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THE ROVAI POND PUMP - RP6

(The Cambodian version of the Rope Pump)

INSTALLATION MANUAL
V. Whitehead, April 2008

The main components of the Rovai Pond pump

1 1. Wheel cover 2. Wheel 2 3. Handle 4. Cement cover 3 7 5. Adjustable pipe clamp 6. Pump frame 4 6 5 7. Protection pipe

Figure 1 Main components of the Rovai Pond pump's upper parts

8 9

8. Rope & pistons 9. Ceramic guide 10. Outlet pipe

10 11 12

11. Upper guide box 12. Frame bolts (x4)

Figure 2 Details of the Pond pumps outlet assembly

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13
13. Float 14. Strainer

14

15. Inlet pipe 16. Flexible rubber joint

15 16 17

17. Elbow and reducer

Figure 3 Details of inlet assembly

18 19
18. Riser pipe 19. Return pipe

20
20. Bottom guide box

Figure 4 Cutaway view inside protection pipe

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Tools equipment and consumables

Please make sure all the items listed below are ready before installation startsthis will save time if they are prepared in advance
Equipment Rovai pond pump head Upper guide box and outlet pipes assembly Protection pipes (100mm diameter) Riser & return pipes + PVC connector Bottom guide box Rope & pistons Reducer and elbow assembly Float Strainer, PVC inlet pipe and rubber hose Cement cover & 0.8m cement ring M10 Nuts & washers Tools Spanners No. 6 adjustable x 2 Hacksaw Tape measure (10m) Scissors or knife Consumables Sandpaper PVC glue Oil Sand cement (approximately 5kg) and clean water Tie wraps

Thin string & weight (fishing line) Pliers Cigarette lighter or matches Fishing line + weight Spirit level Cement trowel

--------------------------------------------------------------------Pond pump cement ring base construction note:

It is important that users, especially children, can reach and operate the pump comfortably. It is recommended that when constructing the cement ring part make sure that the height from the apron to the top of the well is between 40 and 50 cm.

40cm to 50cm

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ROVAI POND PUMP INSTALLATION INSTRUCTIONS

1. Firstly make sure the pond pump will be installed at a place chosen by the community which provides the best access from the village and that this is agreed by the community. 2. It is best if the Rovai pond pump is installed before the well apron (platform) is made. This allows the correct positioning of the pump in both height and distance this is essential to allow the protection pipe to sit straight and well supported on the pond slope. A 0.8m diameter cement ring is a convenient item for installing the pump on. This can easily be purchased at the nearest cement ring maker before installation starts. Note:

3. Prepare the area of ground where the pump will be installed by making it level and compacted (makes sure there is no deep rooted vegetation). The area should be approximately 1meter from the edge of the pond slope. Place a layer of rocks (size approximately 50 x 100) under the ring to raise it up. Place the 0.8m diameter cement ring on the rocks make sure it is reasonably level.

Rocks under ring

4. Lift the cement cover on to the top and put the pump on to the four screws. Make sure there is a washer and nut above and below the four feet as shown opposite.

5. Cut the flared end off one of the large 100mm diameter PVC pipes (A) then fit them all these pipes together (use PVC glue on the joints).

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6. Lower the pipes into the water until the pipe is level with the slope of the pond (B) and it is sitting on the bottom of the pond (C). Move the cement ring forward or backward until the pipe is level with the adjustable pipe clamp.

D B C

NOTE: It is important to position the 0.8m cement ring the correct distance from the water line so that the protection pipe sits on the slope of the pond. This keeps it straight and gives it support.

40mm

7. When the pipes are in place and you are confident B C and D are correct then mark the pipe approximately 40mm above the clamp. Check the length is correct then remove the pipe then cut it with a hacksaw at the mark to this length. TIP: wrap a piece of paper around the pipe and use a pen to mark around the edge of the paper, this will give you a guideline to cut the pipe off nice and level.

8. Remove the pipe from the water and lay it on a clean area of ground or preferably on some plastic sheet or similar material.

9. Using a spirit level (E) recheck that the cement cover is level, adjust it if required. When it is level put cement mortar around the base of the cement ring and under the cement cover to seal it.

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10. Lay the riser and return pipes (F) level with top end of the PVC protection pipe.

15-20cm

G
11. Lay the bottom end of the guide box (G) about 15-20cm from the bottom of the protection pipe. Mark off on the riser and return pipes level with the top pipes of the guide box then saw the pipes off at this length.

12. Tie a small weight (one or two M12 nuts for example) to the end of a long fishing line (at least 14m long). Push this through the upper guide box return pipe as shown. Then pass the the weight and fishing line down through the flared return pipe (H) NOTE: the return pipe has a larger inside diameter than the riser pipe so make sure you chose the correct one.

Small weight

13. Push the fishing line rope and weight through the 34mm PVC connector, then pass it through the guide box. Dont pull the line through too far.

14. Apply some PVC glue around the outside of the bottom end of the return pipe J and push it on to the riser pipe K. Allow a few minutes for the glue to dry. NOTE: Do not put glue inside the end of the return pipe as excess glue may be pushed inside the pipe and when it hardens the pistons may not fit through the pipe.

J K

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15. It is important to glue the guide box 90 degrees to the upper guide box. This is to stop the pistons rubbing against the bottom of the protection pipe. Simply make sure the holes in the upper guide box are vertical and the pipes in the bottom guide box are horizontal.

90 degrees

16. When the bottom and upper guide box are correctly orientated apply PVC glue to the short return pipe on the guide box and then push the 34mm connector on the glued return pipe.

1m
17. Next tie a piston on every 1m with a knot above and below the piston on to the 5mm diameter rope as shown opposite. Make sure the pistons all face the same way.

1m

18. Then pull on the fishing line until there is about 0.5-1m of the rope sticking out of the top of the upper guide box. Then thread the fishing line and weight through the bottom guide and through the riser pipe

19. Thread the fishing line through the upper guide box outlet then pull the rope with the pistons on through the pipes until the two ends are level.

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L
20. After this apply glue to the ends of the pipe and push it into the hole in the upper guide box. Tie a knot in the ends of the rope L to stop them falling back down the pipes.

21. Now check that the pistons can move through the pipes freely. First check that the knot tied above is tied securely and the ends of the rope are quite short so that they wont get caught on edges of the pipe. Pull on the rope that comes out of the riser pipe M until the knot appears again. If the rope is not free to move through the pipes find out the reason and rectify the problem before moving on to the next stage.

22. Push the Elbow and reducer assembly on to the bottom end of the large PVC protection pipe. NOTE: do NOT apply glue to this as it is important that it can be removed for cleaning out in the future.

23. Then push the flexible rubber pipe on to the end of the elbow assembly. The short piece of pipe is slightly flared which helps to stop it from slipping off easily.

24. Use a tie wrap to squeeze the rubber pipe onto the PVC pipe as shown in the two stages opposite. NOTE: Do not use metal clips to grip the rubber pipe as these will rust very quickly.

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25. Now add the float assembly to the intake pipe. Use fishing line (N) to securely tie the float through the holes in the end caps. Also tie the line under and around the strainer as shown at (P). NOTE: the strainer should NOT be glued on as this allows it to be removed for cleaning in the future.

26. The guide box, riser pipe and upper guide box assembly can now be pushed into the protection pipe.

27. Push the upper guide box down on to the protection pipe. NOTE 1: Make sure the upper guide box is orientated correctly: the outlet hole on the upper guide box should be at the top (Q) and inline with the float NOTE 2: Do NOT glue the upper guide box on. It will need to be removed in the future for cleaning or repairs.

28. The whole of the intake assembly can now be lowered in to the water. Keep the intake pipe and float in a vertical position as this is done. This will take a few minutes as the pipes will slowly fill up with water.

29. Now push the upper guide box up through the clamp arms. The clamp arms can be pulled open slightly at R to allow the upper guide box to pass through.

R R

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30. Refit the 2 x M5 screw nuts and washers on to the clamp S (one at front and one at rear of clamp). NOTE: Do NOT over tighten these as it will damage the plastic pipe.

31. Untie the knot and pass the rope through the outlet pipes as shown opposite. Then fit the pipe small pipe bracket on to the angled upper pipe T.

32. Pass the rope around the wheel as shown opposite. Hold both ends in your hands and pull up and down to check that the rope and pistons are free to move around the bottom guide box. Then tie a knot as shown below.

33. Follow the five steps as shown below for tying a knot in the rope. After step five pull the rope on each side of the knot and check that it will not come undone. STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

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NOTE: After cutting the ends burn the ends of the rope with a small flame (cigarette lighter) to stop them from fraying. Make sure the rope is dry first!

34. Fit the cover as shown using the four stainless steel M5 bolts, nuts and washers on each corner of the cover P.

35. Slowly turn the handle to check that the rope and pistons are free to move through the pipe. Increase the speed until water comes out of the outlet pipe and that the flow rate is acceptable Dont forget make sure that an apron (platform) should be made after the installation of the pump. This provides protection, and a clean surface to stand on when operating the pump. Key features of an apron are given below: 1. Approximately 1m of apron floor around pump (mortar finish) 2. Sloping surface on apron to lead water to drain 3. Drain leading to a soak-away pit for spilled water 4. Raised edge around apron and drain

1 2 4

Dont forget to tidy up around the area you have been working on after you have finished It demonstrates you care!

It is strongly recommended that a responsible person is chosen to take care of the pump. If this is a communal pump then this could be the pump caretaker of the villages water user group. This person should receive training in operating and maintaining the Rovai Pump. There is a separate manual for this and it should be used as part of that training, a copy of the manual should be given to that person for their use.

NOTE: After installation of the pond pump please read through the RP6 Operation and Maintenance manual
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