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PowerSpout

React Pump Installation

© 2019 EcoInnovation Ltd (NZ) V2.1

Page 91

7.2. React pump Components

In order to reduce the length of this installation manual, instructions on how to service and
assemble the React pump are in a separate videos that will be available from 2020.

for our React Pump YouTube channel

NEVER work on your React pump while it is in operation.

React pump Protection

7.2.1.

React pumps arrive fully assembled, other than oil.
The PowerSpout React pump is encased in a durable housing, ensuring all internal parts are
protected from rain, rodents, children and UV.

This housing does not provide freezing

protection, the installer must make provision to ensure that the React Pump is not
exposed to freezing temperatures.

7.3. Commissioning procedures

Checks with cover off - before start-up

7.3.1.

These tests ensure you have completed the plumbing connections and have no leaks.
By this stage you should have:



Installed the suction (foot valve and filter sock) or a gravity feed intake.



Securely attached the React pump to a suitable base.



Connected React pump suction and delivery pipes.



Connected the delivery pipe to the tank with a ball cock fitted (inside the tank) if you

want to React pump to turn off when full.



Filled the React pump with SAE15W/40 oil

to the top edge of the level glass

.



Manually primed the React pump suction line if required (if suction head exceeds

3m). If you pipeline to tank is already full of water you will need to open the bypass
valve to purge out trapped air before closing again.



Ensure the on/off switch on the BLDC is on.



Secured all protective fairings.

Commissioning the React pump

7.3.2.

Check that there is sufficient sunlight for the solar panels to provide adequate power.  Turn
the React pump on at the switch. Provided you have good sunshine on the panels the React
pump will start to rotate.  It will spin fast at first, and there should be little noise. As the
delivery pipe fills with water and the backpressure builds up, the React pump will steadily
slow in speed. While the pipe is filling keep an eye on the React pump pipefittings for any
leaks.  Turn off and fix them if observed.

If the delivery pipe is already filled with water following a React pump service (for example).
You will need to open the bypass valve for air to purge from the React pump. After 15-30s of
observed water flow this valve can be closed.

Once the sun gets too low in the sky there is not sufficient power for the pump to continue to
work and it will stop. It may still attempt to start (clicking noises) but will in due course stop
completely. Likewise, on sunrise the pump will attempt to start and in due course will run
continuously increasing speed with sun intensity.

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Содержание React Pump

Страница 1: ...2020 Version 2 1 React Pump System Design and Installation Manual 1080W of PV on movable frames 540W per frame React pump pontoon mounted Please read this manual carefully before beginning the instal...

Страница 2: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 2 4 panel React pump ground mounted adjacent to a farm pond 2 panel React pump ground mounted above a shallow farm well...

Страница 3: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 3 8 panel East West twin React pump install Note valve riser pipes for priming of each suction line...

Страница 4: ...270W panels Today 280W or larger panels may be more common cost effective Please note that the intended application of this solar pump is for high country stock water pumping from Spring to Autumn Ope...

Страница 5: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 5 React pump with fairing removed Fairing in place Rebranded React pump previously SHP TX or SHP Triplex...

Страница 6: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 6 Typical East West Truss mounted array remote from the React pump location React pump shed mounted with fairing removed...

Страница 7: ...list 14mm stroke with 20mm diameter ceramic 2 1 2 plungers 23 Pump parts list 23 2 1 3 Image of React pump with body fairing 24 2 1 4 Image of React pump with body fairing removed land mounted 25 2 1...

Страница 8: ...umped volume in winter or poor weather conditions 3 1 5 43 1620W PV facing morning midday and evening sun 160 300m head in the shade 3 1 6 free zone 43 3 2 Wiring the PV to the React pump 44 ELV Wire...

Страница 9: ...le pontoon 1 x React pump s 73 5 1 1 How to make a simple plastic pallet pontoon 1 2 React pumps 74 5 1 2 How to make a large pontoon for 1 x React pump and 540W or 1080W array 75 5 1 3 Making the pon...

Страница 10: ...ct pump 96 8 2 1 Changing a foot valve 97 8 2 1 8 3 Particular points to monitor 97 Oil 97 8 3 1 Operating conditions 97 8 3 2 Rapid pump deceleration 97 8 3 3 Pump stopping for a few second and then...

Страница 11: ...OR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Revisions...

Страница 12: ...any of the dealers listed on our website We will answer this as quickly as possible PowerSpout is a product proudly designed and manufactured by EcoInnovation Ltd 671 Kent Road New Plymouth R D 1 New...

Страница 13: ...er such events The client has read the manuals viewed online videos and understood installation examples before starting on this project We advise engaging an experienced qualified installer who has g...

Страница 14: ...ve KWhr meter Flow meter Seal service kit and valve set x6 Plunger ceramic liner set x3 Wet side seal kit Oil side seal kit Complete React pump seal valve service kit System design service For New Zea...

Страница 15: ...o turbines For example You might see Serial number 00235 as the serial number This means you have number 235 made Write the serial number in your records as from this number we can locate when it was...

Страница 16: ...such a manner that hazardous conditions can occur compliance with this manual does not by itself assure a 100 safe installation If the equipment is properly selected and correctly installed and operat...

Страница 17: ...you are unsure of the rules in your country Also call your insurance company to check that your cover meets your needs in this regard Warning if you do not comply with standards codes and laws in you...

Страница 18: ...y job and seek paid assistance if as required This document and supporting videos are sufficient training and knowledge to enable a capable owner installer to perform the tasks required If you feel yo...

Страница 19: ...when a set pressure is reached The pump will stop if is detects a pressure above 300m this can be easily adjusted downwards or reset a reset returns default to 300m INSTALLING YOUR REACT PUMP Make sur...

Страница 20: ...user of the pump in routine care and maintenance of the React pump and general solar system SERVICING Keep the React Pump packaging and red oil transport cap If you ever need to return the pump under...

Страница 21: ...sent to pump water for stock and domestic home needs it is a permitted activity unless your resource is the habitat for an endangered species If however you intend to build a buffer storage pond in th...

Страница 22: ...compares the PowerSpout React pump to other solar pumps and other methods of water pumping click here All PowerSpout React pump s are shipped fully assembled We will provide a service guide for the Re...

Страница 23: ...1 4 M6 hex bolt for rear cover 5mm A F hex 2 1 Rear cover with oil level glass 3 1 Rear cover seal 4 3 Big end bearing 5 3 Gudgeon pin 6 3 Plunger base 7 1 Pump body 8 1 Crank shaft 9 1 Crank shaft fr...

Страница 24: ...bearing cover plate 40 4 M6 hex bolt for rear cover 5mm A F hex 41 1 Transit plug Yes 42 1 Oil vent and dip stick 43 1 Pressure transducer not shown Yes if operated below freezing Note consumable part...

Страница 25: ...5s pressure limit successfully set Blue blinking pump waiting the pressure sensor has activated will try to start again in 30 minutes Clear no light ignition switch is off or DC switch is off or floa...

Страница 26: ...required to cut fit as shown 2 1 7 Wire float switch here remove link Wires to solar PV DC switch Wires to motor for anti clockwise rotation when looking on motor end of SHP TX To change direction sw...

Страница 27: ...NZ V2 1 Page 27 Smart Drive motor 2 1 8 The magnetic rotor black high power 300m head or beige standard power 160m head is mounted on the pump shaft The stator is stationary There are no wearing parts...

Страница 28: ...lts in a very high friction head then you will get a little less The pump will work fine on heads as low as 10m where it will run most of the time at full speed and peak flow rate For heads below 50m...

Страница 29: ...n verify from a simple test that all is working correctly As you can see peak flows for the React pump do not fall much with increasing head This is because as the head increases more of the solar PV...

Страница 30: ...ered flow will change throughout the year with sunlight intensity but this tends to be a good match to demand In general farm animals drink much more water from troughs on sunny days than wet overcast...

Страница 31: ...ents 2 3 1 As we only make one version of the React pump and as it will pump in the range 10 300m head we need no site information from you prior to purchase But you do need to survey the site to esta...

Страница 32: ...h with annual maintenance checks With many water source combinations 3 x PV array sizes multiple React pumps parallel and series installations the React pump can solve almost any stock water pumping p...

Страница 33: ...ely Fencing work is about to start and that means water for paddock troughs is needed urgently Your gut feeling based on decades of farming experience is that 5 000 10 000 L day in summer should do it...

Страница 34: ...an be connected to the same delivery pipe to increase your flow High head series installations 2 4 2 A series installation is where one pump feeds another one half way up the slope Series installation...

Страница 35: ...se points You may require more costly pipes or a pressure reducer to prevent pipes from bursting at lower locations due to the high pressure If most water on the farm is consumed at the lower troughs...

Страница 36: ...Your React pump may pump more water than you need at times your React pump is fitted with a pressure transducer which will turn the React pump off at a pressure you can set via a button When you start...

Страница 37: ...itting where the pressure is greatest as this could spray water all over the internal workings of the React pump and cause serious damage You can weaken the pipe by filing a flat on the top of the pip...

Страница 38: ...nk is not lost to the leak as you have a reserve capacity The supply pipe can be used to feed troughs on the way to the tank Overflow pipe 2 7 1 If you do not intend to use the pressure sensor to turn...

Страница 39: ...contact Do not install a switch on the PV supply wires This solution will stop the pump at the lowest acceptable level of your water intake resource Floating switches that are tethered by their own wi...

Страница 40: ...ave good access so that you can easily lift out the foot valve and replace the sock as needed and to check that the foot valve is always in perfect working order Our advice for rather dirty water reso...

Страница 41: ...hat the microprocessor can measure the Voc to obtain the maximum power point voltage Vmp Vmp 0 8 x Voc The rpm of the pump is then continuously adjusted to ensure it runs at the Vmp until the next che...

Страница 42: ...ers day in NZ but all this 300W can be used so the pumping yield does not suffer as much as you might expect Winter sun is never directly overhead unless you are close to the equator The angle of an E...

Страница 43: ...ter or poor weather conditions On cloudy sites or where more water is desired it can be helpful to add a third array bringing the total rated power to approximately 1 620W but the pump will never use...

Страница 44: ...the power cables are low cost compared to the long delivery pipe pipe typically has 10 30 loss at rated flow The SEIDP guideline states that Under maximum load conditions the voltage drop from the mo...

Страница 45: ...be labelled to identify its use and purpose We supply the switch with a new React pump purchase for you Maximum Series Fuse rating and the possible need for string fuses 3 2 3 Note that your PV panel...

Страница 46: ...trings are connected to our React pump triplex 3 3 5 1 In 1 5 x 8 95 13 43A In 2 4 x 8 95 21 48 In 20A Hence a fuse 20 amp and 13 43 A is required per string but only when 4 or more strings are connec...

Страница 47: ...ed AS NZS 5033 states in section 3 3 6 that In ELV arrays overcurrent protective devices where required for string and sub array cables shall be placed in either the positive or negative conductor the...

Страница 48: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 48...

Страница 49: ...This may not be the case in Australia and other countries which may require lightning protection to be fitted and or the PV frame to be earthed In NZ lightening damage is normally covered by your insu...

Страница 50: ...Wiring schematic for 1620W PV array 3 2 9 Notes If all your wires are black mark the wire with red PVC tape every 0 5m Check the maximum series fuse rating to determine whether string fuses are needed...

Страница 51: ...to the parallel connector Note the connectors shown allows for 3 connections as may be needed for a largest 6 panel PV option only double connectors are normally supplied with the React pump you can u...

Страница 52: ...day sun 6 x PV panels in an East Midday West position or on a large truss then the leads from each PV panel pair may not all be long enough to reach the parallel connectors In such cases you will need...

Страница 53: ...t in and chew on wiring Rats and other small gnawing rodents can be very difficult to keep out Putting a metal skin around the 4 posts of a trussed mounted array can prevent rodents from getting up on...

Страница 54: ...s we have used PVC saddles Some installation variations may require them PV wires are double insulated with UV rated plastic and when located in the shade under the panels require no extra UV protecti...

Страница 55: ...ns up to 50m long are easy to do this way If longer then do 50m at a time and use a joiner 4 Once through connect wire to the string securely and tape 5 Pull wire through pipe 6 Connect to switch box...

Страница 56: ...larity wrong if you have made up extension cables that are male male or female female instead of male female If you do this you will kill the BLDC driver in the React pump so you must take care and re...

Страница 57: ...normal Slide on metal fitting and crimp hard as shown Crimp again with the blunt end of a 3mm or 3 5mm drill bit inserted as shown Push the metal fitting into the plastic connector until it clicks You...

Страница 58: ...React pump can often meet these needs as well This is easy to arrange so consider doing it at the same time Skin the East West truss mounted PV frame in plywood and or corrugated steel and make a wat...

Страница 59: ...armers who need to pump more water and also need power for tools etc should consider expanding the solar to 6 x 270W PV panels Having reliable power at a shed on your remote farm can aid farmer worker...

Страница 60: ...se has rubbed on a rock and developed a pin hole leak Foot valve is partially open due to grit stuck on the seat Foot valve is badly worn and no longer water tight so leaks down at night Snails have g...

Страница 61: ...low the point where water is extracted from a small creek or stream The pump will prime itself Our Coanda intake is ideal for collecting clean water for this application A 1 2mm intake screen to filte...

Страница 62: ...ing galvanized stakes into the ground or by attaching to large boulders with brackets bolts and cement Intake screens can be purchased Opposite is a leaf slide made for domestic downpipes These are a...

Страница 63: ...y secured against flood flows and flood debris For lakes and dams that are not exposed to such risks ropes from the pontoon and anchored to the bank are sufficient for the pontoon to maintain located...

Страница 64: ...and rivers where occasional flood flows breach the river banks Do not install this solution on the following streams and rivers in deep ravines use the bore pump option that follows subject to large...

Страница 65: ...ve Reflection of sunlight off the water surface can assist solar PV power generation Security of the equipment from theft is improved although theft is less common these days as PV prices have fallen...

Страница 66: ...r surface and it will prime itself This is not advisable where flood levels can reach the pumps and submerge it in water Suction lines with 3 6m lift will need to have a manually assisted 4 2 8 prime...

Страница 67: ...tions between the React pump and the small low cost bore pump while always ensuring a positive head to the React pump Note small bore pumps with external controllers can have an external float switch...

Страница 68: ...ump online can be overwhelming as there as so many options So here are a few tips Buy one that Can run on a single 240 270W panel Can lift to about twice the head you need The head stated in the sales...

Страница 69: ...er is completely blocked with debris after only a short duration then fit a larger wire basket and fabric screen until an acceptable cleaning duration is achieved For reasonably clean water resources...

Страница 70: ...head we were testing to Pressure ratings working pressure do include a good factor of safety and bursts are unlikely provided the water temperature is not too high If pumping to 16 bar 160m the fittin...

Страница 71: ...upply pipe 1 Fittings supplied for the suction line all React pump applications Reducing Hex Nipple 20X15mm 3 4 x 1 2 stainless or plastic Suction inlet to React pump 1 Female Threaded Elbow 20mm 3 4...

Страница 72: ...pumps are often drowned in flood events as it is not practical to put them on a floating pontoon as they need refuelling and are heavy If you fail to move petrol diesel pumps quickly during heavy rain...

Страница 73: ...e on hand It is all held together with angled brackets and stainless tek screws It took less than 1 hour to make at a cost of 50NZ The four containers are held in place with perforated stainless strap...

Страница 74: ...s with larger floats both options are shown below These larger floats can hold 33kg of water EcoInnovation can supply these floats to NZ clients only This took less than 20 minutes to make at a cost...

Страница 75: ...sily made from treated timber This truss solution can also be used for a land frame mounted on four 4 treated corner posts As there is much more wind loading once the PV is installed such a pontoon wi...

Страница 76: ...used for lateral bracing It is all held together with common tek screws gang nail plates and angle brackets Making the pontoon 5 1 4 In this installation example we already had a pre existing pontoon...

Страница 77: ...nted East West installation using the same trussed frame was then permanently installed close to our factory so that we can use it to test each React pump prior to sale All that is required are 4 larg...

Страница 78: ...the 4 corner posts as shown 5 2 1 Posts are 2 1m long 1 0m in the ground and dry mix concrete rammed to secure in place Position trussed frame 5 2 2 Bolt or use several long tek screws to secure truss...

Страница 79: ...into this rail If you prefer you can use 4 aluminium rails to replace the timbers rails completely but this will cost a little more to do Or you can secure the PV panels like we did in the pontoon ex...

Страница 80: ...are happy to manually prime the React pump is in a deep ravine and you intend to use a submersible lift pump Then the instructions that follow illustrate how to install the React pump on land React p...

Страница 81: ...l normally be some distance from the PV array on the other side of a stock proof fence and in closer proximity to the water resource The pictures that follow are from the construction of our React pum...

Страница 82: ...h 4 x 50mm stainless teks Check pump cover fits These covers are made from stainless steel sheet on production models Pump cover is held in place for safety and weather tightness it is a rotating mach...

Страница 83: ...two ratchet tie downs as shown to prevent the wind from blowing over the frames For high wind sites fit and secure a fifth drum in the centre position You can also use old plastic or steel drums Fill...

Страница 84: ...s than 3m the lengths of your suction and delivery pipes the height of your header storage tank above the React pump static head Based on the tables provided in this document you will need to select p...

Страница 85: ...1042m 4 If your pipe is shorter than this length your loss will probably be under 20 so this internal diameter choice will be fine If your pipe is longer then consider using a larger pipe size If the...

Страница 86: ...the pipe pressure rating along the length of the run to minimise costs For example if you have a 160m delivery head you start with high grade 16 bar pipe at the React pump 12 bar then 9 bar and final...

Страница 87: ...e 4 5m on the table above When you can find this figure at the intersection of the 15 L min row and the 20mm ID column then proceed to read what follows Dynamic head on 20mm pipe 82 10x4 5 127m Dynami...

Страница 88: ...owing reasons Pipe flow will rarely be at 15L min so friction head is less in reality this reduces the dynamic head on the smaller pipe to a greater extent than the larger pipe Pump is more efficient...

Страница 89: ...best if possible no suction at all See the next section for intake design and React pump priming issues in detail Multiple React pumps can share the same suction line but only if the water can gravit...

Страница 90: ...ound the React pump can be a fire vector refer to section 1 3 3 for detailed advice Secure the React pump to the ground with steel or timber pegs not provided as most NZ farms will have suitable mater...

Страница 91: ...ct pump with SAE15W 40 oil to the top edge of the level glass Manually primed the React pump suction line if required if suction head exceeds 3m If you pipeline to tank is already full of water you wi...

Страница 92: ...roblems to deal with See next page for a table of problems and suggested solutions 7 4 Commissioning checks It is important to formally commission the React pump and associated system to ensure it is...

Страница 93: ...ite to have less suction head by lowering the React pump to be closer to the water resource Fit the React pump on a floating pontoon if possible or fit a submersible lift pump The React pump is dead I...

Страница 94: ...ey install it themselves The above is a mandatory requirement for LV systems As your system is ELV the above can be regarded as good practice To comply with good practices the installer shall prepare...

Страница 95: ...5033 these are advised only 7 5 4 e f g h l m are not relevant to this React pump ELV installation 7 6 Feedback We welcome your constructive feedback on how we can improve our products including this...

Страница 96: ...ill run fast for a while Very good Will run fast for a while Good Will run fast for a while Full delivery pipe Full suction pipe Excellent Good OK if foot valve and filter sock always in good clean co...

Страница 97: ...body with clean SAE15W 40 oil see section 8 6 to the top edge of the oil level indicator glass If you significantly over fill the oil level drain some out before starting Oil level should never be le...

Страница 98: ...d pad An old chest freezer makes a great small insulated building This enclosure does need venting as the React pump makes some heat Only fit the insulated cover close the chest freezer lid at times o...

Страница 99: ...any checks at all until the React pump stops they then run about trying to fix it quickly but do not have the parts required on hand A full set of spare seals and ceramic plungers are available for a...

Страница 100: ...nd replacement if needed Upgrade BLDC driver software to latest release Test for leaks Premium warranty extension for a further 12 months Return to you by courier NZ clients who choose not to enter th...

Страница 101: ...arts from the date of sale as stated on the invoice from EcoInnovation to the buyer or dealer Where dealers hold stock warranty starts within 12 months of purchased from us or at the time the dealer m...

Страница 102: ...we seek the full picture What appears to be the problem TICK A part has failed after running fine from some time details Product does not work at all Product works but flow output is lower than expec...

Страница 103: ...llation may result in damage to the React pump property and injury Therefore the manufacturer assumes no responsibility and liability for loss damages or costs which result from or are in any way rela...

Страница 104: ...or solar radiation two extra solar panels can be added to boost the pumped volume This will benefit sites with head above 150m and sites that are often cloud covered where more water is needed than fo...

Страница 105: ...Ba Minimum pressure stop setting 60m 6 Bar Input fitting size 25mm hose tail for suction hose Fittings can be removed leaving a BSP female thread to connect onto Output fitting size 20mm up to 30bar...

Страница 106: ...t Suction pipe inside diameter mm or inch Suction pipe length m or ft Static delivery pressure React pump off kPa or PSI Dynamic delivery pressure React pump running kPa or PSI Suction pipe lift or st...

Страница 107: ...PowerSpout React Pump Installation 2019 EcoInnovation Ltd NZ V2 1 Page 107...

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