WOLDIA UNIVERSITY

SOLAR WATER PUMPING SISTEM TRAINNING MANUAL

LO3: Perform Operation SWP System

This learning guide is developed to provide you the necessary information regarding the following
content coverage and topics:

 Identifying PPE, operational tools and supporting SWP System

 Performing safe operation SWP System
 Evaluating the functionality of SWPS.
Learning Instructions:
1. Read the specific objectives of this Learning Guide.
2. Read the information written in the information “Sheet 1 and Sheet 2”.
3. Accomplish the “Self-check 1, and Self-check 2”.

Information Sheet 1 Identify PPE, operational tools and supporting SWP System
1. Introduction
PV water pumping systems require much less operation compared to other water pumping systems.
However, they will still require proper operation. Responsibilities for solar water pumping system
operation and maintenance must be clearly specified after system handover and adequate resources
must be provided. Inadequate operation is the reason cited most frequently for PV water pumping
system failure in Ethiopia and in other countries. Some of the issues include unclear responsibilities
for operation inadequate human capacity for proper care and operation of the system (due to no or
insufficient training, salaries for operators and guards), lack of funds for maintenance and service
(sometimes even for minor maintenance).

The following are tasks to be performed to operate solar water pumping system. Before we start to
operate, we have to do pre start checks (listed in C1 as follows) and after we perform those checks, we
can go through to the steps for starting the PV generator (listed in C2 as follows). Then we have to
ensure that the PV generator can generate an output that is needed and we have to shut down the PV
generator properly (stated in C3) then finally we have to clean the PV generator area and return the
tools to their position.

A. We do not have to attempt to operate the PV water pumping systems without consideration of
OH & S precautions

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B. We have to ensure that the PV water pumping systems is protected from shadow or dust and is
located in the appropriate area that is free from any insecure items that could inhibit operation
or cause injury, damage of system are screened clear safe guards.
C. Next, we have to avail tools & instruments that are necessary for this operation.
D. Let us to be proceed with the following steps before start, to start & operate and stop or
provided as follows in C1 C2 & C3. While doing these we have to see and record related data
on the operation log and operation checklist.

1.2 . Safety Instructions on SWPS operation

Safe operation of this system depends on its correct transportation, installation, operation and
maintenance. Failure to follow these instructions can be dangerous to life or health and/or properties.
 Read and follow all instructions
Warning – Disregard can lead to injury, death or damage the system.
Caution – Recommended to avoid damage, premature ageing of the pump or similar negative
consequences. When installing and using this electrical equipment, basic safety precautions
should always be followed, including the following:
Warning – To reduce the risk of injury, do not permit children to use this product unless they
are closely supervised at all times.
Warning – The appliance is not to be used by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless they are
instructed and closely supervised.
Warning – To reduce the risk of electric shock, replace damaged cords immediately.
Warning – It must be assured that all grounding connections are properly made and that the
resistances meet local codes or requirement
The manual contains basic instructions which must be observed during installation, operation and
maintenance. Before installation and start-up, the manual should be carefully read by the person in
charge of the installation. The manual should also be read by all other technical personnel/operators
and should be available at the installation site at all times.
 Personnel qualifications and training: - All personnel for the operation and inspection must
be fully qualified to perform that type of job. Responsibility, competence and the supervision
of such personnel must be strictly regulated by the operator. Should the available personnel be

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lacking the necessary qualification, they must be trained and instructed accordingly. If
necessary, the operator may request the manufacturer supplier to provide such training.
Furthermore the operator/user must make sure that the personnel fully understand the contents
of the manual.
 Dangers of ignoring the safety symbols: – Ignoring the safety directions and symbols may
pose a danger to humans as well as to the environment and the equipment itself. Non
observance may void the warranty. Non-observance of safety directions and symbols may for
example entail the following: Failure of important functions of the equipment/plant; failure of
prescribed methods for maintenance and repair; danger to persons through electrical,
mechanical and chemical effects; danger to the environment because of leakage of hazardous
material; danger of damage to equipment and buildings.
 Safety-oriented operation: – The safety directions contained in the manual, existing national
regulations for the prevention of accidents as well as internal guidelines and safety-regulations
for the operator and user must be observed at all times.
 General safety directions for the operator/user: – If hot or cold equipment parts pose a
danger then they must be protected by the operator/user against contact with people. Protective
covers for moving parts (e.g. couplings) must not be removed when the equipment is running.
Leaks (e.g. at the shaft seal) of hazardous pumping media (e.g. explosive, toxic, hot liquids)
must be disposed of in such a way that any danger to personnel and the environment is
removed. All government and local regulations must be observed at all times. Any danger to
persons from electrical energy must be eliminated by using good installation practices and
working to local regulations.
 Unauthorized operation: – The operational safety of the equipment delivered is only
guaranteed if the equipment is used in accordance with the directions contained in this manual.
Limits stated in the data sheets may not be exceeded under any circumstances.
1.3. Developing an Electrical Safety in SWPS Program
An electrical safety in SWPS program outlines requirements, policies and practices to address hazards
associated with working near electricity. It should be aligned with the requirements of the safety
management system, be practical, sustainable and a measurable program to mitigate or reduce the risk
of exposure to electrical hazards. On the other end of the spectrum, a small operation that undertakes
work with a low risk profile may need only a small task-specific program that requires only minor

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amendments to an existing safety management system. Regardless of the size and scope, what matters
is that an electrical safety in SWPS program is designed and implemented to keep people safe.
1.4. Safety rules
Safe working habits in work shop is essential to prevent accidents which may result i n personal injury
or health hazards, damage to tools, equipment & property.
 Common causes for accidents are:
 Improper use of tools & equipment's, etc.
 Failure to use protective equipment
 Failure to follow correct procedure
 Faulty equipment & tool
 Condition of walking & working surfaces
 Unguarded or inadequately guarded machinery
Safety is a matter of a common sense & good work habits. A person who has does not have knowledge
of or regard for his tools, machines, equipment & himself cannot effectively & safely perform his
work. A good knowledge of tool is very important for safety. Any tool can cause harm if not properly
used. So any one who uses tools must use them carefully & safely to avoid injury. Anyone who knows
about safety rules takes good care of himself & the tools. He can avoid the danger that may be caused
by carelessness & ignorance.
SAFETY - is the control of hazard to attain an acceptable level of risk

 HAZARD - unsafe acts/unsafe conditions.

 RISK - chance of personal or physical loss.
 ACCIDENT - is an undesired event that results in physical harm to a person or
damage to property.
 General Statistics/Data:
 Unsafe Acts - people/personnel- 88 %
 Unsafe Condition - equipment, material & environment – 10 %
 Acts of God - natural calamities – 2%
1.5. Personal Protective Equipment (PPE)
PPE are those that are worn by personnel to protect them against hazard exposure. It sets-up a frail
barrier against hazard.

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 Classification of PPE
 Head and Ear Protection
 Face and Eye Protection
 Respiratory Protection
 Hand, Foot & Leg Protection
 Body or Torso Protection, Protective Clothing
 Fall Protection
 Requirement on PPE
Employees shall be required to wear and be provided with appropriate PPE when performing any
activity where potential hazard exists.
 Common PPE Used
 Head Protection - bump caps, safety helmets, and hard hats.
 Body Protection – hand gloves, safety shoes, coverall, vests, rain coats, safety
belts.
 Eye Protection - safety glasses, goggles, masks or face shields.
 Respiratory Protection - dust/gas mask
 Ear protection
 Basic tool safety rules
 Maintain on a regular basis
 Inspect before use
 Operate according to manufacturer‟s recommendation
 Use the right personal protective equipment(PPE)
 Use guards
1.6. Safety signs
These are special signs posted to warn against immediate danger or potential hazards that the
Personnel may be exposed to and instruct them on the special precautionary measures they have to
take in order to prevent accidental injury to personnel, property damage or both.
 Classification of Safety Signs According to Use
 Danger Sign - these signs shall be used only where immediate danger /hazards exist
to make the personnel aware of the immediate danger and special precautions they

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have to take prevent accidents. Ex. DANGER, HIGH VOLTAGE. These are in red
letters with white background

Figure1: Danger Sign

 Caution Sign - used to remind personnel against potential hazards and to instruct
them to take the proper precautionary measures to prevent accident. Ex. CAUTION:
Watch your step. These are in black letters with yellow background.

Figure 2: Caution Sign

1.7. General First Aid

First aid, by definition, is the immediate and temporary care given to a person or those suddenly
taken ill before the services of a physician can be obtained. Adequate first aid kits and/or
paraphernalia should be available, generally, in working areas where personnel have access
especially during emergencies.

 Objectives of first aid

 To prolong life
 To alleviate sufferings
 To prevent additional sufferings

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 DO’s and DON’T’s in FIRST AID

DON’T’s:
 Do not arouse unconscious person by means of pulling, biting and pouring water into
his face
 Don‟t give fluids to an unconscious person
 Don‟t panic
 Don‟t let the person see his own injuries
DO’s:

 Keep calm and deliberate

 Keep handling to the minimum
1.8. General Safety Practices

ON THE JOB:
 If you are not sure about how to do the job safely and correctly, ask your immediate
supervisor or manager.
 If you are transferred to another department, learn the safe practices of that department.
 Report at once to your supervisor/manager any unsafe practices or potential hazards.
 Wear the appropriate PPE.
 Walk cautiously on wet or slippery floors and stairs. Running in the control building is
not safe. Use care in going up or down the stairs. Hold on to the hand rail. Take one step at a
time.
 Ask for help when lifting objects which are unusually heavy. When lifting, keep the legs
as close together as possible and the back straight. Lift with your leg muscles - not your
back.
 Practice good housekeeping. Place oil waste, scrap, and waste paper in covered metal
cans. Wrap broken glass separately or place in special container.
 Avoid wearing oil-soaked clothes. They could readily catch fires.
1.9. Handling of material
Handling of material is responsible for approximately one fourth (1/4) or 25% of the
occupational disabling injuries. In order to establish efficient material handling procedures, it is
necessary to consider the following:

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 The properties of the material.

 The characteristic of the operation process or location to or from which the material is to
be moved.
 The quantities to be handled to maintain a constant flow.
1.10. Safety tagging:
Tagging is an effective safety method wherein tags are posted and/or attached on
component/equipment/system which is/are under testing or maintenance/repair as one of the control
protection to personnel and equipment/system.
 When Do You Need to Post a Tag?
 During testing of equipment or system;
 Maintenance/repair of substation which require opening of PCBs and DS;
 Maintenance/repair of transmission line/s;
 Force outage which requires inspection & clearance before energization.
 Requirements on Tagging
 Complete all the necessary information needed.
 Log all the tag posted with corresponding control number.
 Post and/or attach the tag/s to the equipment/item.

Generally, never use aluminum ladders on any electrical job. A metal is always an electric conductor.

2. Tools and instruments for operation solar water pumping system.

Table 1. Tools and instruments for operation solar water pumping system

No. Tools Purpose

1 Total station Use to measure distance, angles in
both the horizontal and vertical
planes.

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2 Used to indicate directions

Compass

3 Used for indicating direction,

Global Positioning location, altitude
System (GPS)

4 Used to measure current, Voltage,

Multi-meter resistance and other parameters

5 Megger (insulation Used to measure insulation

tester) resistance of the cable and motor
against the ground.

6 Marking tool set (pencil, Used to mark

market, chalk)

7 Distance measuring Used to measure distance

tape

8 Levels measuring Used for water level and structures

angle adjustment

9 Well depth meter Used to measure depth of water

level

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10 Set of pliers and Used for turning or twisting nuts,

socket wrench bolt heads or the like.

11 Set of screw drivers Used for turning or twisting

screws heads or the like

12 Set of pliers Used for cutting, to hold objects

firmly, for bending, or physical
compression.

13 Crimping tool Used to join two pieces of metal

by deforming one or both pieces to
hold the other. And also used to
attach a terminal or contact to an
electrical conductor
14 Hammer Used to manually drive nails,
brads, and other fasteners into /out
of softer materials

15 Rubber Hammer Used for striking a surface without

causing damage.

16 Hack saw Used to cut or grind metallic

materials

17 Wooden saw Used to cut wooden materials

18 Ladder Used to access elevated areas from

the ground during installation

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19 Water pipe wrench Is an adjustable wrench/spanner

used for turning soft iron pipes and
fittings with a rounded surface
20 Ratcheting pipe Used to manual cut pipe threading
threading set and cutting

21 Plastic tube cutter/ Used to cut plasitice pipes

scissor type

22 Calliper Used to measure external or

internal dimensions

23 Cordless drill machine User to drive drill bits and nuts

24 Safety, Used for safty

Gloves/goggles/ear plugs

25 Tripod and pulley For lowering and rising pipes and

pump from a well

26 Swivel nipple For holding a pipe during raising

or lowering

27 Pipe clump Securing pipe during lowering and

raising

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28 Propane burner/ For heating water proof epoxy

torch sealant for electric wire

connections
29 Teflon coating/tape For sealing pipe joints to make
them water tight

Information Sheet 2 Perform safe operation SWP System

1. Operation and checking of SWPSC

Figure 3 SWPS controller unit

Check 1 - Pre-Operation Checks

Below are routine Operation Procedures that need to be followed by a SWPS operator:
During start up, operation and shutting down the SWPS:
1. Check that all valves are in open position (Gate valves, check valves, etc.)

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2. Make sure that the solar array is clean from dirt

3. Check weather condition of the site
4. Check status of the system reservoir.
5. Switch ON/OFF the Strat Button on the System Controller

Figure 4 clean array from dirt

Figure 5: check ON /Off switch

Check 2 – during operation -Start
1. If the pump starts properly, make a regular check on the piping system for any Leakages
2. If the pump starts but no or small amount of water is supplied, check the pressure gage.
3. If the pressure gage indicates a high pressure, this means there is a blockage in the pipe system.
Stop the pump and check if all valves are open, in case of mechanical overflow control in the
water tank, check that it is not stack in the close position, read the controller for any error code
generated and refer the manual for the type of error it refers to.
4. If these actions don‟t resolve the problem, then the blockage could most probably be due to
piling up of silt in the pipe system. This requires a thorough check if the whole pipe system.
5. Check if all signals and displays on the controller indicate normal operation of the pump

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6. If the display signals in the controller indicate a problem, Switch Off the pump and refer the
manual to follow the instruction. If the required action is beyond the level that the operator is
trained to address, an expert technician must be called.
2. Operating the solar water Pump
1.Make sure that an unhindered water flow is possible and not blocked, e.g. by closed valves.
2. Switch on the PV generator disconnect switch.
3.Toggle the power switch on the controller to ON.
4.A solar-direct pump will now start when sufficient irradiation levels are reached and neither
the well probe nor float switch respond to a low water Source or full tank.

Figure 6: Starting operation of SWPS

3. Time Delays pump start
Table 2 time delay pump start
Event Time delay
Pump stops due to insufficient irradiation 120 seconds
Full-tank float switch resets 2 - 3 seconds
Low water well probe regains contact with water 15 Minutes
Shutdown due to over temperature Automatic restart after cooling down
Shutdown due to overload Manual reset of POWER switch necessary

To force a quick start: - the above listed delays can be by passed by switching the POWER switch
OFF/ON. The pump should now start immediately if sufficient power is present
NOTE – Please always refer to the Pump Scanner documentation available on Partner NET for the
latest developments. It is highly recommended to make an initial configuration of the Data Module
inside the PS controller using manufacture Pump Scanner

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Check 3- switching off: -

 To shut down the SWPS, turn off the load by switching the pump controller to “OFF”.
 Allow the SWPS to keep on no load by OFF position of the controller for few seconds‟
 Then turn the key switch to OFF‟ position .Then PV generator shuts down safely.
 In case of an emergency where immediate shutdown is necessary, stop using emergency stop
(if the SWPS has an emergency stop) or use the key switch should be turned to „STOP‟
position immediately without disconnecting the load (if the SWPS has no emergency stop)

4. Inspections or evaluating SWPS

The electrical inspection verifies that your installation meets minimum requirements for electrical
safety, according to current codes. In other words, its purpose is to protect you, the homeowner, and
anyone else who will be occupying the premises, from fire or electrocution.
Electrical inspection is a must for every SWPS to ensure the safety and security of the habitants. In
fact, it is required, but it most certainly does not need to be a cause for high blood pressure. Knowing
what to expect beforehand can be one of the best ways of dealing with electrical inspection. If you
have the loopholes rectified as per the requirements of the state, then there is no way you will fail the
inspection.
1. Inspection cover Guidelines specifying the electrical inspection criteria for your location may
be obtained at the time you apply for your permit. The basic areas are:
 equipment listing and labeling
 electrical services
 general circuitry
 AFCI (arc-fault) protection
 GFCI (ground fault) protection
 grounding and bonding
 underground wiring
 Wiring methods.

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Figure7: Testing and measuring

1.1 Clean up all the system

 Clean the SWPS operation area & return the necessary tools used for pre & post operations
and adjustments

 Now after you confirm that the SWPS starts its operation safely & after you properly shutdown
it, keep clean the surrounding of a SWPS and return the tools used for operating the SWPS.

Operation Sheet 1 Perform safe operation SWP System

Techniques or procedures for Perform safe operation SWP System:

Step 1- Use PPE and Wear safety clothes
Step 2- Follow all the electrical & mechanical safety procedure required in SWPS installation
manual
Step 3- Plan and prepare work place
Step 4- Select appropriate tools and equipment for operation
Step 5- Check all PV module, installation cable, PV power disconnector controller, PV pump
equipment and accessories
Step 6 – Check Connection of the PV array generator
Step 7 – Operate the solar water Pump
Step 8- Check time of Delays pump start
Step 9 - Check the functionality of the system with multimete

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Step 10 - Inspections or evaluating SWPS condition during operation.

Step 11- To shut down the SWPS, turn off the load by switching the pump controller to “OFF
Step 12- clean up the operation system

Self-check Sheet -1 Identify PPE, operational tools and supporting SWP System

Name: ___________________ Date: _______________

Time started: ______________ Time finished: __________

Directions: Answer all the questions listed below. Use the answer box below.
Multiple Choice Questions: Choose one. (1 point)

1. The following operation tools are used to test live power

A/ Compass and GPS B/Tape meter C/.meltimeter D/ All of the above
2. Tools used to during operation lowering and rising pipes and pump from a well
A/ Pipe clump B/ Bench C/ Tripod and pulley D/ Ladder
3. Instrument Use to measure water flow is____
A /. Water flow meter B/ Compass C /.Try square D/ Meter
4. Daily SWPS maintenance is_______
A. Cleaning PV module B. pump casing C. Controller D. All

Mach the following question column A to column B

A B
1. Compass A. Used to measure current, Voltage, resistance and other
parameters
2. Global Positioning
System (GPS) B. Used to measure depth of water level
3. Multi-meter C. Used for indicating direction, location, altitude
4. Well depth meter D. Used to indicate directions
5. Pipe clump E. Used to join two pieces of metal by deforming one or both pieces
6. Set of screw drivers F. Used for striking a surface without causing damage
7. Rubber Hammer G. Securing pipe during lowering and raising
8. Crimping tool H. Used for turning or twisting screws heads or the like

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Self-check Sheet -2 Perform safe operation SWP System

Name: ___________________ Date: _______________

Time started: ______________ Time finished: __________

Directions: Answer all the questions listed below. Use the answer box below.
Multiple Choice Questions: Choose one. (1 point)

1. The following general safety rules are furnished as a guide

A/ Obey safety rules and regulations-they are for your protection. B/, Wear proper clothing and
protective equipment. C/. Conduct yourself properly at all times-horseplay is prohibited
D/ All of the above
2. Pre-Start Checks operations are------------
A/ Check that all valves are in open position B/ Check weather condition of the site
C/ Make sure that the solar array is clean from dirt D/all
3. An OHS Policy is simply a method of how stating ------------
A/ working with environment policy B/ simple work C /. Checking work D/ hazard
4. The mechanical protection needed against cuts, abrasions, punctures and electrical injuries
by_______
A/. Goggle B/.Glove C/.Helmet D/.Apron
5. During operation If the pump starts but no or small amount of water is supplied _______
A/ If the pressure gage indicates a high pressure B/ check the pressure gag C /. Blockage in the
pipe system D/ All

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