing gears. The selection of
pipes is done by checking their pressure and temperature rating, ease of
fabrication and Suitability for outdoor application. PVC pipes are generally used,
and the diameter of the pipes vary according to the size and head (in case of
submersible pump).

Safety Equipments

Safety equipment including earthing materials and personal protection gears. For
full protection against open circuit, accidental short circuit and reverse polarity, the
components need to be Earthed using an earthing rod. For personal protection,
rubber gloves, boots and insulated tools are to be used when working on the
system.

Safety Helmet Safety goggles, Protective safety Protective Gloves Hearing Protection
preferably with shoes
side shields

A first aid kit needs to be carried by the installation team in case of any mishaps.
The Solar water pumping system should be provided with overvoltage protection.
The aim is to reduce the over-voltage to a tolerable value before it reaches the PV
or other subsystem components. The source of over voltage can be lightning or
another atmospheric disturbance.

IP Rating of Exposed Components

The Ingress Protection or IP is a rating system designed to check the protection of
the components of the pumping system from solid and liquid damage. The first
digit in the rating represents the protection level against solids and the second digit
indicates protection level against liquid damage. The submersible pumps are
usually rated IP56 or above (the liquid protection rating needs to be 6 or higher for
submersible pumps, since the pump is submerged in water constantly).
System Configuration

There is a range of possible components and configurations for photovoltaic water

pumping systems, as shown in figure. Selection of the most suitable components
and configurations for each specific application and site is critical to the economic
viability and the long-term performance of the system.

Paired with the right environmental conditions, the right amount of PV panels and
controllers and the right installation setup of energy storages, converters,
inverters, pumps and motors — the solar water pumping system can present a
farm and a nation with numerous benefits.
Evaluation

1 PV modules are rated according to their

a. Input
b. Power Output
c. Temperature
d. Solar cells

2 When AC motors are used in solar pumping system they

require
a. Capacitor
b. Inverter
c. Battery
d. None
3 For long distance cabling, it is not suitable due to power loss
in cable.
a. True
b. False

4 The mounting structure is designed for solar modules to

optimize
a. Maximum yield within minimum area
b. Minimum yield within large area
c. Maximum yield within maximum area
d. Minimum area

5 What is the device that orients solar panels towards the sun?
a. Maximum Power Point Tracker
b. Solar tracker
c. Controller
d. Inverter

6 Solar tracker is used to minimize __________ between the

sunlight and solar panel.
a. Angle of reflection
b. Angle of incidence
c. Total Angle
d. Angle of irradiance
Evaluation

7 The ground terminal of lightning arrester is connected to

a. Battery
b. Solar Modules
c. Earthing rod
d. None

8 What is the purpose of earthing?

a. Maximize the output of the system
b. To protect system from lightning
c. To minimize the risk of electric shocks
d. Both b & c

9 Water storage tank in solar pump system is useful when

a. There is no sunlight to generate electricity
b. System doesn’t work due to technical issue
c. Both a & b
d. When there is excessive sunlight

10 MPPT will help the system to increase

a. Decrease heat generated in the system
b. Increase Efficiency
c. Decrease Efficiency
d. None

_________ are used to send signals to controller to stop the flow

11
of water when tank is full.
a. Inverter
b. MPPT
c. Water level sensors
d. None

12 Power output of solar PV panels is _____________

a. AC
b. DC
Evaluation

13 Thin Film Solar Panels have ________ efficiency than crystalline

modules.
a. More
b. Less
c. Almost equal
d. Cannot compare
14 Which silicon cells are made from an ingot of melted and
recrystallised silicon?
a. Thin film
b. Monocrystalline
c. Polycrystalline
d. None
15 The manufacturing process of __________ cells is complicated
compared to other technologies.
a. Polycrystalline
b. Monocrystalline
c. Thin film
d. None

16 The most commonly used material for manufacture solar cells

is
a. Silicon
b. Iron
c. Wood
d. Glass

17 Controller box should be placed far away from the PV Panels

a. True
b. False

18 VFD is used
a. AC Pumps
b. DC Pumps
c. In both AC and DC pumps
Evaluation

The water output of the Solar panel is variable as it depends

19
on the
a. Ambient temperature
b. Irradiance
c. Capacity of motor-pump set
d. All of the above
20 Controller box is used in solar pumping system
a. To increase the water output
b. To store energy from the solar panels
c. Fault protection
d. Matching of input and output power

21 On non cloudy day, water output of solar pumping system is

more in morning hours as compared to afternoon
a. True
b. False

22 Inverters are used to convert AC current into DC current

a. True
b. False
Answers

1 b. 2 b. 3 a. 4 a.

5 b. 6 b. 7 c. 8 d.

9 a. 10 b. 11 c. 12 b.

13 b. 14 b. 15 c. 16 a.

17 b. 18 a. 19 d. 20 c & d.

21 a. 22 b.
 Chapter 3

Theory of Pumping
Technology
TOPICS COVERED

Introduction to Water Pumping

Theoretical Pump Equation

Real pump equation

Head determination

Flow rate determination

System Curve

NPSHr and NPSHa

Tagging of Pump
Introduction to Water Pumping

Various methods can be used to lift water against gravity. One such method is to
shift water into a bucket and lift the bucket with a rope. In electric pumps there
are two ways in which this can be achieved - Dynamic and Displacement methods.
In both cases, an electrical motor driven pump is required to achieve water lifting.
Let’s see the principle in both cases. The two principles are explained here:

Dynamic and Positive displacement Pumps

Dynamic pump makes use of the simple fact that any fluid or gas moves from
higher pressure to lower pressure. It creates pressure difference with the help of
a fast-rotating blade called impeller in a controlled and specially designed
chamber called volute. Most popular Dynamic pump used is Centrifugal pump.

A Positive Displacement pump uses the technique of trapping a fixed volume of

water and moving it up without letting it fall back to source. Drawing water from a
well in a bucket is positive displacement, wherein a certain volume of water is
trapped in the bucket and slowly it is pulled up. Most commonly used Positive
displacement pump is the Helical Rotor Pump. Water is trapped in small helical
screw threads and every time it rotates, water moves

A dynamic pump does two things to lift water: Suction and Delivery.

Suction
From the water source, the pump sucks water in the same manner we suck water
through a straw into our mouth. This phenomenon is called suction. When we
suck water using a straw, a temporary vacuum (or low pressure) is created near
the mouth which causes atmospheric air to push the water through the straw into
our mouth. This happens because the atmospheric pressure around is higher
than the low pressure created in our mouth.

Similarly in a centrifugal pump, the rotating vanes create a low pressure in the
suction inlet causing flow of water into the inlet of the pump. But there is a
limitation. The maximum atmospheric pressure available on earth is 14.7 pSi
(pounds per square inch) near sea level. This atmospheric pressure is enough to
lift water to only a maximum of 33.9 feet against vacuum. So no pump can suck
water above 33.9 feet with the help of atmospheric pressure. The atmospheric
pressure also reduces with increase in altitude (2 feet reduction for every 1000
feet height above sea level), thus reducing the maximum suction height further, as
the altitude increases.
Did you KNOW?
Add Page 4
Delivery
Once the water is sucked into the inlet of the pump, the impeller vane rotating at
high speed comes in contact with this water. All the energy of the rotating vane is
transferred to the water and the water gets a lot of kinetic energy. This causes the
water to be thrown out with high velocity due to centrifugal force. The water
thrown out reaches a chamber around the impeller called the Volute.

Impeller Veins
Discharge outlet
Impeller Eye(Suction
Inlet)

Volute

Cross section of centrifugal pump volute chamber

The volute is designed to have a small diameter near the impeller and large
diameter near the delivery outlet.

When water moves from small diameter to large diameter, it loses some of its
velocity but proportionally it gains some pressure to maintain the total energy in
the system constant (This is known as Bernoulli’s principle). Since the pressure at
the delivery outlet is higher than atmospheric pressure now, the water moves
upward. As it moves upward, it loses both its velocity and pressure energies to
build up the height energy (potential energy). Please note that the total energy in
the system will still be the same.

If the delivery pipe height reaches a height where all velocity and pressure has
been transferred to potential energy, the water won’t be able to move up further.
At this point velocity will be zero, pressure will be equal to atmospheric pressure
and the maximum height is called the shut off head of the pump.
Did you KNOW?
Add Page 5
Priming

Although the above explanation compares suction of a dynamic pump with

sucking water through straw, in reality there is a difference. In a straw, we first
suck the air and then the water or juice follows. But in a dynamic pump designed
to lift water, it cannot develop enough pressure difference to lift air. If there is air
inside the pump chamber, it can damage the pump itself. So before starting the
pump, we have to somehow make sure there is no air in the pump chamber. To
achieve this, we usually fill the suction pipe and rotating impeller chamber with
water manually before starting the pump. We also let out air through an air vent.
This is called priming.

We also use a foot valve in the suction pipe to prevent this water from draining
out. In some self- primed pumps manual priming may not be required or may be
minimal. Please note that even while running, it is important that the pump shuts
off when water is not entering the inlet. This is called dry-run protection, it is
required in both surface and submersible pumps. In submersible pumps, priming
is not usually required as it is anyway submerged in water.

Displacement Pumps

In a Displacement pump, a volume of water is taken from source and it is trapped

such that it cannot fall back to the source. Now using various mechanisms, it can
be lifted up. When we draw up water in a bucket, we trap water in the bucket and
lift it up. So, it is a positive displacement. Here, the volume of the water pumped is
independent of the height to which water is pumped to. Trapping water in a
rotary vane, by a reciprocating piston or diaphragm, by a rotating screw is all
common. It is also common to use one side valves at the inlet and outlet to trap
water in such techniques. Hand pumps also use one of these techniques.

Though displacement pumps are more efficient than dynamic pumps, the
maintenance costs are high due to stator rubbing against rotors and hence they
are used rarely. Even slightest gap to avoid such wear will affect trapping of water
through leak. However, in specific cases, if the flowrate required is very less at
very high heads, maintenance requirements can be controlled by lowering
rotational speeds of displacement pumps to make it more economical than
dynamic pumps.
Theoretical Pump Equation

Irrespective of the method used, the energy required to lift water vertically up from a water
source, is determined by the formula given below:

Pump Energy = M x H x g

where M is mass of water to be lifted in kg, H is height to which neater is to be lifted in metres
and g is the acceleration due to gravity = 9.8m/s2 to get the energy in Watt-Seconds (Same as
Joules)

The energy mentioned above is called Hydraulic Energy. Since water is generally measured in
volume (m3, Litres, Gallons, etc.) the equation can be changed to:

Pump Hydraulic Energy Eh = V x p x H x g Joules

where is V is volume of neater to be lifted in m3, p is the density of water (1000 kg/m3), H is
height to Which water is to be lifted in metre and g is the acceleration due to gravity = 9.8 m/s2

Now if above is pump hydraulic energy, what would be the pump hydraulic power required to
lift the water? If Volume (V) of water needs to be lifted up within a second, the power required
is:

Hydraulic Power in Watts = (Eh in Joules) / 1 sec

Instead, if the same volume needs to be pumped slowly over an hour, the hydraulic power
required is:

Hydraulic Power in Watts = (Eh in Joules) / 3600 sec

If we know rate of water to be pumped in litres per hour and we want to know the Hydraulic
Power required for pumping in HP (Horse Power), the equation will be:

Hydraulic Power Ph = Q x p x H x g x 1.34 / (3600 x 1000) HP

where is Q is flow rate of water to be lifted in ltr/hr, p is the density of water (kg/ltr), H is height
to which water is to be lifted in metre and g is the acceleration due to gravity 9.8m/s2
 Real Pump Equation

Although we have seen the pump equation above, there is a slight difference in
practical application of pump. We already saw in the theory of dynamic pump, that a
rotating vane first develops high velocity in water, then it develops pressure as it
moves through volute to a large diameter discharge outlet etc. So the energy
developed in the pump is used for not just building height, but for four purposes
according to Bernoulli’s principle:

a. To build velocity of water: At first all the rotary vane energy is converted to high
velocity of water called kinetic energy (K.E).
K.E = ½ mv2 where m is mass of water and v its velocity

b. To build pressure: In any pipe, at a given height, if the pipe cross-section area is
increased, the pressure increases and velocity decreases. In a centrifugal pump,
as the volute diameter increases towards the discharge outlet, pressure energy
increases.
Pressure Energy = PV where P is gauge pressure of water and V is volume of water

c. Potential Energy: This is what we commonly call the height. The theoretical pump
equation we discussed was based on only this factor. As we have seen Potential
Energy (P.E) = mgh where m is mass in kg, g the acceleration of gravity, h the
height of water column

d. Friction Loss: As water moves in a pipe, there will be friction with the wall of the
pipe. Some energy will be lost thus. Friction loss is dependent on volume of
moving water and density of the fluid

Friction Loss = VpF where V is volume of water, p density of water, F the friction
factor of the pipe

Considering all above, we can write the revised Hydraulic energy equation as

Eh = ½ mv2 + PV + mgh + VpF

If we replace volume V with flow rate Q and replace mass m with Qp (Since mass of
flowing water = flow rate x density) then we can get the hydraulic power equation;

Ph = (1/2 Qpv2 + PQ + Qpgh + QpF) × 1. 34/ (1000 × 3600) HP

where Q is flow rate in ltr/hour, p is density in kg/ltr, v is velocity in m/s, P is gauge
pressure of water in kPa, h the height in m, F is friction/factor

Let us take out Qpg as a common factor, then;

Hydraulic Power Ph = Qpg (v2/2g + P/pg + h + hf) × 1. 34/

(1000 × 3600) HP
where Q is flow rate in ltr/hour, p is density in kg/ltr, u is velocity in m/s, P is gauge
pressure of water in No, h the height in m, hf=F/g is friction factor equivalent in mtr

Compare above equation to the theoretical Ph derived which was;

Hydraulic Power Ph = Q × p × H × g × 1.34/(3600 × 1000) HP

The only difference is, instead of just height H in the theoretical formula, there are
four factors (v2/2g + P/pg + h + hf) in the newly derived formula. This component is
known as Total Dynamic Head TDH. It has following four factors in it:

● v2/2g called velocity head

● P/pg called Pressure head

● h the static head, and

● hf the friction head.

In short the practical formula we will be now using as pump equation is:

\ Hydraulic Power Ph = Q × p × TDH × g × 1.34/(3600 × 1000) HP

In any pump system design, we have to determine Q — the required flow rate and
TDH — the required head based on customer need.
Head determination

Static Head

In the TDH, we have seen height (h) is one of the four factors and the most
important one. This height to which water needs to be pumped is the basic
requirement we need to understand from the client and it is called a static head. It
is called static as it is the only factor in TDH which doesn’t change if the flow rate
(Q) requirement of the client changes.

In any pump Static Head (hs) = Discharge Head(hd) - Suction Head(hsuction)

Here the suction level where water enters the pump impeller is considered the
reference line. Head above suction level is positive and below suction level is
negative.

Determination of static head of Surface Pump

SL is the suction level and from the line of reference

HL- The maximum height in the discharge side including the pipes rind discharged water column
ML- Water Level of the source
 Determination of static head of submersible pump

As seen above,

Discharge head is the height difference between suction level and the highest
point to which water gets lifted by the pump. (Please remember to respect the
sign convention of head)

Suction Head

It is the height difference between suction level and the estimated lowest water
level in the water source. In a submersible pump, water near the pump inlet
bends down a little from the water level while the pump is running. This is called
drawdown. So the lowest estimated drawdown level should be considered instead
of water level. (Please keep in mind the sign of head)

Dynamic Head (PV Head — Pressure and Velocity Head)

We have seen that TDH has both pressure and velocity head factors.
Velocity head is W/2g and Pressure head is P/pg

There is a reason why they are explained together here. At any given height in the
pump, we can change pressure to velocity head and vice versa simply by changing
the cross section of the pipe carrying water. If we increase pipe diameter,
pressure head increases and velocity head decreases. It is also true vice versa. So,
what is important is together as PV head how much energy they
hold. When the pump impeller rotates, its energy is received by water as PV head.
Then we strategically select pipe diameter such that pressure is above
atmospheric pressure, at the same time velocity doesn’t drop to zero. As long as
this condition is met, water keeps rising up which means its static head keeps
increasing.

As the static head increases, the PV head sacrifices its energy to build the static
head. Finally, when the PV head is exhausted, the water cannot go further up as all
PV heads have been converted to static heads. This maximum static head is shut
off the head of the pump.

We should tap water at a height where most of the PV head has been converted to
static head. Conversely, if we select the pump correctly at its peak efficiency
operating point, most of the PV head would have been exhausted at our required
static head. If not, the extra PV head available at the final discharge point will be a
waste of energy and of no use. There is one exception to this. You can purposefully
plan to have some extra PV head for sprinklers or cleaning/gardening hose etc
which can utilize the extra velocity/pressure. Hence, unless there is such a special
requirement by the customer, PV head requirement is usually taken as zero for
pump selection.

Note that PV head will change if customer changes their flow rate requirement as
they are dependent on velocity and volume of water. Hence, they are categorized
under Dynamic head.

Friction Head

The Pressure developed in the pump is not fully utilized to just lift the water to a
height. Some of it is lost as friction in pipes, bends etc. This is why pumps are not
100% efficient. The friction in pumps, pipes is also measured in units of length
(usually metres or feet). The friction thus measured in metres or feet is called
Dynamic Head. It is dynamic because every time flow rate changes, the friction
also changes. Higher flow rate causes more water to come in contact with the
pump impeller and the connected pipes at a given time causing higher friction.
Friction head can be calculated by:

hf = f × (39.37 × L/d) × V2/2g OR hf = 1.66 × 10-4 × (L/d4) × Q

where f is a friction constant depending on pipe material, L pipe length in mtr, d is
inner diameter of pipe in inches, Q is flow rate in ltr/hour end V2/2g is the velocity
head due to voter movement in mtr
 Nominal Size ID (inches) Velocity(ft/sec) Head loss (feet)
3.5 3.548 12.98 16.2

4 4.026 10.08 8.5

5 5.047 6.41 2.7

6 6.065 4.44 1.1

8 7.981 2.57 0.3

A typical head loss (hf) data given by a manufacturer for looft straight length steel
pipes of various diameters while carrying 1500 litre/minute. Elbows and T bends
cause higher frictional loss (An approximate thumb-rule is 12ft additional length
equivalent for every bend).

For example, if a pump has both suction and delivery pipe together 4 mtr pipe
length. There are 3 elbow bends in the pipe. The flowrate is 25000 lph and the pipe
diameter is 3 inch. Let us estimate the friction loss.

Total length of pipe = 40m

Since each bend is equivalent to 1m and there are 3 bends;

Total length of pipe to be considered L = 40 + 3 = 43m

Diameter d = 3 inch
Q = 25000 lph

Friction head hf = 1.66 × 10.4 × (43/34) × 25000 = 2.2m

Flow rate determination

The flow rate is the amount of water pumped in a certain time period. The flow
rates able to be met by a pump are usually quoted in L/min or L/hr or m 3/day or
Litres per Day (LPD).

The flow rate is a critical figure in the design of a solar pumping system and it must
be accurately determined to optimise the pumping system design. Overestimation
of flow rate will lead to pump oversizing which in turn increases cost of solar
modules installed to run it. It will result in a larger amount of water being pumped
than required since solar pumps are generally not manually controlled.

In irrigation, it is always recommended to consult experts in the agri sector to

figure out ways to reduce water requirements (Eg; adopting drip irrigation) and
determine the lowest possible water requirement, before planning to adopt a solar
pumping system. The daily water requirement in each month needs to be
determined. If the irrigation demands pumping only in intervals of a few days and
not daily, then it may be economical to pump water daily to an overhead tank and
release water from the tank as per requirement. Solar modules will be economical
if the daily generated power is fully utilized instead of wasting without usage.

System Curve

When the total dynamic head is plotted against the flow rate, it is called system
curve. System curve is extremely important in designing a pump system.

Example of a System Curve (The red fine is the system curve)

If the requirement has just one flow-rate, instead of a line, the system curve will
be a point of operation where TDH meets the required flow rate.
NPSHr and NPSHa

For every pump, the pump manufacturer specifies a minimum value of head
based on the pump design, beyond which if suction head is increased, it causes air
bubbles to enter the pump impeller. This can cause serious damage to the pump.
If the pressure in the inlet side of the pump goes below the vapour pressure of
water, water starts to evaporate. These water bubbles in large numbers burst
inside the pump and damage the pump. This phenomenon is called cavitation. This
value given by the manufacturer is NPSHr (Net Positive Suction Head required) of
the pump.

Now let us see what is NPSHa (Net Positive Suction Head available)

When we keep a surface pump at a height above the water level, there is a height
from the water level to the inlet of the pump. This is Suction head.

Now we know that it is atmospheric pressure that helps water move up this
suction pipe to the pump inlet. So before installing a surface pump, we need to
know the atmospheric pressure available on the water surface that will help it
move water up the suction pipe.
The atmospheric pressure has to do two more things apart from lifting the water
through suction pipe:
1. The atmospheric pressure has to help overcome the friction in the suction
pipe
2. The atmospheric pressure has to overcome the vapour pressure of water so
that water doesn’t turn to bubbles. Vapour pressure depends on the
geographical conditions of the region and the temperature of water being
pumped

From the above description, we can say that the value:

Pa - Pv + hsuction - hf should always be more than the NPSHr

Where,
Pa is Absolute Pressure on the surface of water to be pumped in metres of Water
column
Pv is Vapour pressure at ambient temperature in metres of water column below
u›hich water becomes water vapour
hsuction is the suction head in metres (-ve below impeller and +ve above it)
hf is head loss expected inside suction pipe due to friction in metres
The term Pa - Pv + hsuction - hf is called NPSHa (Net Positive Suction Head available)

For a surface pump to function properly without cavitation, following condition

should be met:

NPSHa > NPSHr × safety margin

Safety margin is typically a factor of about 1.5

Which also means while placing a surface pump, the positive suction head should
be such that:

Suction head > NPSHr × safety margin - Pa + Pv + hf

where, Suction head is negative below pump suction level and positive above
pump suction level

Note: If distance between pump inlet to water level is 5m, suction head is -5. If it is
3m, the suction head is -3. We know -3 > -5 and hence our aim is to reduce
distance between water level and pump inlet to increase the positive suction
head. This is why in some wells you would have seen surface pumps lowered into
the well or we even use floating surface pumps.

suction head

Negative suction head

suction head

Positive suction head

Tagging of Pump

A pump has two parts. The motor which drives it and the pump itself.

Motor

Most commonly, AC Induction motors are used in running pumps. DC motors are
also gaining popularity due to its higher efficiency, in spite of its higher cost. This is
because higher efficiency reduces the cost of Solar Power required, significantly.
But, due to the simplicity of design, availability and easy serviceability, AC induction
motors continue to be the most popular.

Below are the specifications to look for in a motor:

HP: This is the mechanical power generated in the shaft of the motor in
HorsePower (and not electrical power), “when the motor is running at its peak
efficiency”. Sometimes motor power is given in kW too.

Input Power: Required input electric power to run the motor while running at
peak efficiency. Usually given in kW.

Volts: The voltage of input electric power.

● If this voltage is AC, the motor will have an additional parameter called
‘Hertz’ which is the frequency and ‘Phase’ which is the number of phase
inputs required.
Current: Given in Amperes, it is the current drawn while operating in its peak
efficiency. If AC motor, this will be phase current

Power factor: For AC motors, a part of the current keeps circulating in the
motor to keep the magnetic flux alive. It doesn’t get transferred to shaft power. If
Power factor (pf) is 0.8 it means Phase Voltage × Phase Current × number of phase
× 0.8 is the available input power to the motor for rotation.

RPM: Speed at which the motor rotates in Rotation per minute during its peak
efficiency. Eg: 1800 rpm

Pole: Number of magnetic poles to provide magnetic force needed in a motor. In

an induction motor, the number of magnetic poles and frequency decide the
speed of the motor.

Capacitance: Single phase induction motor uses a capacitor to start as it is not

self- starting. This capacitance is mentioned in Micro-Farad on the motor.

IP: Ingress Protection is mentioned in two digits. Eg: IP35. First letter signifies the
degree of protection against solids. 1 is protection from objects above 50mm size
like stone. 6 protects from even fine dust. Second digit signifies protection from
liquid. i is protection from dripping water vertically and 8 means it can be fully
immersed in water still water doesn’t enter the pump. Outdoor motors should be
at least IP56 rated

Duty:-It mentions if the motor is designed for continuous running or periodic

running. S1 duty means it is designed for continuous running.
Pump

The specifications of the pump are as given below. Most common pumps are
centrifugal pumps. So let’s focus on nameplate of same:

HP/kW : This is the shaft power that the motor develops while running at the
motor's maximum efficiency point. The shaft is connected to pump and hence
same power is available to pump.

Head: If we keep increasing the discharge head by increasing height on the

discharge side of the pump, the flowrate keeps reducing and at a particular
pressure (or height) it cannot pump water further. This is the head of the pump in
metres of feet. It is not dependent on fluid. It depends on the diameter of the
impeller, its speed and the volute design. However, the pressure developed
depends on its viscosity of fluid {Since Head = Pressure/(Density x g)}

NPSHr: Required suction head to avoid cavitation. The suction head should not
be less than a limit to avoid cavitation.

Bore: This is the diameter of the outlet and inlet of the pipe. Do not use a pipe less
than this diameter to connect to the pump. It will unnecessarily increase the
pressure. Also, if using a higher diameter pipe, use eccentric couplers only.

Number of stages: A larger impeller diameter can create a larger head for a
pump. But in some cases, the pump needs to have an impeller of smaller diameter
(Eg; A submersible pump inserted in a borewell hole). In such cases multiple
impellers of smaller dia are connected in series into a single enclosure to achieve
the desired head. This is called multistage pumps and the number of stages
signifies the number of pumps in series. Eg: 2 stage, 3 stage etc.

You would have noticed that the flowrate is typically not an important nameplate
parameter. This is because it is not a pump characteristic. Only Bore diameter is a
pump characteristic. To know the relation between the head developed in the
pump and the flowrate, the pump curve needs to be referred to.
Evaluation

Positive Displacement pump uses the technique of _____ a

1
fixed volume of water and moving it up without letting it fall
back to source.
a. adding
b. mixing
c. trapping
d. Throwing

2 What is the maximum atmospheric pressure available on

earth?
a. 10 pSi
b. 14.7 pSi
c. 14 pSi
d. 12 pSi

3 Where does the water thrown out reaches a chamber around

the impeller reach?
a. Volute
b. Conduit
c. Store
d. None of the above

4 Why is priming not required in submersible pump?

a. Submerged in water
b. Borewell is already primed
c. Submersible pumps have oil, so priming is not needed
d. All of the above

Which of the following is not required to calculate the Pump

5
Hydraulic Energy?
a. Volume
b. Density of water
c. Gravity
d. Diameter of the conduit pipe
Evaluation

6 RPM is the Speed at which the motor rotates in Rotation per

minute during its peak ________
a. Efficiency
b. Voltage
c. Current
d. Power

7 Which of the following is correct in case of a surface pump

a. NPSHa + NPSHr = safety margin
b. NPSHa = NPSHr × safety margin
c. NPSHa < NPSHr × safety margin
d. NPSHa > NPSHr × safety margin

8 What is the unit of frequency?

a. Volt
b. Second
c. Hertz
d. Pascal

9 What does the first number in IP56 signify?

a. Degree of protection against solids
b. Degree of protection against liquids
c. Degree of protection against fluids
d. Degree of protection against pressure

10 What feature of a borewell are not required for pump

design?
a. Diameter
b. Depth
c. Perimeter
d. Water table
Answers

1 c. 2 b. 3 a. 4 a.

5 d. 6 a. 7 d. 8 c.

9 a. 10 c.
 Chapter 4

Solar Array and

Connections
TOPICS COVERED

PV Module Characteristics

Tagging of Solar Panels

Irradiance and Insolation

Sunshine hours

Design of Solar Power and Energy required

Design of Solar Array

Series Connection of Solar Modules

Parallel Connection of Solar Modules

Series-Parallel Connection of Solar Modules

Example of connections in solar modules

Design of Cables
Did you KNOW?
Add Page 6
PV Module Characteristics

Solar modules contain photovoltaic (PV) cells that convert energy from the
sun into electrical energy. These cells produce DC electricity that can be used
either by AC-compatible appliances such as many household electrical items, or
by an AC water pump.
The electricity produced by a PV module is characterized by the I-V curve:
this depicts the relationship between the current (I) and the voltage (V) of the cell.
For a given set of operating conditions, the PV module can be manipulated at any
point along the I-V curve; for every operating voltage, as shown on the x-axis,
there is a corresponding current output, as shown on the y-axis.
One point along the curve will produce the most power. This point is known
as the maximum power point (MPP) and is located at the ‘knee’ of the curve.
Operating a PV module at its maximum power point will result in the greatest
possible amount of power. Sometimes, however, it is more beneficial to operate
the PV module at a specific voltage or current value that does not correspond to
the maximum power point. A maximum power point tracker (MPPT) is the most
common way to control the electrical output of a PV module.
The operating conditions – namely, the solar irradiance levels and
temperature of the module, affect the I-V curve of a module. In essence, as solar
irradiance levels increase, more current is available; hence, there is more
available power.
 Effect on solar PV pumping of solar radiation
levels and temperature

The operating conditions – namely, the solar radiation levels and

temperature of the module, affect the I-V curve of a module (Figure a). In essence, as
solar radiation levels increase, more current is available; hence, there is more
available power. As cell temperature increases, less voltage and hence less power is
available (Figure b).
The amount of solar radiation energy received in a period of time is measured
in kWh/m² or in peak sun hours (PSH).

Current (A) Power (W)

Voltage (V) Voltage (V)

80 25 C G=1000
70 -25C W/m2
60 75 C
Power (W)

50
40
30
20
10
0
0 5 10 15 20 25
Voltage (V)
● Increased solar radiation levels = greater power output.
● Increased module temperature = lower power output.
● The amount of solar radiation energy received in a period of
time is measured in kWh/m2 or in peak sun hours (PSH).
 A common myth is that solar panels do not work during winter, but
on the contrary, the cold temperature will typically improve solar panel
output. So, on a sunny winter morning, the panels will actually be more
efficient.

Increased Solar radiation levels = Greater power output

Increased module temperature = Lower power output
Tagging of Solar Panels

There should be a Name Plate fixed inside the module which will give:
a. Name of the Manufacturer or Distinctive Logo.
b. Model Number
c. Serial Number
d. Year of manufacture

Each PV module must be use RF identification Tag (RFID), which must contain the
following information:
● Name of manufacturer of PV module and their logo
● Unique Serial No and Model No of the module
● Month and year of the manufacturing
● Country of origin
● I-V curve for module
● Peak wattage, Imp, Vmp and power tolerance of the module
● Date and year of obtaining the IEC PV module qualification certificate
● Name of the test lab issuing IEC certificate.
● Other relevant information on traceability of solar cells and modules as per
ISO 9000 series

A distinctive serial
number starting with
NSM will be engraved
on the frame of the
module or screen
printed on the tedlar
sheet of the module.
Irradiance and Insolation

The sunlight has seven colours and many other radiations which are not visible to
the human eye. Each of these visible colours and invisible radiations corresponds
to a particular energy. All the radiations put together, sun rays falling on a square
metre area of earth typically gives about l000 Joules of energy every second.
Which technically means the power of sunlight is an irradiance of about 1000
Watt/m2 on earth’s surface. This is not always true everywhere. During cloudy
conditions it would be less. During early mornings and late evenings, it would be
less. At night it would obviously be zero irradiance. Under shade too, irradiance
would be less.

We read above that although sunshine is available for about 12 hours every day,
1000 Watt/m2 irradiance is not available throughout the day. Hence the total
energy available per day would be much less than l2000 Watt-hour/m 2. For
example, in Delhi its average is about 5500 Watt-hour/m 2 per day or 5.5 kWh/m2
per day. In summer months, it may be slightly higher and in the rainy season less
than that. This energy over the day is called Insolation and its unit is
Watt-hour/m2.

Although predicting irradiance of any given moment is impossible, Insolation per

day on any surface can be easily predicted. This is because studies have shown
that in most regions, daily energy of sunlight on a particular date of a month is
almost the same every year. Given below is the monthly average of Insolation per
day of different years in a place in Delhi.

All over the world, meteorological departments of many countries collaborate to

collect data of solar insolation in different parts of the earth through satellite and
on-ground measurements. This data is available with a history of more than 3
years for most regions on earth. Below is a link to one such website from NASA
which can get you insolation data for a given coordinate (Latitude and Longitude).

There are two types of Irradiances:

● Direct Irradiance: The power of sunshine per sq.m due to direct sun rays
falling on the surface
● Diffuse Irradiance: The power of sunshine per sq.m due to sun rays falling
on the horizontal surface after reflecting off clouds, buildings, lakes and
other hindrances on the way.

The sum of both the above irradiances is called Global Horizontal Irradiance (GHI)
and can be measured with a pyranometer in any surface at any given time
 Months 1985 2001 2005
Jan 4.2 4.4 4.4
Feb 5.2 5.4 5.5
Mar 6.5 6.6 6.5
Apr 6.8 6.8 6.7
May 6.3 6.4 6.6
Jun 6.1 6.0 6.2
Jul 5.8 6.1 6.1
Aug 5.7 5.9 5.5
Sep 5.3 5.2 5.2
Oct 5.2 5.2 5.1
Nov 4.4 4.5 4.4
Dec 3.5 3.8 3.7
Yearly 5.4 5.5 5.5
Average

Comparison of monthly average of per day Insolation in kWh/m2 over 3 different

years at a place in Delhi.

Sunshine hours

The graph given aside is an indication of

how the Irradiance varies from 6 AM to
6 PM on a day. Depending on the
month and which place we are in, this
changes completely. Let us assume
overall during that day, the Sun gave us
5 kWh/m2 energy in the place where
this graph is plotted.

Modules are rated in 1 kW/m2

irradiance.

This means a 100 Watt-peak rated module will give 100 Watt when 1 kW/m 2 falls
on it. So on a day when 5 kWh/m2 Insolation falls on it how much energy will it
give?

100 Watt X 5 kWh/m2 = 5 Watt-hour.

So here the value 5 kWh/m2 is behaving like hours. The only reason why this
happened is because modules are rated in 1 kW/m 2 irradiance. Hence, we call this
value Sun-Shine hours or Equivalent Sunshine Hours (ESH). In this example, we can
say the day received 5 hour ESH. It is same as the overall Insolation per day in
kWh/m2.
Design of Solar Power and Energy required

The electric power to run a pump

Pe = (Hydraulic Power/EfficiencyPump) / Efficiencymotor

In a Solar Pump system, it is the responsibility of Solar PV Modules to provide this

electric power. But for designing a solar pump, we prefer to design based on
energy required in a day and not power, because solar power keeps varying and
hence we cannot predict instantaneous power.

So let's modify above equation to calculate energy:

The electric energy per day needed
E = (Hydraulic Energy per day/EfficiencyPump) / Efficiencymotor

We have learnt that

Hydraulic energy per day Eh = V (Ltr/day volume) x p (1 kg/Ltr) x H(m) x g (9.8m/s 2)
The unit is in Joules

Hence the Solar energy needed E = (Eh / 3600 x Efficiency Pump x Efficiencymotor) in
Watt-hour

Now the responsibility of solar is to give this energy over a day. Let’s design that
step by step

● Step 1: Calculate E for each month based on water requirement

● Step 2: Get the coordinate (Latitude and Longitude) of the area where
pumping is required

● Step 3: Check the average insolation per day of every month in the
coordinate from NASA website
httns://power.larc.nasa.gov/data-access-viewer/

● Step 4: Select the month with highest value of E

● Step 5: For the month see what the average insolation per day is (Assume
5.5 kWh/m2)

● Step 6: Get solar power required = E/Insolation = E/5.5

 ● Step 7: Assume inefficiency of 5% losses due to dust, temperature etc, 3%
loss in cables and 25% losses in equipment like MPPT, Inverter, VFD etc. So,
7% of efficiency is assumed for the solar power system components on the
supply side (Efficiencysupply). If actual values of efficiency are available for all
components, multiply all the efficiencies to get supply efficiency.

● Step 8: Solar power required

Ps = E / (Sunshine hours x Efficiencysupply) in Wp

● Step 9: Calculate the water pumped per day in each month from above
Solar power using
Qmonth = Ps x SShr x Efficiencysupply x Efficiencymotor x Efficiencypump x 3600/
(p x H x g) where SShr is average daily sunshine hour of the month being
checked.

● Step 10: Cross check if in any month water pumped is more than the
requirement and plan to employ manual or auto switching off of the pump
in those months after enough water is pumped.

Water conservation methods and replacement of pumps for higher efficiency etc
need to be done before designing solar. Only then we can design solar for the
least cost.

After solar is installed if water conservation and better efficient pumps are
implemented, already oversized modules will be a waste investment. Also it may
cause higher than required water to be pumped out of the source due to higher
efficiency.
Design of Solar Array

We learnt to calculate solar power theoretically. Now practically there is a certain

capacity of solar modules available in the market. Eg: 45 Wp, 100 Wp, 250 Wp, etc.
Hence an array of such available modules needs to be designed to add up to the
rounded-up value of Ps.

Example if Ps is 2.3 kWp, either 10 numbers of 250 Wp modules can be used or 23

numbers of 100 Wp modules can be used or 8 numbers of 330 Wp modules can be
used. Altogether they form an array.

So, what are the factors we should consider to decide which modules are to be
used in the array?

● Rule 1: Different types of modules cannot be mixed and matched. It reduces

output due to mismatch losses
● Rule 2: Rounding up should not cause too much oversizing and value should
not be rounded down.
● Rule 3: The voltage generated by the array should be a value market
available devices are compatible with. Especially, the voltage range of the
device the solar gets directly connected to (the motor or the MPPT or
inverter etc), needs to be able to accept this voltage generated by the array.
● Rule 4: The current generated by the Array should be compatible with the
device it gets connected to directly.
● Rule 5: Try to maximise voltage and minimize current within the restraints
mentioned above
● Rule 6: The cost should be optimized (Certain modules have lower Cost per
Wp for being fast selling like 330 Wp)
● Rule 7: Where space is restricted consider higher efficient panels like
monocrystalline or multi-junction cells. Usually, solar pump installations are
in open fields where space restrictions are not common and hence this rule
may not be applicable.

Other than overcoming space restriction, efficiency of modules is not an important

parameter for selection of modules. Ultimately selection of module type to be
used is based on the impact on IRR (Internal rate of return).
Series Connection of Solar Modules

When the system voltage required is much more than a single PV module
can produce, a number of solar modules are connected in series to deliver the
required voltage level. Connecting the panels in series will increase the voltage
while keeping the current same. In series connection, the positive of one solar
panel is connected to the negative of another solar module. This is similar to
installing batteries in the torchlight.

Series connection has

only one path and can be
extended upto longer lengths as
per required voltages. It is
continuous and a closed loop,
and breaking this connection at
any point stops the entire series
from operating. Shading of the
solar panels can also affect the
entire series as they depend on
each other.
Parallel Connection of Solar Modules

When the system current requirement is more than a single PV module

can produce, the solar panels are connected in parallel to increase the current.
Connecting the panels in parallel will increase the current in amps while the
voltage remains the same. In parallel connection, the positives of multiple
modules are connected together and all the negatives of the same modules are
connected together.

Close Parallel Circuit. Each light

bulb has its own Connection to
the power source. So it still works
even with one Bulb removed.

When connected in parallel, if

the connection between any two
modules is broken, it will not affect the
other modules and power transmission
will continue. It is similar to the
connection in our household electrical
wiring. When you turn off the TV, it
doesn’t turn off your lights. These are
mostly used in smaller, basic systems
as the high amperage is difficult to
travel long distances without using very
thick wires.
Series-Parallel Connection of Solar Modules

When we need to generate

large power from the PV system, we Note:
need to connect the modules in a For Series Connection: Current
combination of both series and parallel. remains constant
Usually in this type of connection, the For Parallel connection : Voltage
modules are connected in series known remains constant
as PV module string to get high voltage
levels and these strings are connected
in parallel to obtain the required
current level for the system.
Example of connections in solar modules

Let us consider a solar cell having voltage of 0.6 V and current 0.8 A.

1.00
Current (A)

0.80
0.60
0.40
0.20
0.00
0.00 0.20 0.40 0.60
Voltage (V)
(a) Single cell
When two identical cells are connected in the series, the voltage between the
two cells will be added while the current through the combination will be the
same (see figure). In order to connect the cells in series, the positive terminal of
one cell should be connected to the negative terminal of the next cell.

1.00
Current (A)

0.80
0.60
0.40
0.20
0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40

Voltage (V)
(b) Two cells connected in series
When two cells are connected in parallel the current from two cells will be added
while the voltage of the combination will remain the same as that of a single cell.
 2.00
Current (A) 1.60

1.20

0.80

0.40

0.00
0.00 0.20 0.40 0.60
Voltage (V)
(c) Two cells connected in parallel
When more than one set of cells that are connected in series are connected in
parallel to each other, both current and voltage single cell can be obtained as a
combination of cells in series and connection of two such series and parallel is
shown in the figure. The combined voltage is 1.2 volt and current is 1.6 ampere. In
this way, both voltage and current can be increased to the level of our desire.

2.00
Current (A)

1.60

1.20

0.80

0.40

0.00
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40
Voltage (V)
(d) Series and parallel combination of cells
In typical solar PV modules 36 solar cells are connected together in series in
which case the voltage of 36 cells are added. Considering the details provided in
figure above, the cells in series combination of 36 cells will provide us 0.6 V × 36 =
21.6 volt and 0.8 ampere.
 Various combination of series parallel
connection to get desired power output

150W 265W 340W

Max power: 150W Max power: 265W Max power: 340W
Short Circuit Current: 9A Short Circuit Current: 8.7A Short Circuit Current: 9.5A
Open Circuit Voltage: 22V Open Circuit Voltage: Open Circuit Voltage:
Max Power Current: 8.4A 36.6V 46.2V
Max Power Voltage: 18V Max Power Current: 7.68A Max Power Current: 8.9A
Max Power Voltage: 30.6V Max Power Voltage: 38.2V

Design of Cables

Electric cable carries current from the solar module to the load connecting all
power conditioning equipment in between. In solar pumps, the current from solar
panels is DC current and the motor could be AC or DC. Whether DC or AC current,
as current passes through the cable, it loses voltage and power due to the cable's
electric resistance. The voltage and power lost are given below:

V=IxR
where V is voltage loss, I is current in ampere and R is resistance of cable

P = I2 x R where P is the Power loss

Now R is pL/A where p is resistivity constant of the cable material, L is length of the
cable and A signifies thickness of the cable mentioned in sq.mm of cross-section
area

As you can see above with more length of cable, resistance increases and with
more thickness of cable, resistance decreases. So, we try to reduce cable lengths
of connections and increase thickness of cable. But since the cost of cable
increases with its thickness, we need to optimize the thickness.

Usually accepted practice is to design cable to limit voltage drop to 4% of the

system voltage. So, if a copper cable is carrying 2 Amp current from a 24V solar
array to a distance of 10 m, the thickness of cable to be used is:
A = I x pL/V where I = 8 Amp, p = 0.017 Ohm-mm 2/m for copper, L = 10 x 2 = 20 m
(multiplied by 2 because two cables carry current in case of DC and 1 Ph AC
currents. If 3 Ph AC current, then 3 cables each carry the phase current in one
direction and neutral carries zero current. So multiplied by 2 is not required to
calculate thickness of each phase cable), V = 4 % of 2.4 V = 0.96 V

Hence, A = 8 x 0.017 x 20/0.96 = 2.8 mm2

So safely a 4 sq.mm cable can be used in above example 3sq.mm is not a standard
available thickness in market

Note: Please note that when system voltage is high, current becomes less and thus
voltage & power loss also becomes less. So if given a choice, we always prefer
higher voltage to reduce cable loss. But higher the voltage, higher the cost of
protective devices. Also a particular module available in the market would be for
certain voltage ratings only. Hence the trade-off should be properly analysed.

Ingress Protection of cable: Since the cable is used in outdoor installation, it should
be weatherproof and UV protected with proper protective sheathing around the
cable. Specially designed cables are available for solar applications. Usually
4sq.mm and 6sq.mm cables are common for most systems.
Evaluation

The Solar PV is used to generate electricity anytime and

1
anywhere provided __________ is available.
a. Wind
b. Water
c. Sunshine
d. Silicon

2 The conversion of Solar Energy into Electrical Energy is based

on the principle of
a. Photosynthesis
b. Photovoltaic effect
c. Radiation
d. Heat

3 Traditional solar panels produce __________ electricity as

output.
a. Alternating current
b. Direct current
c. Both a and b
d. None

When two cells are connected in series, _________ of the two

4 cells is added.
a. Power
b. Current
c. Voltage
d. Energy

5 The current of the two cells is added when they are

connected in
a. Series
b. Parallel
c. Combination of series and parallel
d. None
Evaluation

Higher power can be obtained using low power solar cells by

6 making ________ Connection of cells.
a. Parallel
b. Series
c. Combination of series and parallel both
d. None

7 What are the two types of insolation?

a. Direct and diffuse insolation
b. Straight and bent insolation
c. North and south insolation
d. East and West Insolation

8 What is the formula to calculate the electric power to run a

pump?
a. Hydraulic Power/EfficiencyPump
b. (Hydraulic Power/EfficiencyPump) / Efficiencymotor
c. (Hydraulic Power/Efficiencymotor) / Efficiencypump
d. EfficiencyPump / Efficiencymotor

9 When do we observe maximum solar irradiance?

a. Morning
b. Afternoon
c. Noon
d. Evening

10 Power cables are designed to handle how much voltage drop?

a. 2%
b. 4%
c. 10%
d. 5%
Answers

1 c. 2 b. 3 b.

4 c. 5 b. 6 c.

7 a. 8 b. 6 c.

10 b.
 Chapter 5

Solar Pumping
System Design
TOPICS COVERED

Basic Considerations

Site Survey

Site Selection

Pump Parameters

Factors affecting solar pump selection

Types of Pumps

Pump Selection Process

Flow chart for Pump selection for Solar PV System

PV Modules required per HP of Pump Power

Evaluation
Basic Considerations

In order to design and successfully implement solar water pumping systems, you
need an understanding of several concepts as well as information specific to how
you will use your system. These include:

● Daily water requirements and usage — drinking, irrigation, etc. Requirements for
high volumes or flow rates may limit applications.

● Available sunlight, which depends on location. Low levels of sun may limit PV
energy production.

● Well characteristics, such as depth of water table, drawdown levels and recharge
rates, seasonal variations, discharge elevation from earth’s surface to water
discharge point, total length of pipe, nominal diameter of the borewell and
discharge pipe, valves, and elbows, etc.

● Storage systems like catch tanks, concrete or plastic storage tanks, etc., to
ensure the daily water requirement is available during low-light conditions.

● Costs — capital, operation and maintenance, labor, life-cycle, etc.

Site Survey

While planning for installation of a solar pumping system it is important to identify

key parameters and anticipate major risk involved. Especially in large scale
installations it is critical to decide in advance what to do, how to do it, when to do it,
and who should do it. Well planned activities can significantly reduce the time of
installation and proper process should be followed while deploying the system.
The following steps should be kept in mind while conducting the site survey.
● For conducting this survey the tools required are
– Survey sheets
– Camera, or a good quality mobile phone camera
– Measuring tape and rope or water level indicator
– Compass
● In this survey the farmer or group of farmers are asked regarding their
– Land area to be irrigated
– Size of existing borewell if any
– Crops grown
– Water requirement
– Water level in their area especially during summer season
– Distance from the borewell to the farthest point of water requirement
– Site where the solar pump will be installed
– Any other details that the farmers would want to share
● Photographs and 360 degree video of the installation site is captured using
the mobile phone camera for site identification and designing purposes.
 Sample Site Survey Questionnaire

Survey Questionnaire
Client name, address, phone and other details:
Single point of contact:
Name of the surveyor: Date of survey:
Purpose of enquiry:

Water requirement:
Can water requirements be reduœd?
When is the water need year round?

Any existing solution?

Plan to replace the existing power source or pump?

Water source details:

If well, its diameter, water recovery rate etc:
If river/stream the coordinate of water drawing point:

Depth of water availability throughout the year and history of water table:

Area where pump is expected to be installed with coordinate:

Geographical description of the area (attach photographs):

Vertical and horizontal pumping distance with contour of the area:

Suction side details:
Delivery side details:
Coordinate of nearest shadow free region for module installation with photographs:
Existing pipeline and storage tank details:
Pressure requirement if any (Eg; for sprinklers):
Current energy expenses for the requirement:

Nearby buildings, lightning arrester etc:

 How to Determine the Groundwater Level of the area

Groundwater level in the area is checked by either conducting a drop test through
an open borewell at the site, and inquiring neighbouring farmers, local pump
technicians or from the agriculture office. The most reliable way to check
groundwater at the site of pump installation, is to do a drop test. To conduct a drop
test, a heavy object like a rock is tied to one end of a rope and lowered through the
open borewell till the water level is reached. The dry length of the rope from the
surface of water to the opening of the borewell is then measured which gives the
depth of water level in the borewell. Keep in mind the water level reduces during
peak summer time, since it is the lowest during that season and that needs to be
estimated and enquired from a local reliable source.

How to Determine the Water Output of Borewell

To determine the amount of water required per day on an average, based on crops
grown and agricultural land area to be serviced by the pump, the water output of an
existing pump if used by the farmer is measured. This can be done by a bucket test.

In the bucket test, a 20 Litre bucket is taken and water pumped out is filled in it. The
seconds taken to fill the bucket is recorded with a stopwatch. The time taken to fill
the bucket is then multiplied by the total time the pump will operate in a day - this
will give us the average water in litres required by the farmer for irrigation. This will
then need to be verified by the land area for irrigation and crops to be grown.

For example if the bucket is filled in 10 seconds,

then the water output is about

(60 ÷ 10) x 20 litres = 120 litres of water per minute.

Now, if the pump is operated for 2 hours everyday to irrigate the agricultural land,

then the pump runs for 2 x 60 = 120 minutes every day

Thus, the water requirement is 120 x 120 = 14,400 litres per day.
Site Selection

As a rule of thumb, the solar modules and solar pump installation requires a
south-facing square or rectangular area of 100 square feet per HP of the solar
pump. For example, if the farmers install a 5 HP solar pump, then the farmer
needs an area of approximately 500 square feet. The area should be shadow free
at all times of the day and year, otherwise solar power generation will not be
adequate to run the solar pump. The areas for installation of solar module
mounting structure, earthing pits and pump boring are measured and marked.

The pump needs to be facing south since the installation is being done in the
northern hemisphere. In case of the southern hemisphere, the solar modules
should be installed facing the north direction.

Preferably the pump should be installed near the solar module to reduce the
repair and transmission costs. During site selection, the distance between the
solar modules and pump is measured. This is important to calculate the length of
pipes and wires required.

Solar PV Location

The location for installing solar panels should fulfill the criteria given below:
● Even surface for mounting the solar panel structure;

● Shade-free area (no shade from nearby houses, structures, overhead tanks,
electricity poles, etc.)

● Low dust and dirt, low incidence of bird droppings;

● Easily accessible for cleaning of panels;

● As close as possible to the pump and water source; and

● Provision of space for unrestricted tracking movement.

For a proper site selection, there are a few things to be kept in mind.

● Trees or other structures that may cause shading near the borewell need to
be noticed and marked and asked to be removed or cut partially before
installation.

● Any other physical feature like mound, ditch/pit, any overhead electrical
cable which could cause a hindrance in installation need to be avoided.
Did you KNOW?
Add Page 7
 ● An access road or path needs to be maintained to the installation site to
carry out any maintenance operations if required.

Hence, a shadow free south facing site has to be selected for module installation
to ensure uninterrupted solar irradiation on the solar modules. The farmer
technical and site survey are extremely critical and can lead to the success and
failure of a solar pump selection and installation.

Pump Location

The location of the pump should fulfill the criteria given below:
● Minimal suction head should be preferred: If the water level is within 10
meters, a surface pump can be installed; when water level is below 10
meters, submersible pumps are installed.
● Low suction lift (vertical distance between the water surface and the surface
pump);
● As close as possible to solar panels;
● Suitable (higher/central) location within the area to be irrigated; and
● In case where multiple water sources are available, the location with the
highest water table should be chosen
Pump Parameters

a) Pressure:
The force per unit area of resistance in the system. The pressure rating of a
pump defines how much resistance it can handle or overcome. The amount
of pressure exerted by the fluid at a particular point. The strength of flow of
water depends on the water pressure.

Unit: Pascal (Pa), N/m²

b) Flow rate:
Flow rate is defined to be the volume of fluid passing by some location
through an area during a period. It is referred to as capacity, is the volume
of liquid that travels through the pump in each time.

Units: Cubic Meter per Second (m³/s)

c) Head:
Head is the maximum height that a pump can move fluid against gravity.
The purest example of this is if you have a vertical pipe extending straight
up from the discharge outlet. A pump with 5m of head will pump fluid up
the pipe 5m from the discharge outlet.
Units: meters

d) Pump Efficiency:
Pump efficiency is defined as the ratio of water horsepower output from
the pump to the shaft horsepower input for the pump.

ηpump = Pout/Pin
Water horsepower is the minimum power that is required to move the
water. Shaft horsepower is the power delivered to the shaft of the pump.
Keep in mind that any efficiency rating of the pump given by the
manufacturer assumes certain system conditions such as the type of fluid
transported: water is a typical standard. The efficiency may not be accurate
if these assumptions differ from the consumer's intended application.
Factors affecting solar pump selection
There are many factors that should be considered before deciding on the size of
solar water pumps, like

● Daily water requirement, based on the area to be irrigated and crops

grown throughout the year
The daily water requirement depends upon the landholding size and cropping
pattern of the particular farmer. A typical 2 HP solar pump can irrigate about
1 acre of land per day when the depth of water for irrigation is 2 inches in a
day. Thus, the irrigation requirement is high, especially required for growing
crops like Rice. In case low water intensity crops like mustard, sesame, and
pulses are grown, a 2 HP pump can irrigate about 2 acres of land while a 7.5
HP pump can irrigate upto 10 acres of land.

● Amount of water required to be drawn or flow rate

The actual flow rate varies depending upon the season and the water level of
the region. So, it is difficult to estimate the actual maximum flow rate in the
water pipe. However, the solar pump manufacturer provides the maximum
flow rate for the pump supplied with the system.

● Total Dynamic head or the Depth of water source

As you can see from the table for a 1 HP or 750 Watt solar water pump if
the water level is upto 5 metres or 16.4 feet, the flow rate is significantly
high. However, when water level goes down below 10 meters or 32.8 feet,
the flow rate reduces by two thirds, reducing the water output in the same
proportion.
● The size of the boring well if already present
The size of the existing bore well is important, for example if the bore size is
6 inches, then before selection of pump we need to check the diameter of
the pump and the pump diameter should be less than the bore size. This is
only applicable for submersible pumps.
Boring depth is required by the engineering team to determine the length of
the column pipe.
For submersible pumps the pump inlet should be matched with the bore
diameter or plumbing fittings need to be incorporated as per pump and
bore.

● In case of surface pump, distance of the water source from the pump
and running length of discharge pipe is important
A surface pump’s suction lift is maximum upto 20-25 feet, and the horizontal
pumping distance is 100 feet for every 10 feet vertical head. If a customer
uses a 100 feet pipe for water discharge, as a rule of thumb 10 feet of
vertical head or depth is added in the original head of the pump. Thus, the
distance from source to supply location for the solar pump is important. If
the distance to be pumped over ground is more, a submersible pump is
advisable.

● Water level of the region in peak summer season

From the summer groundwater level data, the engineering team can
understand the head range of the pump to be installed. The depth of peak
summer water level and the delivery of discharge water distance information
is required for pump selection.

● Grid power availability at the site and if it is single or three phase

If Grid power is available at the site and the customer wants to run the pump
through the grid, then we need to incorporate an AC change over switch
between Solar and Grid in the pump controller. Depending upon which grid
connection phase available at the site, the pump selection will vary
accordingly/. 1 and 2 HP pumps can only run through a single phase line,
while above 3 HP, a three phase power supply is required to run the pump
via grid.

● Budget
The cost of a solar pump is a determinant factor in pump selection as well.
DC pumps have higher efficiency and lifetime, but come at higher cost, while
AC pumps have lower efficiency but are cheaper and can be serviced locally.
 Characteristic Why is this characteristic important?
Static water level The static water level is the level the water source reaches
without pumping applied to it. This figure forms the basis
for calculating the total dynamic head.
Water source depth The depth of the water source must be known in order to
determine its volume.
Recovery rate The recovery rate is the rate at which water enters the
source from natural processes. The recovery rate must
exceed the proposed pumping rate or the water source
will run dry.
Topography The topography of the site must be known in order to
determine distances and gradients of water movement.
This information is used to determine pump sizing and
the location of components.
Water quality The quality of the available water can affect pump
selection as well as whether the water is suitable for its
intended usage.
Seasonal variations Seasonal variations in the available water source must
be known in order to evaluate a pump’s performance
over the whole year.
Other water losses Other potential water losses, such as evaporation, must
be considered when planning a pumping system.

Types of Pumps

As discussed in the previous chapter, we have seen there are various kinds and
quality of solar water pumps available in the market. To summarize we will get total
four combinations of motor-pump sets:

1. AC Surface Pump 2. DC Surface Pump

3. AC Submersible Pump 4. DC Submersible Pump

Pump Selection Process

Step 1: Determination of the amount of water required per day

The amount of water required each day or week will depend on the actual
application. If the water is being used within a village, household or a resort then
data should be available on the amount of water required per person in the village,
household or resort. This information could be obtained from the relevant
government departments or could already be known by the client. The designer
might need to have an ongoing consultation with the client to determine the actual
daily volume of water required.

As an example, the World Health Organization (WHO) states that a person requires,
as a minimum, 20 liters per day. If the site includes showers, washing machines etc.
then the water usage would increase accordingly.

If the water is required for agricultural use, then the requirement is determined
using the survey done pre-installation The water requirement depends upon:
1. The total agricultural area to be irrigated
2. The type of crop grown
3. Growing season

Let’s learn this with an example.

A field of 10 hectares needs to be irrigated where a cereal is growing which needs 4 mm

of water per day. Determine the water requirement for the field per day, assuming there
is a 30% wastage or loss of water due to various environmental factors.

Now we know 1 hectare = 10000 m2 = 1010 mm2

So, water required per day = 4 × 1010 mm3
1 litre = 106 mm3

Water requirement per day in litres = 4 × 1010 mm3 / 106 mm3 = 4 × 104 litres =
40,000 litres

Considering 30% wastage, water requirement per day = 40,000 + (30% of

40,000) = 52,000 litres

Based on the rain, a plan of pumping system and tank storage needs to be done.
This is site specific and is done by the engineering team of the solar installation
company.
Step 2: Check the available type of water source (Open Well, Borewell, etc)

The type of solar pump (Surface/Submersible) will depend on the water source. If
the source is a borewell, then a submersible pump that fits the borehole or well
should be selected. If the water source is a river, shallow well, pond or lake, then
either a surface or floating pump may be selected. During the site visit the
designer selects the pumping system that is most suitable for the site.

If groundwater is to be extracted for irrigation, then a submersible pump is used.

If the system is connected to a borehole then the designer must obtain
information on the diameter and depth of the borehole during site survey.
Diameters of boreholes are typically 100 mm (4 inch) diameter or 150 mm (6 inch)
diameter but they can be greater.

Step 3: Determination of total dynamic head

The Total Dynamic Head or TDH signifies the effective pressure at which the
pump must operate. It primarily consists of four parameters - pressure head,
velocity head, friction head and static head. Out of these the variable values are of
vertical head or total vertical lift and friction head or total frictional losses.

Total vertical lift = Elevation the pumping + Standing Water Level + drawdown of
pump + height at which water is discharged.

Standing water level is the difference between the ground surface and the water
level in the well, when the well is fully charged.

Drawdown is the height by which the standing water level drops due to pumping.

Frictional Loss is the pressure required to overcome friction in the pipes from the
water pump outlet to the point of water discharge. It is given in meters. Due to the
frictional losses, the total dynamic head increases. Use of borewell with higher
diameter and reduction in the number of turns the water delivery pipe reduces
the frictional loss.

In case of surface pumps, the suction head or total dynamic head is based on the
vertical elevation and the friction head. The drawdown effect is absent for open
sources of water.
The head loss due to friction in the diameter of borewell is given in the following
table:

Diameter of Borewell (in inches) Head Loss due to friction (in feet)
3.5 16.2
4 8.5
5 2.7
6 1.1
8 0.3

SQFlex Solar Curve:

The SQFlex solar performance defines the range of solar pumping for particular
capacity of wattage or Wp. At particular head it will show expected water output.
In the graph, the x-axis represents the total dynamic head or effective depth of
water. On the y-axis, the water output is represented in m 3/day. 8 separate lines
are shown, each representing a corresponding power obtained from the solar
panels, ranging from 100 to 1200 Wp. At a constant head of 20 meters, we see
there is a significant difference in the water output as shown in the following table:

Point Wattage of panels Head Water Output (m3/day)

A 100 20m 3
B 200 20m 8
C 300 20m 12
D 400 20m 16
E 500 20m 20
F 700 20m 25
G 900 20m 32
H 1200 20m 45

The SQFlex Solar performance curves are based on:

• Solar panels placed at 20° tilted angle
• Solar insolation at the rate of 6 kWh/m² per day
• Ambient temperature is 30°C
• The supplied voltage is 120 Volts with direct current supply

Step 4: Determination of the solar radiation available at given location

The insolation at a location is the total solar energy falling on a surface on a day,
and measured in watt-hour/m2. This is the summation of the direct irradiance and
diffuse irradiance.

The average value of solar insolation is approximately 5500 watt-hour/m 2, with an

equivalent sunshine for 5.5 hours every day. Therefore, the average insolation per
hour is 1000 watt-hour/m2 which is also the standard test condition (STC) for solar
energy calculations.
 Step 5: Determination of hydraulic energy required per day (in
Watt-hour/day) to pump the required amount of water

Total hydraulic energy required by the submersible pump = Mass x g x Total

Dynamic Head where g = acceleration due to gravity = 9.8 m/s 2

Also, hydraulic energy required = Density x Volume x g x TDH

or, hydraulic energy required (in Wp) = ( Density x Volume x g x TDH ) ÷ 3.6x10 3
where 3.6x103 is the conversion factor.

Taking cue from the previous example, let us see how much energy is required to
pump the field per day.

Daily water requirement = 52,000 litres

Effective sunshine hours = 5.5 hours
Hourly effective water supply = 52,000 ÷ 5.5 = 9455 litres

Therefore, volume of water required per hour = 9455 litres

Density of water = 1 kg/litre

Assuming the total dynamic head of the region to be 20 metres,

Hydraulic energy required per hour (in Wp) = (1 x 9455 x 9.8 x 20) ÷
3.6x103 = 514.7 Wp

Thus, this is the total hydraulic or potential energy of the water raised due to
pumping, which must be supplied to the pump. For a surface sump, the total
dynamic head is replaced by the length of vertical lift of water from the source to
the pump.
 Step 6: Determine the Pump capacity and size and number
of PV modules required

Nowadays, various types of PV modules are available, with capacity ranging from
5 Wp to 400 Wp. Panels with suitable specification are used for solar PV systems.
Most commonly used panels are 300 Wp panels, widely available in India.

Solar PV modules have an efficiency of approximately 15-20% depending upon the

type and condition of the panels. The average efficiency of solar PV modules is
18%. This is considered while providing the power rating of the solar panels.

Pumps-motor set has an average efficiency of 80% and the controller including
VFD and MPPT has an efficiency of 90-95%.

Operating factor is the estimate of the actual output from a PV module. The
operating factor is between 0.6 and 0.9 implying the output power is 60 to 90% of
the rated output power in normal operating conditions, depending on
temperature, dust on module, etc.

System efficiency = Pump-motor efficiency x Controller efficiency x Operating

Factor

Total power requirement from the solar modules (in Wp) = Hydraulic power
required ÷ System losses

Number of Solar PV Panels required = Total power requirement ÷ Power rating of

each module

Power rating of motor (in HP) = Total power requirement ÷ 746

Let us determine this with the solar panels and size of pump required for
the example we were discussing before.
Considering,
Pump-motor efficiency = 80%
Controller efficiency = 95%
Operating factor = 0.85

System efficiency = 0.8 x 0.95 x 0.85 = 0.646 or 64.6%

Total power requirement from the solar modules (in Wp) = 514.7 ÷ 0.646 =
796.75 Wp

Solar panels of rating 300 Wp are commonly used.

Number of Solar PV Panels required = 796.75 ÷ 300 = 2.65 ~ 3 panels

Power rating of motor (in HP) = 796.75 ÷ 746 = 1.06 ~ 1 HP

Step 7: Choice of motor based on efficiency and other factors

The above calculations are done considering the DC motor driven pump. A
system can also be designed for an AC motor but one must consider the inverter
and its efficiency in the calculations.

Voltage of the solar pump motors can be AC (alternating current) or DC (direct

current). Direct current motors are used for small to medium applications. The
cost of DC motors are higher than AC motors and for the same capacity they
provide better water output as compared to AC pumps. But recently, prices of DC
motor driven solar pumps have reduced considerably.
Flow Chart for Pump selection for
Solar PV System

Off Grid Surface and Submersible Pumps (AC / DC)

1 Find Head and LPD

2 Get Insolation

3 Find Litre per hour

4 Plot the system curve

5 Find the Pump shaft power

Compare pump curve of few pumps with

6 required shaft power

Select the one which matches system curve at

7 its maximum efficiency point

Ensure NPSHa and decide

pump positioning

8 Calculate motor input energy

9 Design solar array

If intended to use tracking check its feasibility

10 and design solar array accordingly

Select the MPPT, Inverter and VFD

Common Steps panels as per requirement
Additional Steps for AC
Select the MPPT, DC-DC Converter and
Additional Steps for DC
Voltage regulator as per requirement
 Off Grid Solar Pumps with battery backup

Find Head and LPH 1

2 Plot the system curve

Compare pump curve of
few pumps with 3
required shaft power Select the one which matches
4 system curve at its maximum
efficiency point
Select pump position 5

6 Calculate motor input energy

Design battery bank 7

8 Design solar array

If intended to use tracking
check its feasibility and design 9
solar array accordingly
Select the MPPT or Charge
10 controller, Inverter or DC-DC
Converter

On Grid System - Surface or Submersible

Find Head and LPH Plot the system curve

Find the Pump shaft power

Compare pump curve of few pumps
with required shaft power

Select pump position

Select the one which matches system

curve at its maximum efficiency point

Calculate motor input energy

Based on scheme running

decide solar array capacity Select the MPPT and Grid tie Inverter
that is economically feasible
PV Modules required per HP of Pump Power

We know, 1 HorsePower (HP) is 745.7 or 746 Watts.

Considering the PV modules are connected in series, the voltages are added while
the current remains constant.
If the PV Modules are connected in parallel, then the currents are added, while the
voltage remains constant.

Total Voltage = 36.7 V + 36.7 V + 36.7 V = 110.1 V

Total current = 8.18 A
Total Power output of PV array = 110.1 x 8.18 = 900.62 Wp

To run a motor-pump set of 1 HP capacity, considering the system losses, we need

3 Solar modules of 300 Wp connected in series to get 900 Wp.
Similarly for higher pump capacity more number of panels can be added to get
desired power output, as shown in the following table:

Motor Pump set Motor Pump set Solar PV Power No. of Modules
capacity (HP) capacity (Watts) (Wp) of 300 Wp
1 745.7 900 3
2 1491 1800 6
3 2236.5 2700 9
5 3727.5 4500 15
7.5 5591.25 6750 23
10 7455 9000 30

The number of panels need to be aligned with the structural compatibility with
the mounting structure and connections. For example, if 200 Wp modules are
used, then the number of panels will vary according to the following table:

Motor Pump set Motor Pump set Solar PV Power No. of Modules
capacity (HP) capacity (Watts) (Wp) of 200 Wp
1 745.7 800 4
2 1491 1600 8
3 2236.5 2600 13
5 3727.5 4400 22
7.5 5591.25 6400 32
10 7455 8000 40

Note: When an odd number of panels are used, especially when more than 3 HP
pumps are being installed, then there can be issues with alignment and
connections. Therefore, even numbers of panels are preferred.
Evaluation:

If depth of the water source is 110 feet then it is advisable to use

1
surface pump
a) True
b) False

2 Overall efficiency of AC pumps is better than DC

a) True
b) False

Submersible pumps are used as they are more efficient than surface
3 pumps
a) True
b) False

Which type of pump should be required to draw 25,000 liters of water

4
every day from depth of 30m
a) DC Surface pump
b) AC Surface pump
c) DC Submersible pump
d) AC Submersible pump

Calculate the water output from the SQFlex Solar graph, if 900 Wp of
5 panel is connected to 1 HP pump at a total dynamic head of 30m.
a) 8 (m3/day)
b) 12 (m3/day)
c) 23 (m3/day)
d) 32 (m3/day)

6 In above question water output flow rate will increase when

a) Increase in radiation
b) Decrease in radiation
c) Increase in Total dynamic head
d) Decrease in Total dynamic head

7 Efficiency of pump will increase with increase in ambient temperature

a) True
b) False
Answers

1 c. 2 b. 3 b.

4 c. or d. 5 c. 6 a&d

7 b.
 Chapter 6

Solar Pump Installation

TOPICS COVERED

Material management checklist for Installation of Solar Pumping System

Civil Work for Solar Pump

Construction of the Civil Foundation

Assembly of Module Mounting Structure

PV Array installations

Installation of Submersible Pump

Installation of Surface Pumps

Installation of Controller Box

Installation of Earthing Rod, Lightning Arrestor and RMS

Quality Standards

Quality Check Report Format

Commissioning

Common Errors
 Material management checklist for
Installation of Solar Pumping System

1. Solar PV Array
✔ Note brand & references of solar panels on the identification sheet
✔ Count number of solar panels
✔ Measure tilt of solar panels
✔ Verify state of solar panels, note number of damages panels if any
✔ Cover the solar panel with a blanket/cardboard cover while
transportation

2. Motor-pump set
✔ Note brand and model on identification sheet
✔ Verify depth of immersion
✔ Carry a wire rope to support the suspension of pump
✔ Cable is not tense (reserve for pipe elongation)
✔ Note length of borehole pipe
✔ Note length of cable

3. Controller box
✔ Note brand and model on the identification sheet
✔ Verify connection within the box
✔ Verify height from the ground
✔ Disposed under shadow

4. Structures & Support

✔ Verify support alignment
✔ Verify verticality of poles
✔ Verify the good sizing and robustness of foundations
 Material management checklist for
Installation of Solar Pumping System

5. Cables
✔ Verify type and section of cable
✔ Verify cable tightening in cabinet and at terminal connections
✔ Presence of cable glands at cabinet entrance
✔ Cable correctly fixed and attached
✔ Underground cables are installed inside ducts
✔ Cables between structures (panels groups) are undergrounded if any
✔ The solar panel support is connected to the ground with a cable
✔ Solar panels are connected to their support with suitable cables
✔ Pump and its controller are connected to the ground by a cable of same size than
power cables

6. Lightning arrestor & Earthing

✔ Lightning arrester connected to ground by a cable of 16 mm² at least
✔ This should be attached to structure as per drawing
✔ Earthing rod (grounding) should be connected with lightning arrestor

7. Water-level sensor (Optional)

✔ Generally float switch is used as a water level sensor
✔ Suspend the water level sensor in the tank at appropriate height
✔ Check the connections with controller box

8. Pipes
✔ Select the pipe of suitable length as per requirement
✔ Diameter of pipe depends upon the type of discharge
✔ Length of pipe is sum of depth at which submersible pump is suspended and
distance at which water is discharged
Precautions for Solar Pump Installation

Most of the pump manufacturers provide the pump, water pipes, controller,
nozzles, foot valve and connectors with detailed installation manual. Hence, pump
installation has lately become a plug and play system. The PV module, mounting
structures and associated components however are usually tailor designed for the
terrain and application. In any case there are certain safety precautions and
preparations to be taken care of before installing the system. Few are given below:
● The entire process of installation, safety precautions, naming, labelling,
quality standards to be adhered to, customer training and documentation
need to be planned beforehand. All the activities, their sequences and the
responsibilities need to be clearly communicated to the team members
● Safety boards, equipment, emergency instruction etc. need to be accessible
to all, easily
● Solar PV modules need to be treated as electrically live during daytime
● Risks at the site should be anticipated based on survey. Mitigation plan
against risks like snake bite, marshland etc. need to be made as necessary
● Transport documents, invoice etc. to be secured before supply of material
● Cable continuity and resistance, module batch and serial number details,
equipment identifiers etc. need to be captured before transport or at site
before opening the package
● Tools should be handy as per plan. Electrical measuring tools, tools for
fastening, grinding and cutting, adhesives, Teflon tapes, level tube,
pneumatic measurements, flow meter, spares of few consumable items etc.
are some examples
 Civil Work for Solar Pump

Civil work is a very important part for the solar pumping system, as it bears the load
of steel structure and solar panels. Any mistake in civil work can cause irreversible
damage to the structure and solar panels. The foundation should be strong enough
to support the structure and moreover it is very important that concrete work
should facilitate the alignment of structure as per design. Mis-alignment in structure
can lead to misalignment of panels. Exact shape of the civil work foundation may
slightly vary depending upon the design of the structure which is used, but more
less a basic pattern is followed.

Before installation and commissioning of the solar pump, some important

documents need to be shared with the Installation team. The documents that needs
to be shared with the team before going to site are:
● Site address with customer contact details
● Site survey report with open site map
● Balance of materials list (BoM) including electrical equipments, mechanical
tools and safety gears
● Structure drawing and design of the installation site
● Single line diagram ( SLD ) of the solar pump system being installed

The first task undertaken is clearing the undergrowth of herbs, shrubs and trees
from the installation site. The plants are uprooted and any debris in the area is
removed to facilitate formation of civil structure on clear ground.
 Types of Civil Foundations

Typically there are 3 types of civil foundations for solar pumping systems.
Foundation bolt grouting type with RCC (Reinforced cement concrete)

This structure is made using GI rods and

Reinforced concrete base and fixed with
anchor bolts to fix the module mounting
structure. These structures are used for
single pole module mounting structures
which are used for smaller sized solar pumps
(1 to 3 HP). These are structurally strong and
can resist flood damages. However, the
structure base is strengthened with iron,
which is susceptible to corrosion after a few
years of use.

Foundation pipe type

The pipe type structure is the most preferred
civil structure due to ease of installation as well
as durability of the structure. The structure
includes a pole pipe and pipe holding structure
embedded in the ground in a concrete pillar.
This civil structure is easier to construct as well
as has lesser chances of loss due to corrosion.
However, the pipes can bend in case of severe
winds, so they are not suitable for single pole
mounting structure, and used mostly for four or
more legged mounting structures.

Foundation with fixed structure

These structures are similar to the pipe

type, however, instead of pipes, GI
rods are used to make the base and
they project out on the ground, and on
them the module mounting structure
is fixed. These are cheaper and easier
to install, however they are more
prone to corrosion and damages due
to environmental factors.
Construction of the Civil Foundation
Foundation bolt grouting type with RCC (Reinforced cement concrete)

Structure Sketch of Bolt Grouting Type Foundation for Solar Modules

Step 1: Dig up the pit with Step 2: Prepare the concrete

dimensions of 1.5 X1.5 metre with M20 ratio (refer
as shown in photograph annexure for composition).
Pour appropriate amounts of
water in the concrete
mixture. Pour the cement
upto 15 cm height before
placing the RCC cage.
 Step 3: The RCC Cage is
inserted in the hole.
Anchor bolts (nut with two
legs) inserted in each
corner that go up. L Step 4: Place the column at
structure fixes in mesh. the centre of the RCC cage.
The space between the
RCC cage and base is filled
with cement mixture.

Step 5: Set up the column

shuttering using wooden
planks
Step 6 : Pour the concrete
mixture into the pit.

After concreting, the foundation needs to be cured by pouring water

frequently and keeping it wet for a minimum of 3 days. Before curing, if
we start loading the column with weights, it may fail to hold the load.

The bore size, the column post size etc. is decided based on the weight
of the mounting structure and on the strength of the soil. In cases
where soil is of very low strength (Like black cotton soil), first soil
strengthening measures like compacting may have to be carried out
before laying the foundation. In certain cases, instead of plain PCC, RCC
(reinforced cement concrete) will be required by placing steel bars in
the bore before concreting.

For large projects cement and aggregates used need to be sent for
Design Mix test in authorized labs to ascertain strength of concrete.
 Step 7: Fix the bolt into the
column using pro-farma
plate Step 8: Check the
alignment with a spirit level
indicator

Step 9: Put cement

concrete into the column
for fixing the nuts

Step 10: The structure is

ready for installation of the
single pole module
mounting structure.

If motor-pumpset, motor controllers etc. are planned to be mounted on a

concrete plinth or stand, foundations for the same can be built similarly.
Foundation for Fix Structure (for Multiple legged Structure)
Installer Tip: This is a common mounting structure used for 5 HP and higher
sized solar pump installations.

Step 2: The fixed mounting

Step 1: Line up posts 2 m
posts or structure legs are
apart. Dig holes about 1.2 m
fixed by placing them in the
depth there. (As per design
holes and pouring the
provided by manufacturer)
concrete in the foundation
and setting the piers

Step 3: Make sure the Step 4: Posts are fixed in

ground is level and use string these holes with the help of
line or chalk to mark the cement mixture for strong
exterior measurements and foundation. Some shuttering
the location of the posts. support is given for elevated
ground structure, providing
higher support. The
foundation is cured with wet
Step 5: Make sure all the posts are
of the same height. gunny bags overnight for a
strong foundation.

Please note that if there are multiple column posts,

their height level needs to be adjusted before concreting
is complete. After the concrete is set, no change in the
height or position of the column post will be possible.
Did you KNOW?
Add Page 8
Assembly of Module Mounting Structure

Solar arrays can be installed on structures (roof-mounted), tank mounted, on the

ground, on poles or on trackers. Suitable mounting structure can be selected
based on the requirement and site conditions. The structural supports used to
attach the PV panels to their mounting posts are typically provided by the solar
panel manufacturer. The supports must be installed per the manufacturer’s
specifications to avoid any unintended stresses.

Solar module mounting structures contribute to only around 10% of the entire
Solar Pumping system cost. However if chosen the wrong structure, it may have
an adverse impact on the overall installation. Today, there are wind speed and
galvanizing norms such as 150 km /hr and minimum 85 microns for design of
structure.

Various module mounting structure solutions are available as per requirement of

site / project / customer. They are designed in order to maximize yield within a
minimum area. Tailor made structures are also available to suit project
requirements, which maximize the generation from solar modules. Before
mounting the solar module on the mounting structure, the module serial numbers
are noted for warranty and maintenance purposes.

The MMS drawing, component details etc. need to be handy before starting MMS
installation. The sequence of installation should be clearly understood

2
 Assembly of Single Pole Structure on Bolted Civil Structure

Step 1: Place the main pole on

the structure and fix it on
foundation bolts Step 2: Fix the top plate and
vertical bracket plate

Step 3: Place the main rafter

on top plates Step 4: Place the panel
mounting purlin on main raft

Step 5: Similarly place the Step 6: Fix the side support

other panel mounting purlins bars and purlins to main rafter
the on main raft
 Step 7: Fix the clamps on the panel mounting purlin

Step 8: Place the panels on

the structure
Step 9: Place the panels such
that connectors output should
be near the centre pole for
easier connection with the
pump controller

Step 10: Similarly put the

other panels on the rafter.
Check the south direction
facing structure of the
module. Angle of tilt from the
ground parallel level should
be the latitude of the
installation location
 Assembly of Pipe or Fixed Module Mounting Structure

Step 1: In case of fixed mounting structure, rafters are attached to join two
structure legs. Two rafters are attached on each side of the mounting structure.
Galvanised iron nuts and bolts are used to join the structures.

In case of pipe mounting structure, place the main pole on the ground pipes and
fix them with screws provided.

Step 2: The module mounting member is installed on the foundation of

C-channels.

Step 3: The structure alignment is checked using a spirit level indicator. If the
bubble in the spirit level comes to 90 degrees, then the installation is properly
aligned.

Step 4: The back legs of the structure and rafters are joined by rods at a defined
angle as per the mounting structure plan, and they are called cross members.
These cross members are attached using GI nuts and bolts.

Step 5: Each end of the C-channel is bolted to the structure legs. Stainless Steel
nuts and bolts are to be used to prevent corrosion and rust.

Step 6: The Tilt bracket is installed on the mounting structure to hold the solar
modules in place. This is fixed with stainless steel nuts and bolts.

Step 7: Once the alignment of the mounting structure is checked, the modules
are placed on the mounting structure one by one and fixed using anti-theft
stainless steel nuts and bolts.

Step 8: The orientation and tilt angle of the solar array is checked using an angle
finder instrument. The angle of tilt from the ground parallel level should be the
latitude of the installation location.

All the fasteners (like nuts and bolts) will have a torque value for the required
tightness. The basic principle is that it should not be too tight to cause stress in
the MMS nor should it be loose causing the MMS to fail from holding the module
weight. Also, it is a good practice to keep the fastened slightly loosened until the
modules are all fixed, since for levelling the modules, the rafter and purlins will
need to be adjusted a little bit. After the adjustments, when the module is
completely installed, all the fasteners can be tightened properly.

In case of tracking mechanism, the actuator unit, motor and the tracker MMS
need to be installed in the presence of the manufacturer of the tracker or by a
trained expert.
PV Array installations

Solar PV array is one of the main components of any solar PV water pumping
system. Thus, the performance of the solar PV water pumping system highly
depends on the proper installation of solar PV arrays.

Determine the position where the array needs to be installed

The solar PV array is to be installed carefully at a proper location to avoid
shadowing of any part of the array or other obstructions throughout the
day any time of the year. The output from the solar array is maximum
when solar radiation falls perpendicular to the surface of the module.

For optimum power output, the array should be south facing and tilted at
an angle equal to the latitude of the site. A manual tracking system is a
cost-effective option for maximizing power output. The array can be tilted
monthly or every couple of months, according to the required scheduling.

Following factors shall be considered while installation of solar PV array:

a. Shadow: When a solar panel is shaded in whole or part, for example, by tree
branches and or a building, it captures less energy from the sun, thus its
performance is reduced. Even minor shading can result in significant loss of
energy. It is recommended that the solar PV system be installed in a shadow
free area.

Possible sources of shading include:

● Vegetation – trees, bushes, long grass, leaves
● Structures – buildings, shelters, fences, telegraph poles,
● Landforms – hills, rocks, and
● The array itself – not leaving enough room between rows of tilted
modules can cause one row to shade the row behind it.
b. Orientation: In the northern hemisphere, south facing panels are in the best
possible orientation. If the solar PV is to be mounted at a tilt, a wider range of
orientations will still give a reasonable energy yield.

c. Tilt: A tilted array will receive more light than a vertical array. For
self-cleansing, a minimum tilt of 20° to the horizontal is recommended to allow
the rain to wash dust off the solar panels. The solar module has to be installed at
a tilt angle approximately equal to the latitude of the area.

Installation of Solar Modules

Step 1: Modules are placed over the purlins and secured to the purlin with the
fasteners provided. Please ensure two persons handle each module installation to
avoid any risk of breaking.

No matter how small or big the system, the modules should be neatly arranged
over the purlin and secured properly. If required, spacers can be used to keep the
same space between each module. A small gap needs to be given between
modules for air movement

Step 2: For module interconnections it is always recommended to use MC4

connectors instead of joining them in the module junction box with lugs. All cables
need to be properly dressed without hanging using cable tie.

For parallel joining all the string +ves and —ves and taking out just two cables out,
a string junction box can be used. Also, a DC SPD is provided for protection.

Step 3: Please follow the Single line diagram or SLD provided by the engineering
team.
● For pumps upto 5 HP, modules are mostly connected via a series
connection, wherein adjacent modules are connected to each other and
the positive wire from first model and negative wire from last module is
connected to the pump controller.
● For pumps over 5 HP, we may need to connect modules in series and
parallel connection as per SLD. It must be noted that the positive and
negative terminals of the connectors need to be connected correctly.

Step 4: The voltage and current of each solar module must be checked using a
multimeter. For this, the positive and negative terminals of the solar module are
connected to the positive and negative heads of the multimeter and the
multimeter reading is recorded.

Step 5: Before the solar array is connected to the pump controller, it should be
checked using a multimeter and reading recorded.
 Connections in the PV Modules

Typical connections for 1 HP Pump set with PV array of 300 Wp panels:

Typical connections for 3 HP Pump set with PV array of 300 Wp panels:

Typical connections for 5 HP Pump set with PV array of 300 Wp panels:

Installation of Submersible Pump

Installation of the motor-pump set includes placing the set in the designated
region and installing the suction and delivery pipes.

The pump should be located at least 1 metre (3.3 feet) above the bottom of the
borehole/well and sufficiently below the “drawdown level” so as not to allow the
pump to operate dry.

It is recommended that a water level sensing system be incorporated into the

system to prevent the pump from going dry during operation.

Step 1: Inspect the well/ Borewell

● Check the depth and standing water level.
● Check the well total depth – the distance from the ground level to the
bottom of the well.

Step 2: Check components

● Carefully check all the
components required for the
installation.
● Check the details of the motor
such as power supply ratings,
whether its 3-wire single
phase or 2-wire single phase
and if it needs a pump starter
box or 3 phase configurations.
Look for signs of external
damage to casing,

Step 3: Check the power rating

Check the details on the surface/submersible motor looking for power supply
rating.

Step 4: Check the cable rating

Check the cable rating that suits the motor cable and motor and is correctly rated
for submersion in water.
Step 5: Pipe & Fitting
Check that the fittings match the outlet on the pump, the rising main and the bore
cap.

Step 6: Fit motor to pump

In case of submersible pumps, pumps and motors come in different boxes. Motor
needs to be fitted with pumps.
● Check the shaft of the motor to match with the pump set.
● Use the grease provided and lubricate and seal the splined shaft on
assembly.
● Use a poly pipe or lay flat fitting with thread tape and screw into the pump
and fix the motor to pump.

● Splice drop cable to motor cable with supplied cable splice kit When drop
cable is connected to motor, it is necessary that the splice be water tight.
 ● Carefully follow the instructions on the kit you start the splicing process.

Step 7: Cover the motor pump joint to prevent

stone particles from entering into the pump set.

Step 8: Tie the rope : In case of submersible motor

tie the rope or wire rope with knot as shown in
diagram or as shown in the figure

Step 9 : Fix the pump

● Fit the rising main to pump carefully and roll
out.
● Fit bore cap to the other end of the rising
main. Rising main is the pipeline that conveys
water from pump discharge to distribution
chamber.

Step 10: Roll out drop cable

● Connect the safety cable to pump, the rising
main and drop cable
● Attach safety cable end to bore cap allowing
for rising main to stretch

Step 11: Check the connections are tightly held

Step 12: Cable tie

● Tie the cable along the length of pipe at regular
intervals to prevent the cable damage
● If it is loosely suspended attach stainless steel
safety cable to pump and roll out with rising
main and drop cable.
● Attach safety cable end to bore cap allowing for
the rising main to stretch
 Before lowering the pump to the water source, complete the electrical
connection as well.

Step 13: Lower motor pump set into the well

■ If the weight of the assembly is light enough to handle, gently lower the
pump end into the well with an assistant to hold the bore cap end.
■ Feed the assembly down the hole, pay particular attention to preventing
damage to the electric drop cable.
■ The assembly should be suspended by the bore cap on top of the casing.
■ Recheck all the fittings to ensure every component is perfectly attached and
working.
■ Lower the pump end into the water well to hold the bore cap end.

In case of an open well submersible pump, the installation shall be on the

floor of the water source or at any planned height inside the water source.
Either it can be hung from a support or placed in a housing made inside the
water source for installing the pump.

■ Connect pump starter, pump controller and pump protection device to

power supply and test pump.
■ Allow a few moments for the water to reach the surface.
■ On completion of the initial test proceed to connect the required pipe work
to the bore cap.
■ Finally test pump operation and operation of pump protection devices and
controls.
■ Position roller over in the well/borewell. Slowly allow the pump to be
lowered into the well.
■ Lower the last meter by hand if possible or allow the well cap to bump over
the roller and into position on the casing.

If recommended by the pump manufacturer, a non-return (check) valve

should be installed in the discharge pipe just above the pump.

Step 14: Installation of Delivery Pipe

● The discharge pipe should be screwed into the outlet of the pump to help
support the weight. All connections should be watertight.

If any portion of the delivery pipe needs to be run horizontally on ground and
to the storage tank, necessary precautions must be taken for either burying
the cable in ground at lm or supporting the cable with a metal raceway,
properly clamped. In any case, avoid leaving pipes freely on the ground
surface or dangling vertically without support.

● A gate valve should be installed in the discharge pipe after it exits the
borehole.
Cavitations can have such force that it tears apart metals or ages pump materials
prematurely. Air bubbles in pumping applications are when subjected to low
pressures. This occurs because at low pressures, water boils at a lower
temperature than normal, and boiling water releases air bubbles. As water moves
from a low-pressure area to a high-pressure area, these air bubbles can implode,
damaging the pump.

■ To prevent cavitations, it is important to ensure that the flow rate of the

pump will remain on its prescribed curve, as given in the specification sheet.
This will prevent excessive pressure drops in the water that is being
pumped, minimizing the risk of cavitations.
■ Avoid sharp bends and also use the right kind of diameter both for suction
and delivery pipes. The friction losses are less in PVC pipes compared to GI
pipes.
■ Avoid usage of reducers or bends as they normally create impediments and
reduce the head. In case of bends, always use smooth bends rather than
sharp 90° bends.

Installation of Surface Pumps

Step 1: Placement of pump

Mount the surface pump on a secure
and strong base such as a base made of
concrete. This will ensure pumps do not
vibrate or move when in operation. Also
make sure the pump is close to the
water source.

It is also recommended that all pumps be protected from direct sunlight. This
can be done using a sheet metal cover.

Step 2: Check all components

Select the diameter and length of the suction and pressure pipes as well as those
of any additional components. The diameters of the pipes must be equal to or
greater than the connection sizes on the pump. The power rating of the installed
drive system must be sufficient.

In case of wells, if the depth is much higher than the suction head allowed to
achieve NPSHa > NPSHr, then the pump will have to be lowered into the well
and installed inside the well at a height where the suction pipe is within
allowed suction head.
Step 3: Intake piping
● To minimize the vertical lift, the height of the surface where the pump is
placed should be reduced.
● The length of the pipe should be minimal at the suction end.
● Before placing the suction pipe into the water source, make sure to install
the foot valve with strainer (unless manufacturer specifies not to) in the end
of suction pipe to avoid draining of primed water while the pump is
non-operational.
● A short flexible hose is provided to make connection to the pump easy.
● The suction pipe should always be as large as the inlet on the pump. If it
happens to be larger, then an eccentric reducer should be used; a
concentric reducer should not be used
● Suction pump should be full of water while installing.

● Suction pipe should be connected to the suction inlet to the nozzle

provided by the manufacturer.
● First drape the nozzle thread with a Teflon tape and slowly insert the HDPE
or PVC or metal pipe over the nozzle. Then secure the pipe with a metal
clamp around the pipe with a fastener.

Make sure that at least for a distance of 5 times the diameter, no bend is given in
the pipe. Also, if any pressure gauge is to be connected in the suction side, plan it
early to get required accessories for the connection.

If more than 3m of the pipe needs to run horizontally, please bury the pipe
underground in a lm deep trench. If less than 3m, provide a UV protected PVC
conduit or metal raceway support to place the pipe neatly and secure it with a
clamp. In any case the pipe should not be left freely over the ground. It may cause
damage to the pipe and expose it to risks like rodent attack.

Before placing the suction pipe in the water source, make sure electrical
connections are also complete.
When installing the suction pipe:
● Maintain NPSH a > NPSHr
● The length of the pipe shall be kept at a minimum and if using rigid pipe
keep the number of bends to a minimum using sweeping bends instead of
right-angle bends where practical.
● The suction pipe shall be installed such that the end of the suction pipe is
clear from obstruction (e.g.the bottom of the water source) and at a
suitable depth below the water surface, so as not to suck in any air or
floating debris.
● If possible, ensure that at no point in the suction pipe that the pipe is higher
than the inlet of the pump nor should there be a point where the pipe (on
the water source side) is higher than another section of the pipe between
that point and the pump. This may result in air being trapped.

Step 4: Outlet piping

● Similar to suction pipe, delivery pipe also should be connected to the outlet
nozzle given by manufacture by draping Teflon tape on the nozzle thread
and inserting the pipe over the nozzle.
● The pipe needs to be secured with a metal clamp around it with a fastener.
● A gate valve shall be installed at the outlet of the pump as per
manufacturer’s instruction.
● Delivery pipes also need to be buried 1m below ground if more than 3m
horizontal run is expected. The unburied portion needs to be inside a UV
protected PVC conduit or a metal raceway support with clamp, to avoid the
pipe being freely left in open ground or to avoid the pipe dangling without
support vertically.
● If water is delivered to a tank, at the tank end too, the delivery pipe should
be properly secured with clamp and take all measures to avoid leakage in
the pipe in any connections.
● If flowmeter or pressure gauge is to be connected to the pipe, plan the
same prior to installation to avoid rework and cutting of pipes at site.

Always read the manufacturer manual to understand if the pump is

self-priming or not. All priming requirements and associated
accessories need to be understood properly before installing the pipes.
 Plumbing connections

Hose:
Hose is basically a flexible tube
provided to convey water. Most of the
pumps have hose already fixed at the
inlet and outlet. But if not provided, you
can pick the suitable hose that fits the
inlet or outlet hole and fix it.

Suction pipe & discharge pipe:

Suction and discharge pipes are the
pipes attached to inlet and outlet of the
pump respectively for the water flow.
The suction pipe should always be
either equal or larger than the inlet size
of the valve and minimum length of the
pipe is recommended to avoid bends.
Discharge pipe is also recommended to
be in large size.

Foot valve:
Foot valve is used at the end of the pipeline at
the suction end. It acts as a check valve but
they also have a strainer fixed at the open
end. When pressure inside the pump column
changes, the valve opens and stops water
from going back.

Gate valve:
Gate valve is used to shut off or open the fluid flow in a
pipeline. These are fixed at the discharge end of the pipe.
Installation of Controller Box

● Normally a solar pump controller is

intended for operation in ambient
temperatures up to 60℃, but in order
to avoid overheating caused by the
failure, it is recommended to install the
controller in the shadow position.

● The solar pump controller must be

installed into a control box which has a
tight enclosure to avoid direct
sunshine, rain, dust, moisture, animals,
plants, etc. The control box should
have a bottom gland plate for installing
wire cord or conduit.

● These are typically installed on a bracket on the array frame or on the array
mounting pole. They should be mounted as per the manufacturer’s
instructions and should be suitably mechanically supported.

● The solar pump controller shall meet the appropriate ingress protection (IP)
rating for outdoor usage at the site. A minimum of IP56 is required and IP66
or higher is preferred.

● The distance between the array and the pump controller is often known by
the manufacturer/supplier; however this distance should be clarified while at
the site.

● The critical distance is that between the pump controller and the pump. This
must be determined during the site visit so the correct size cables are
selected to avoid voltage drop issues and that the correct length of cable is
either supplied with the complete system or obtained prior to system
installation.

● For surface pumps, the length of cable shall be dependent on the location of
the solar array/pump controller and solar water pump.

● For borehole/well pumps the length of cable will be dependent on the

location of the solar array/pump

● Determine how the cable will be installed between the pump controller and
the pump to avoid the risk of mechanical or local fauna (e.g. rat) damage.
● The input connection to the motor is usually taken from the motor controller
provided by the manufacturer. The solar connections or MPPT output, VFD
connections, Inverter or Grid connection etc. are all usually given to the motor
controller and connection to the motor is facilitated from the controller.

● In case the grid connection is to be provided in the system, provide an IO box

with an isolator to connect using incoming grid line as and when required.

● Lugs are used to connect 3 phase connections. It is important to match the

colour codes in the lug connections. It is a good practice to name the cables.

● Before making any connection to the controller, make sure the solar PV power
connection is OFF at the string junction box or at the controller end. For this
purpose, a breaker needs to be provided at the controller end to disconnect
the DC power from the Solar PV array. Ensure the Grid or VFD or Inverter
output are also OFF before making connections.

● All connection terminals need to be checked with the manufacturer for a

circuit diagram. Separate conduits should be provided for DC power cables,
AC power cables and sensor cables.

● The electric connections can be surface or submersible:

○ In case of surface electric connections, heat sealing of connections need
to be done
○ For submersible electric connections, heat sleeves and cables are used
for waterproofing

● Route markers are used to demarcate the path of PVC conduits and wires.
This prevents the accidental damage of the same during land preparation.
Also, in case of uneven or elevated areas, raceways can be made for the pipes
to pass through to the fields.

● As already explained in the earlier chapters, the controller takes DC inputs

from solar PV arrays and supplies pulsating DC or variable frequency AC to the
motor. Proper care should be taken that the MPPT range of the controller and
the array output voltage match properly.

● It is also advised that the farmers should not open the controller box for the
purpose of repair to avoid high voltage DC shocks.

● The Remote Monitoring system should be installed in the controller, and all
RMS sensors should be connected to the data loggers for data transfer. The
RMS is also connected to the VFD.
 Typical Connection of Controller Box:

Many solar pumping system packages will include solar modules with
interconnecting cables/connectors set up for ‘plug and play’ by using plug and
socket connectors. These modules should be installed and connected according
to the manufacturer’s instructions. The output of the array shall be connected to
the pump controller with the plug that has been supplied by the
Manufacturer/supplier.

1. Before making any connection to the controller, make sure the solar PV
power connection is OFF at the string junction box or at the controller end.
For this purpose, a breaker needs to be provided at the controller end to
disconnect the DC power from the Solar PV array. Ensure the Grid or VFD or
Inverter output are also OFF before making connections.

2. The solar array is connected to the pump controller with Red and Black
wires to the positive and negative connectors of the pump controller
respectively using MC4 connectors.
 3. No compromise should be made on the cross-section thickness of wire as
per design. No cable joints with insulation tape shall be acceptable. Always
use insulated joining couplers if required, or plan such that a requirement
for joining cables midway never occurs.

4. MCB is installed before the solar array is connected to the pump controller
to protect the device from excess current. Also, another MCB is installed
between the pump controller and the pump to overcurrent. A third MCB is
placed if the solar pump is connected to the grid.

5. All connections to the terminals, whether at the motor end or at the

controller ends, should be made with proper lugs or connectors. Direct
insertion of cable threads to terminals should be avoided. It is a good
practice to always use labels on all the cables at both the ends for future
service

6. The pump is connected to the pump controller using a lug connection. The
colour coding is followed, and crimped and connected. The colour coding
followed in 3-phase conductor is red, yellow and blue wiring, along with
black wire for neutral and green wire for earthing.

7. Splice kit is used to waterproof the connection, for otherwise short circuits
can happen during heavy rains.

8. Remote Monitoring System (RMS) is placed in the controller box and

connected to the pump controller through the wires. A recharged SIM card
is installed in the RMS.

9. For monitoring purpose following components may be provided:

CT/PT, energy meter, data logger for remote monitoring with sensor input
terminals for various sensors (like temperature, pressure, flow rate, water
level etc), CAT6 cable connection ports and internet provision.

10. All cables should have a spare length to avoid undue pressure and to utilize
for future service.
Installation of Earthing Rod
The installation of earthing can be split to two parts — the earth electrode
installation and the earth grid construction

Earth Electrode: The basic purpose of earthing is to pass any fault current safely
to earth via a high conducting low resistance path. or an off-grid pump system, it
is generally recommended to have a separate earth pit for the DC side, one earth
pit for AC side and if lightning arrester is used, a separate earth pit for it.

Earth pit can be maintenance free chemical earth pit or maintenance demanding
regular pipe/plate earthing.

Step 1: Ground excavation - a typical hole of 2 metres depth and 10 cm diameter

is made near the solar module installation.

Step 2: Installation of the Earthing rod

● Insert the ground rods or other electrodes deep inside earth.
● Normally charcoal and salt are added in earth pits to make good
conductivity. Water improves the conductivity of earth soil. Nowadays
Earthing compound mixtures are available ready made. About 5 kg of
earthing mix or mixture is required.

Earth grid installation: Once the earth pits are installed, we now need to connect
various metal surfaces and system earthing if involved into these pits.

Step 3: Typical earthing connections are shown in figure. Typically the controller
has provision for earthing. Earthing wire from the coming out of the controller box
is connected to the terminal. 10 or 16mm2 wires are used for the earthing
connections. Red insulators are used to sheath the connections.

Note: : Separate earthing connections are needed for DC

surge protection from solar panels, AC surge protection
from Pump controller and Lightning arrester.
Installation of Lightning Arrester
To protect the system from lightning, a lightning arrester might be installed on the
Earth pit cover provided for installation. In case a lightning arrester is to be
installed at site, a separate earth pit needs to be provided for the lightning
arrester.

Most probably, for systems less than 10 HP, a copper 4 spike lightning arrester
would be provided. The pole on which the lightning arrester is to be mounted
needs to be first secured into the ground or to the wall on which the arrester is to
be installed.

Step 1: Mount the arrester on the pole and secure it with fasteners.

Step 1: Create an earth pit, preferably chemical earth pit with Cu bonded
electrode, separately for the lightning arrester.

Step 2: Using a 25X3 copper earth flat or 16 sq.mm Cu earth cable, connect the
arrester to the earth rod.

Step 3: Then interconnect this earth electrode with other earth pits in the site
using a GI 25X3 earth flat.

Installation of Remote Monitoring System

Remote monitoring system works by installing various sensors in different parts
of the pumping system in order to measure data. Few common sensors are
pyranometer, module temperature sensor, pressure gauge, flowmeter, water level
sensor, dry-run alarm, voltage and current sensors on both DC and AC side,
energy meter etc.

The measured data gets converted to digital signal and is transferred via signal
cable to a datalogger in the controller. The signal cable, if run underground, with
the same trench in which the electrical power cable is laid, maintains a layer of
sand in between and a distance of at least 10 Cm from the power cable. Do not
run both power cable and signal cable in the same PVC conduit or in the same
raceway. The data logger logs these signals in its memory.

The site should have an internet facility. A microcontroller takes data from the
datalogger and sends it through the internet to any location the client wants to
monitor the system from. The client will be given software by the manufacturer,
which converts the signals to readable values and presents it to the user. With the
help of IoT, some manufacturers also allow you to remotely switch off or on the
pump and make other controls when necessary.
Quality Standards

Quality in any system is usually referred to as how close the system is to the
requirement provided by the user. Without specifying a requirement, quality is
meaningless. Also, quality should never be compared for two products made for
different requirements.

Nevertheless, for electrical, electronics and related technologies, the International

Electrotechnical Commission (IEC) has prepared certain codes that detail certain
requirements of the technology and their codes. It is called IEC codes. For
example, the process of pump installation, the process of manufacturing PV
modules, and the design of earthing systems all have certain codes. If we adhere
to the codes, it becomes easy to be accepted internationally as a company
adhering to set standards. Whether small or large firm, adhering to the IE
standards has its benefits.

Although IEC is only for electrical and electronics related technology, ISO
(International Standardization Organization) provides codes for various quality
requirements of all available technologies and processes related to various
technologies. ISO QOO1 is the code for generic quality management practices of
any small or big organization. India also has its own standards named Indian
Standards (IS Codes) prepared by Bureau of Indian Standards. For electrical and
electronics related technologies, IS Codes mostly comply with ISO and IEC
standards with certain additions or adaptations for Indian sub-context.

Few relevant codes for solar pumping system are given below:
● IS 14286:2010 — Crystalline Si PV Module design qualification and type
approval
● IEC 61215-1:2016 — Crystalline Si PV Module design qualification and type
approval
● IS 5120:1977 — Technical requirement of rotodynamic pumps
● IS 3043:1987 — Code of Practice for earthing
● IS 11346:2003 — Agricultural and water supply pump tests — Code of
Acceptance
● IS 6603:2001 — Stainless steel bars and flats
● IS 7538:1996 — 3 phase squirrel cage induction motor for agricultural water
pumps
● IS 8034:2002 — Submersible pump specifications
 ● IS 9079:2002 — Electric moonset pumps for agri and water supply purpose
● IS 9283:2013 — Motors of submersible pump sets
● IS 14220:9 94 — Specification of open well submersible pumpset
● IS 14582:1998 — Single phase AC motor for centrifugal pumps
● ISO 9905:1994 — Technical specifications for Class I centrifugal pumps
● IEC 60068-2-6:2007 — Environmental testing - Test Fc vibration (Sinusoidal)
● IEC 60068-2-30:2005 — Environmental testing - Test Db Damp heat cycle
● IEC 60146-1-1:2009 — Semiconductor converters (Basic requirement)
● IEC 60364-4-41:2005 — Protection in low voltage electrical installations
● IEC 60364-7-712:2017 — Requirement for installation of low voltage solar
PV systems
● IEC 6052 :1989 — Degree of protection by enclosures (IP Codes)
● IEC 60947-1:2007 — Low voltage switchgear — General rules
● IEC 61000-6:2016 — Electromagnetic compatibility — Generic standards
● IS/IEC 616 3:1999 — PV system-Efficiency measurement of power
conditioners
● IS/IEC 61730-1:2004 — PV module safety qualification - Construction
requirement
● IS/IEC 61730-2:2004 — PV module safety qualification — Testing
requirement
● IEC 61800:2017 — Adjustable speed electric power drive systems
● IEC 6210 -1:2010 — Safety of power converters used in PV systems
● IEC 62305:2010 — Protection against lightning

For any organization, it is always recommended to be certified under ISO 9001

quality management practice, not just to avail benefits of the government
schemes and adhere to export requirements, but also to smoothly manage
activities of the organization using best practices followed around the globe.
Practicing the usage of ISO/IS/IEC codes in regular requirement analysis would
also elevate the organization’s trustworthiness. Any organization built on the
mission to adhere to certain quality standards has higher possibilities of being
successful in achieving its goals.
Quality Check Report Format

Site Inspection / Quality Checking Report

Solar Power Plant Capacity
Solar Power Plant Type
Site Address
Contractor Name and
Contact

Check List Of Solar Power Plant Remarks

Inspection
Points TO BE Checked
Solar Panel
Array Voc V
Array Vmp V
Array Isc A
Array Imp A
Photo taken Yes No
Array to Array Distance meter
Manufacturer Stickering Yes No
Photo taken Yes No
Earthing Connection all array Yes No
SPV cleaning arrangement Done Yes No
Photo taken
Array Joint Box (AJB) Remarks
All AJB Fuse are Ok Yes No
AJB Connection Properly Done Yes No
Manufacturer Stickering Yes No
Danger Stickering Yes No
Photo taken Yes
Structure & Grouting Remarks
All nut bolt washer fixing Yes No
Properly
Photo taken Yes No

Grouting Dimension mm✕mm✕mm

Grouting Specification

Curing Properly Done Yes No

Neat cementing Done Yes No

Photo taken Yes No

Lighting Arrester (LA) Remarks
LA Height Yes No

LA Mount in Yes No

mm✕mm✕m
m

Photo taken Yes No

Earthing
Total No. of earthing nos

Pipe Earthing

Plate Earthing
Earthing Type
Chemical
Earthing
Earthing Connected through

G.I.Strip Yes No

Wire Yes No

Earthing Pit Cover Installed Yes No

Earthing Pit Cover Dimension mm✕mm

Earthing Pit Distance metres

Wiring
Photo taken Yes No Remarks
PVC pipe use Yes No
SPV to AJB Cable Tray use Yes No
PVC Saddling Properly Yes No
Cable Tray Use Yes No
Ground Clearance of PVC pipe inches

MC4 Connector Use Yes No

Photo taken Yes No
Cable Gland & Lug use Remarks
AJB Yes No

ACDB Yes No

DCDB Yes No

Inverter all terminals Yes No

Battery Terminals Yes No

Earth Terminals Yes No

Photo taken Yes No

DCDB Remarks
All connection Properly Done Yes No

Manufacturer Stickering Yes No

Danger Stickering Yes No

Photo taken Yes No

ACDB Remarks
All connection Properly Done Yes No

Manufacturer Stickering Yes No

Danger Stickering Yes No

Photo taken Yes No

Inverter Remarks
Inverter Mounted Properly Yes No

Inverter connection Properly Yes No

Done

Ground Clearance of inverter inches

Insulated safety mat use in Yes No

Inverter

Inverter Earthing Done Yes No

Manufacturer Stickering Yes No

Danger Stickering Yes No

Battery Remarks
Battery Voltage Volt

Battery Charging current Amps

Battery Dis- Charging current Amps

Battery Water level (if require) Yes No

Battery Rack installed Yes No

properly

Battery mat provided Yes No

Battery Terminal Clean and Use Yes No

Petroleum gel

Battery Terminal wire Yes No

connected properly

Plant Safety Equipments Remarks

Fire Extinguisher & Sand Yes No
Bucket Placed in proper
location

Photo taken Yes No

Require Spare Tools Placed in Yes No

proper location

Photo taken Yes No

General Check Remarks
Solar Plant All direction photos Yes No
collect and submitted

Plant Handover Certificate Yes No

collect

Solar Plant operational properly Yes No

Solar Plant connected load Yes No

operational properly

End Customer / Beneficiary Yes No

Educated by the contractor to
operate the plant

Contractor Sign with Date : Manufacturer Site Coordinator Sign with Date
:

Rating By Manufacturer Rating By Rating By Sr.Project

Site Coordinator Sr.Project Coordinator
Coordinator

1 - Beyond 4 - Average
Expectation

2 - Very 5 - Below
Good Average

3 - Good 6 - Poor

Senior Project Coordinator

Name & Sign with Date ::
Commissioning

Once all the system components are installed, system commissioning occurs.
Following are the steps to follow while commissioning a system:

● Electrical connections: Check all the physical cables if they all are securely
fastened and also check the electrical system for continuity.
● Water connections: Examine all the pipes and the connections between
these pipes and the pump to make sure everything is well connected
without leakage and well supported. Make sure enough water is available in
the water source
● Pump: Check that the pump and motor are correctly aligned. Check if the
pump is properly lubricated and inspect if all the seals are perfectly closed.
● Pump priming (if required): Some of the pumps will require being primed
when used for the first time which means filling water in the casing.
Centrifugal pumps need to be primed every time they are turned on.
● Check water level : Never switch on the motor if enough water is not
available in bore well/well and make sure enough sunlight is present at the
location
● Check VFD Configurations
● Check grid input voltage (for grid-connected hybrid systems)

The following steps should be followed to start the solar pumping system:
1. Turn on array: Check if the output voltage and current of the solar array are
correct.
2. Turn on the control systems: Check if the system readings are matching
the manufacturer’s specifications.
3. Turn on the pump: Start the pump according to the manufacturer’s
instructions. Monitor its pressure and water flow to confirm that the system
is operating correctly.
4. Observe pump operation: Check if there are any leaks and monitor system
readings while the pump is in operation. If needed conduct a bucket test to
determine the flow rate and assess the system performance.
Common Errors

● Connecting pump directly: Never connect pump directly to the SPV panels
as they may give higher or lower voltage than required by the load equipment
and this may damage the equipment permanently.

● Switch on controller: Never switch on controller switch during installation.

● DC Isolation: All DC wiring should be completed prior to installing a PV array.

This will allow effective electrical isolation of the DC system while the array is
installed; and effective electrical isolation of the PV array while the inverter is
installed.

● Loose connection: If there is no output, then the problem may be with cable,
connector, junction box or charge controller. Check for defects or loose
connection and replace if necessary.

● Internal damage: If output voltage is okay but there is no current, then the
possible failure is cell interconnections. It is due to the internal damage, and
should be returned to the factory if within the warranty.

● Dirt accumulation on PV module: If there is no charging indication on the

charge controller, the possible failure may be in the module or charge
controller. If in the module, it is due to shading or dirt accumulation or
corrosion or damage or module cable. In this case, change the location of the
module and clean regularly. Replace cable or charge controller accordingly.
● Low output voltage: If output voltage is not available in less duration. It is
possibly because of shading, dirt or improper installation or cable/charge
controller damage. Remove shades and clean for maximum voltage output. If
the cable or charge controller is damaged, then they should be replaced.

● Shadow of Fencing: Solar Photovoltaic Panels are installed facing south with
proper angle of tilt where there is no shadow on any part of the panel at any
time of the day to get maximum power.

● Fencing: As far as possible SPV modules should be fenced to protect it from

cattle or from any damage or theft.

● Cleaning agents:
Solar panels require no maintenance; however, the surface of the panels
should be cleaned regularly to remove the dust. None of the cleaning agents
are to be used except for water.
● Distance of controller:
Install the controller close to the PV array to minimize cable length and cable
losses on the input side and reduce the risk of lightning damage. Mount the
controller on a solid board/wall in a shaded, well ventilated location.

● Improper earthing:
It is important for the system (pump, controller, PV generator) to be correctly
grounded and earthed for safety of both the installation and users. Lightning
protection should also be installed.

● Improper motor wiring:

Check that the motor wires are in the right order to prevent reverse rotation
of the motor which could damage the pump. The correct rotation direction
for submersible pumps is counter-clockwise, viewed from the top.

● Electrocution/shock:
Always remember that even a single solar module is a live circuit that can
result in electrocution.

● Improper module connection:

Two or more modules connected in parallel or series if connected incorrectly
to a pump can damage or destroy the equipment.

● Mishandling of PV Modules:
Your solar module consists of glass which can easily break. Do not throw
objects at the solar module, stand or step on the module or try to repair
your solar module if it breaks.

● Unnecessary connections:
Do not carry out modifications on your system without technical guidance
from your system supplier or a qualified technician.

● Cover the module during installation:

Fix all modules securely onto the support structure before doing any wiring
and minimize the risk of accidents by covering and shading modules with
their packaging until the installation is complete.

● Mismatch of PV modules:
Modules that have different characteristics in model, power, voltage and
current should not be connected together in the same system (mismatching)
Annexure

Grades of Concrete Mix Ratio( Cement : Compressive

Sand : Aggregates) Strength

Lower Grade of
Concrete

M5 1:5:10 5 MPa

M7.5 1:4:8 7.5 MPa

M10 1:3:6 10 MPa

M15 1:2:4 15 MPa

M20 1:1.5:3 20 MPa

 Evaluation

1) Float Switch Is used to measure water output

(b)
a) True
b) False

a)

2) If motor is moving in reverse direction, what action should be taken (b)

a) Check the earthing
b) Check the connections
c) Change the controller

3) If 300 Wp of solar panels are available for typical 1 HP solar pump (C)
a) Connect 2 panels in parallel combination to get maximum output
b) Connect 2 panels in series combination to get maximum output
c) Connect 3 panels in series combination to maximum output
d) Connect 4 panels in parallel combination to maximum output

4) Surface pumps are preferred for bore wells and tube wells
(b)
a) True
b) False

5) For optimal performance which type of tracker should be used

(b)
a) Single axis tracker
b) Dual axis tracker

6) Standard structure are designed considering wind speed of

(c)
a) 50 m/s
b) 100 m/s
c) 150 m/s
d) 200 m/s
8) In which direction solar panels be
faced
(b)
a) North
b) South
c) Northwest
d) Northeast

9) What type of mixture is used in earth

pit
(c)
a) Salt
b) Sand
c) Charcoal
d) Cement
Evaluation

Float Switch Is used to measure water output

1
a. True
b. False

If motor is moving in reverse direction, what action should be taken

2
a) Check the earthing
b) Check the connections
c) Change the controller

If 300 Wp of solar panels are available for typical 1 HP solar pump

3
a) Connect 2 panels in parallel combination to get maximum output
b) Connect 2 panels in series combination to get maximum output
c) Connect 3 panels in series combination to maximum output
d) Connect 4 panels in parallel combination to maximum output

4 Surface pumps are preferred for bore wells and tube wells
a) True
b) False

5 For optimal performance which type of tracker should be used

a) Single axis tracker
b) Dual axis tracker

6 Standard structure are designed considering wind speed of

a) 50 m/s
b) 100 m/s
c) 150 m/s
d) 200 m/s

7 In which direction solar panels be faced

a) North
b) South
c) Northwest
d) Northeast

8 What type of mixture is used in earth pit

a) Oil
b) Sand
c) Charcoal
d) Cement
Answers

1 b. 2 b. 3 c. 4 b.

5 b. 6 c. 7 b. 8 c.
 Chapter 7

Operation and Maintenance

of Solar Pumps
TOPICS COVERED

Inspection of Components - with checklist

Maintenance of solar pumps

Warranty

Step wise System Diagnosis Process

Troubleshooting
Inspection of Various Components
Every system regardless of type, must be inspected periodically. It is an important
aspect for good operation of the system. System inspection should be conducted
at least once a year depending on the size and intricacies of the system. Planned
inspection prompt timely maintenance, and in some cases inspection and
maintenance can be carried simultaneously especially when the inspectors also
double up as maintainers. It also highly recommended that the inspectors also
triple as repairmen of the system.

Solar Panels

● Check the solar panels for dirt and cracks,

○ dirt accumulates on the solar panels over time, as they are exposed
to the environment. Cracks may be due to vandalism or heavy
hailstorm.
○ If there are cracks on the panels, one should consider replacing
those panels
○ Dirt can be cleaned off the surface using clean water and cloth, Soap
should not be applied.
● Electrical cables
○ Check to see if all electrical cables are still intact, loose cables should
be tightened up.
● Tilt Angle
○ In fixed solar array this may not be necessary, unless there is
suspicion of tilt on angle if inclination. This should be corrected, to
avoid dust accumulation of flatter inclines, and reduced solar
absorption on steeper inclines.

Submersible Pump

In most cases, three major components should be inspected in submersible

pumps.
● Alarm monitoring
● Pressure Flow checks
● Visual Inspection
○ Inspect for clogging debris on suction inlet
○ Check pump exterior for dents, corrosion and abrasion
Pipelines And Fittings

The inspection procedure outlined here, is a visual inspection. The procedure

includes all fittings and accessories associated with pipelines.
● Identify the pipeline section to be inspected and note it down on the
checklist book.
● Inspect the pipeline for labels, if any are visible on exposed sections.
● Inspect the pipelines for leaks, if leaks are spotted repair should ensue
● Inspect backfilling on pipelines
● Check or inspect pipelines for erosion after events of rainfall
● Inspect pipe supports, for loose brackets, pipe support if they are still intact.
● Inspect pipeline for vibrations, if excessive schedule for attendance
● Inspect pipe insulation against corrosion, pipes especially steel pipes usually
corrode when they leak.

Valves

These are classified as part of system appurtenances. They are used to isolate
certain sections of the system, from the rest. Isolation is usually done when there
is ongoing maintenance in one section, where water flow is not required at the
time.
● Leaks
○ Valves should be inspected for leaks, that is if they are still water tight,
leaks on valves should be attended to, to curb prolonged leakages on
the system.
● Blockages
○ Debris collection in the system may cause valves to let water through
even though they are shut. All debris should be cleaned off valves,
especially gate valves.
○ Grit collection also affects operation of gate valves, hence they should
be stripped during preventive maintenance and cleaned off.
● Corrosion
○ Inspect valve threads for signs of corrosion, all corrosion when
spotted should be attended.

Storage Tanks

● Tank
○ Inspect for leak on the tanks, if leaks are spotted schedule for repairs
○ Inspect leaks on pipes and fittings connecting to tank/reservoir
○ Check for accumulation of algae inside tank, and schedule for
cleaning if spotted
 ● Valves and Fittings
○ Inspect for leaks and breakages on valves. consider changing valves
or repairing them leaks are spotted.
○ Inspect for dirt collection inside valve chambers, and clean
overgrowth of grass in chambers.
● Float Valves
○ Inspect float valves for function, adjust float valves accordingly

Inspection Check List

Submersible Borehole Pump

● Check electrical condition of insulation on power cable(s) and on all phases

of the motor.
● Check for any loose or faulty electrical connections within the control panel.
● Measure resistance between stator windings (in ohms).
● Check voltage supply between all phases of the electrical control panel.
● Check voltage balance between all phases on the load side of the pump /
mixer control panel with pump / mixer running (vac).
● Check amperage draw on all phases of the motor (in amps).
● Check condition and operation of the motor thermal protection control
system (if equipped).
● Remove pump / mixer from the lift station for physical inspection.
● Check condition of upper and lower shaft seals (inspect condition of motor /
stator housing, if applicable).
● Check condition and operation of leakage and bearing sensors (if equipped).
● Check for worn or loose impeller or propeller.
● Check impeller wear rings (rotating & stationary)
● Check for any unusual noise in the upper and lower bearings.
● Clean, reset and check operation of the level control system (if equipped).
● Check for physical damage of power and control cables.
● Check for correct shaft rotation.
● Check operation of valves and associated equipment.
Storage Tanks
Pipeline
Did you KNOW?
Add Page 9
Maintenance of solar pumps

Weekly Checks

Proper maintenance of any machinery or equipment ensures it’s long life. There
are a few weekly maintenance checks that can be easily done by farmers
themselves to ensure smooth running of the solar pump:

Solar Panels
● Clean the Solar Panels to keep the system in a healthy condition and give
better water output. Normal water needs to be used for cleaning the
modules using clean water and wiper or wet cloth.
● Clean early morning and late evening and avoid cleaning during day time as
it hinders the production of electricity and may also lead to glass damage.
● Remove any shadow falling on the solar panels

Cables and Connections

● Keep the Controller, wiring and connections all clean and intact.
● Inspect any kind of leaks in Pipes, tanks and valves for water supply. If any
leaks are found, that needs to be repaired or replaced.
● Check if the motor cable of the pump is heating by touching the insulation
by hand. If it is heating, then it needs to be replaced.

Other Checks
● Regular monitoring of power generation and Water output by using a
Remote Monitoring system needs to be done to monitor the system
performance.
● If water output has reduced, the pump needs to be checked for any
blockage due to accumulation of mud, and that has to be cleared
Monthly Checks

A number of parameters need to be checked monthly to ensure the components

are running smoothly.

Module Mounting Structure

● Check the structural integrity of the module mounting structure. Tighten
the nut bolts on the mounting structure and solar modules. Also, replace
any damaged or rusted nuts and bolts during the monthly check.
● The module mounting structure needs to be painted once a year with
corrosion proof GI paint in order to prevent damage due to rust or
corrosion.

Surface pump
● Inspect the oil seal and packing of the surface pump for any leaks. This is
not required if a mechanical seal is used for the surface pump.
● Inspect the tightness of couplings in the surface pump to ensure no leakage
as well as for vibration during operation. If there is vibration during
operation, then the pump needs to be fixed properly using nuts and bolts.

Submersible pumps
● Monthly cleaning of filters is a good practice, but not feasible for most
farmers. However, cleaning of filters needs to be done after every cropping
season, that is, every 3 to 4 months to keep the system healthy.
● Remove mud and other external blockages from the access points and
joints of the pipes.
● Lubrication of the motor and pump bearing needs to be done as per the
manufacturer’s guidelines after every cropping cycle. The pump should not
be over-lubricated. The vent cap of the bearing needs to be removed
before lubrication and the pump should be run for 30 minutes before
reinstalling the cap.

Controller
The pump controller box should be kept in a clean and dry area, and
regular dusting should be done. The electrical connections need to be
checked monthly by touch and feel. Before any checking or maintenance
work, the MCBs for the module and grid and the operating switch of the
pump should be turned off in the pump controller.
Cables and Connections
● The important connections that need to be monitored are connection
between solar array and solar MCB, connection between pump and pump
controller and connection between pump controller and earthing. Also, the
MC4 connectors in the solar modules need to be checked for any loose
connections.The cable junctions and junction boxes should be intact. If any
break or damage is noticed, the junctions need to be repaired or replaced.
● Insulation is important during conducting any maintenance repair work, and
insulation of all wires need to be checked during the maintenance. If any
damage is noticed, that needs to be repaired immediately using insulation
tape.
● While carrying out electrical maintenance and repair work, it is essential to
use insulated tools and safety gears like rubber gloves and shoes to prevent
electrical shocks.
Did you KNOW?
Add page 10
Warranty
It is common for communities to establish comprehensive maintenance contracts
with suppliers during warranty periods, and it is a good practice to extend such
contracts beyond the warranty period.

1. Monitoring
System operation can be optimized by closely monitoring and recording key
system parameters (data logging), enabling operators to assess system
performance or demand changes.

2. Defect liability period:

Under the defects liability period of 1 to 2 years, any items that fail, are not
installed to standard, except for any damaged by natural calamities must be
corrected on site at cost to the contractor/supplier/ installer (depending upon the
contract).

3. Product Warranty: Product Typical

warranty
Every manufacturer defines their own warranty
period
period. During the warranty period, the supplier is
Solar Panels 10-15 years*
also expected to check system components and
Motor-Pump Set 2-5 years*
perform preventive maintenance at least quarterly (in
any case, neither pumps nor panels require heavy Inverters 5 years

maintenance, with panels only needing periodic Remaining 1-2 years

components
cleaning) to attend to user complaints within a
reasonable period of time, and to resolve any system *varies according to the
breakdowns. manufacturer

4. Performance warranty:
In addition to component warranties, the supplier may also provide a
performance warranty on the system as a whole, ensuring that it will meet or
exceed the design performance for a number of years. Solar panels generally
come with a total performance warranty of 25 years.

5. Training:
Suppliers should further secure system sustainability by training system
operators, namely on basic plumbing skills useful for repairing leakages in the
pipe network and on handling the advanced inverters and sensors common in
modern solar pumping systems.
Step wise System Diagnosis Process
A technician of a solar water pump is like a doctor treating a patient. Just the way a
doctor asks for the symptoms to his/her patients and then prescribes a medicine.
Similarly a technician is required to ask for the problem and then follow the steps
to understand what could have gone wrong and where. A step by step process of
diagnosing makes the process of maintenance easy and fruitful.

Step 1
Check the voltage and current of the solar array using a multimeter, keeping in
mind the weather conditions. The VMP and IMP should be checked in closed circuit
only.
If the Voltage rating comes below the overall solar array VMP rating, a few things
need to be checked.

1. Check if there is dust accumulation on the panels. The panels need to be

cleaned regularly to ensure optimum energy output.
2. Check if there is any shadow falling on the solar modules, and remove the
obstruction. Sometimes due to wrong installation, there can be obstructed
sunlight, which can be fixed by repositioning the modules.
3. Check for any loose connection in wiring or MC4 connectors. If any loose
connection or faulty connector is found, it needs to be repaired or replaced.
If the problem still persists, then individual modules need to be checked using
multimeter and the faulty module or modules need to be replaced

Step 2
Check the condition of the Miniature Circuit Breaker or MCB inside the pump
controller box. If any current or voltage surge occurs, inside the system the MCB
will trip and disconnect the circuit.
The solar module MCB, Grid MCB and the pump MCB must be turned on. If the
MCB is burnt, it has to be replaced with an MCB of the same rating.

Step 3
Check for the continuous Power output from the solar array by using a Multimeter.
If there is a big fluctuation in Power output, it must be the issue of the controller.
The servicing technician must modify the controller setting to ensure the constant
power output is restored, otherwise if there is an internal issue of the pump
controller, then it has to be dismantled and taken to a servicing centre for further
diagnosis
Step 4

The water level is checked for Submersible pumps usage.

If the water level goes down from the minimum head range of the Pump, the
column pipe length can be increased by approximately 10 feet. This will ensure a
water flow, even though the pressure of flow might reduce.Also, groundwater
recharge is recommended to be done in the region to bring up the water table.

Step 5
The pump condition needs to be checked.
For surface pumps, the motor and pumpset are opened separately and checked.
1. The motor winding is checked for any wear and tear and damage
2. The pump must be checked for any blockage or jam that needs to be
cleared.
Once checked, the pump and motor must be joined and lubricated. If an oil seal is
used in the pump, then that has to be checked for any leakage and then placed
back on the pump.
For submersible pumps,
1. The pump is taken out from the borewell and then the same diagnostic
checks are done like surface pumps.
2. During reassembly, water must be added into the pump before re-inserting
the pump into the borewell.
In case the winding coil of the motor gets more than 50% burnt due to long usage
or accident, then the whole coil has to be replaced. Otherwise just the burnt
portion can be replaced.

Pump lubrication is good practice during System Diagnostics.

Step 6
Check if there is any insulation failure by using an insulation tester. If it’s showing
any current at the joining points, it’s very risky to operate the solar Pump. Shut
Down the system immediately and insulate all the connecting points using
insulation tape. Also, any damaged wire needs to be replaced or repaired.

Step 7
Ensure that the controller is properly earthed and checked using an earth meter.
The earth meter reading should be less than 1 Ohm. If the earth meter reads more
than 1 ohm, then earthing chemical compounds need to be added in the ground
where the earth wire is inserted. Otherwise, a mixture of salt and charcoal can be
used and water needs to be poured on it till a reading of less than 1 ohm is
achieved.
 Diagnostic Checklist for solar pump

Check What to do?

Check 1 - If the Multimeter reading is normal, then the system
Check the voltage and is running fine.
current of the solar array If the reading is less than normal range, then clean
using a multimeter the panels and check the MC4 connections and
remove shadows on the panels.
If the reading is more than normal range, then
check the earthing connections and add repair it if
damaged

Check 2 - If the MCB is connected and working fine, then the

Check the condition of the system is also running fine.If the MCB is tripped,
Miniature Circuit Breaker or then check for the fault, repair it and then restart
MCB inside the pump the MCB
controller box

Check 3 - In case fluctuations are observed, then the pump

Check for the continuous controller needs to repaired
Power output from the solar
array by using a Multimeter

Check 4 - In case the water level has gone down below pump
Water level is checked for level then stop the pump usage and ensure
Submersible pumps groundwater recharge
In case water is less than 10 feet above pump,
ensure groundwater recharge and regularly check
water level to prevent dry run

Check 5 - In case the pump winding coil is burnt more than

Check pump condition 50%, it needs to be replaced
In case there is dirt and debris, they need to be
cleaned

Check 6 - In case of insulation break, the pump needs to be

Check if there is any shut and the broken portion needs to be fixed.
insulation failure by using an
insulation tester

Check 7 - In normal conditions, the reading of the earth meter

Check Earthing using an should be less than 1 ohm. In case the reading is
earth meter. more than 1 ohm, then earthing chemical
compounds need to be added in the ground where
the earth wire is inserted till 1 ohm value comes
 Major fault conditions for Pump Controller
If the controller has stopped to indicate a fault code on the display, the associated
time-out delay will vary depending on the nature of the fault. The number
following the “E” symbol corresponds to the error code for the offending
condition. Every controller manufacturer can have their own nomenclature.
Electronic monitoring gives the controller the capability to monitor the system and
automatically shut down in the event of:
• Dry well conditions
• High Voltage Surge
• Low Input Voltage
• Short circuit
• Over heating
Major fault conditions are highlighted in following table:

Fault Fault
Possible Causes Remedy
code description
Check input power
E001 Motor overload ● Too-low input voltage
supply or wiring
● Broken wires in the
output cable
Output phase Check the wiring and
E002 ● Broken wires in the
loss installation
motor winding
● Loose output terminal
● Too-high ambient
temperature
Controller Decrease the ambient
E003 ● Cooling fans of the
overheat temperature if possible
controller stopped or
are damaged.
Wait for water to
● Dry well or slow water
E004 Well Level Fault recover or reinstall the
recover
pump
Over-current at
● Sudden change of load
E005 constant Check the load
● Too low input voltage
running speed
Check if sunlight is
● Insufficient radiation
E006 No power input sufficient
● Improper connections
Check for connections
Earthing or Check the earth wire
E007 ● Improper earthing
short circuit connections
Restart the pump only if
water is available.
● There is no water in
Dry-run Running the pump
E008 the water tank waiting
Protection without water can
for water, it will restart
damage the motor
windings.
Troubleshooting

Problem 1: Surface pump is vibrating during operation.

Reason: The surface pump is not fixed properly with the mounting structure
or ground.
Solution: Fix the pump using nuts and bolts and tighten the joints. Once the
loose joints are fixed, then the vibration stops during pump operation.

Problem 2: Water not coming out of the pump even though voltage
reading is optimum on pump controller.

Reason: This happens due to inoperative pump, which is caused by various

reasons -
1. pump being jammed by mud and dirt
2. wiring or connection problem
3. damaged pump motor winding
Solution:
● If the pump is jammed, then it has to be cleaned by a technician and
reoperated
● If there is faulty wiring or loose connection, then the wiring needs to be
repaired or replaced.
● If there is damaged winding in the motor coil, then the damaged portion
needs to be replaced.

Problem 3: Short-circuit in pump.

Reason: Short circuit happens due to improper or damaged insulation of

cable connections. Short-circuit and jammed pump impeller is shown in the
pump controller display.
Solution:
● The location of the short circuit needs to be identified.
● Then, that particular portion of the cable needs to be replaced with a
new cable.
● If the short circuit happens in the winding of the motor coil, then the coil
needs to be changed.

Problem 4: Reduction In water supply through delivery pipe

Reason: The pipe has too many turns or cascades before delivering water to
the field or the pipe has some blockages due to accumulation of mud or dirt
Solution: The water delivery pipe needs to be straightened. The pipe also
needs to be cleaned to remove blockage due to accumulation of mud and dirt.
Problem 5: FIlter obstruction of borewell and water is not being pumped
out
Reason: Debris gets accumulated on the filter to protect the pump from
blocking
Solution: Remove the debri from the pump filter and reposition the hose to
start pumping again.

Problem 6: Water flow pressure is low

Reason: The delivery pipe diameter is larger than the pump output pipe
diameter or nozzle diameter
Solution: Use a delivery pipe of the same diameter as the output pipe or
nozzle.

Problem 7: Delivery pipe is over bulging or bursts

Reason: The delivery pipe diameter is smaller than the pump output pipe
diameter or nozzle diameter causing friction loss
Solution: Use a delivery pipe of the same diameter as the output pipe or
nozzle.

Problem 8: Motor is running in opposite direction

Reason: Water pumps are designed to operate with the impeller going in one
direction. If it is going the opposite direction, then there is an opposite
connection between the controller and the pump.
Solution: The direction of connection needs to be changed.

Problem 9: PV system not producing power, controller not turning on

Reason: The fault can be caused by either of the following reasons

1. PV module failure
2. Pump controller out of order
3. Wire or loose damaged by birds, rodents or during soil preparation
Solution:
● In case of complete module failure, individual modules are checked and
the faulty modules are removed. Also, the MC4 connectors need to
checked for loose connections
● In case the pump controller is out of order, the wires in the controller
need to be tightened or reconnected if they have fallen out. If the
controller still does not work, it has to be taken to the service centre.
● In case of damage to the cable connections, they need to be replaced or
repaired. Also, care should be taken to ensure minimum physical
damage to cables due to these external factors.
● The entire PV system is down/does not produce power; this may be
related to a problem with the inverter.
Problem 10: The PV system output is less than expected, Water coming in
bursts from delivery pipe

Reason: There can be several reasons for PV system output being lesser
than optimum levels
1. If Module not properly cleaned
2. If there is shadow on the PV module
3. If there is any loose connection in MC4 connectors
4. Controller settings were adjusted wrong.

Solution:
● Clean the modules every week with clean water
● The modules should be placed such that no shadow falls on them.
In case shadow is persistent, the modules need to be relocated
elsewhere.
● In case one panel is damaged in parallel connection, that module
needs to be replaced
● Loose connections need to checked and replaced in case of any
damage
● Lastly, pump controller settings need to be checked and adjusted
such that solar PV output remains optimally used.
Problem 11: Pump controller or controller box giving out electric
shocks
Reason: Improper earthing or earthing connection

Solution:
● Check the wires and insulate them properly, ensuring no naked
wire is touching the controller box
● Check earthing connection, that is, whether the earth wire is
properly inserted in ground
● Check the earthing using an earth meter, and if the reading is more
than 1 ohm, add more earthing chemical compounds and water till
the reading reaches below 1 ohm.

Problem 12: Controller does not show all parameters correctly

Reason: Loose wiring or Display fault

Solution: Open the controller and check for loose connections, and
tighten loose wirings. If problem still persists, the controller may need to
be replaced

Problem 13: Controller shows dry run indicator

Reason: Water level lower than pump

Solution: Increase depth of pump borewell and/or practice groundwater
recharge in long term
 Reference Materials

● Solar for Irrigation A Comparative Assessment of Deployment Strategies

(CEEW)-https://www.ceew.in/sites/default/files/CEEW-Solar-for-Irrigation-Deployment
-Report-17Jan18_0.pdf
● Solar Powered Irrigation Systems in India: Lessons for Africa Through a FAO Study Tour
Draft Report (2019)- https://www.icid.org/FAO-SPIS-Report.pdf
● https://www.bca.gov.sg/publications/others/handbook_for_solar_pv_systems.pdf
● Solar Photovoltaics: Fundamentals, Technologies and Applications written by Chetan
Singh Solanki
● http://www.fulviofrisone.com/attachments/article/455/SpringerVerlag%20Photovoltai
c%20Solar%20Energy%20Generation.pdf
● http://www.energy.wsu.edu/documents/solarpvforbuildersoct2009.pdf
● https://www.worldbank.org/en/topic/water/brief/solar-pumping

● Solar Electric System Design, Operation and Installation

● https://www.worldbank.org/en/topic/water/brief/solar-pumping
www.SwitchON.org.in / SwitchONIndia