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THE ROVAI POND PUMP - RP6(The Cambodian version of the Rope Pump)

INSTALLATION MANUAL

V. Whitehead, April 2008

Ideas at Work (IaW)#5, Street 21,

Tonle Bassac,Phnom Penh

Phone : +855 (0)23 350 911

Mobile : +855 (0)12 593 973 (Khmer)

Mobile : +855 (0)12 700 482 (Eng)

Email : [email protected]

Web : www.ideas-at-work.org


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IaW/Pond pump installation manual/Rev 1/18th Apr 08/Eng Page 2 of 12

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The main components of the Rovai Pond pump

1. Wheel cover

2. Wheel

3. Handle

4. Cement cover

5. Adjustable pipeclamp

6. Pump frame

7. Protection pipe

8. Rope & pistons

9. Ceramic guide

10.Outlet pipe

11.Upper guide box

12.Frame bolts (x4)

6 5

1

3

2

4

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

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Figure 2 Details of the Pond pumps outlet assembly


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13. Float

14. Strainer

15. Inlet pipe

16. Flexible rubber joint

17. Elbow and reducer

18. Riser pipe

19. Return pipe

20. Bottom guide box

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Figure 3 Details of inlet assembly

Figure 4 Cutaway view inside protection pipe

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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 communitywhich provides the best access from the village and that this is agreed by thecommunity.

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 isessential to allow the protection pipe to sit straight and well supported on the pondslope. A 0.8m diameter cement ring is a convenient item for installing the pump on. Thiscan easily be purchased at the nearest cement ring maker before installation starts.Note:

3. Prepare the area of ground where the pump willbe installed by making it level and compacted

(makes sure there is no deep rooted vegetation).The area should be approximately 1meter fromthe edge of the pond slope. Place a layer ofrocks (size approximately 50 x 100) under thering to raise it up. Place the 0.8m diametercement ring on the rocks make sure it isreasonably level.

4. Lift the cement cover on to the top and put thepump on to the four screws. Make sure there is a

washer and nut above and below the four feet asshown opposite.

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

A

Rocks under ring


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6. Lower the pipes into the water until the pipe islevel with the slope of the pond (B) and it is sittingon the bottom of the pond (C). Move the cementring forward or backward until the pipe is levelwith the adjustable pipe clamp.

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

8. Remove the pipe from the water and lay it on aclean area of ground or preferably on someplastic sheet or similar material.

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

B

C

D

40mm

NOTE: It is important to position the 0.8m cement ring the correctdistance from the water line so that the protection pipe sits on the slope

of the pond. This keeps it straight and gives it support.

E


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

11. Lay the bottom end of the guide box (G) about15-20cm from the bottom of the protection pipe.Mark off on the riser and return pipes level withthe top pipes of the guide box then saw the

pipes off at this length.

12. Tie a small weight (one or two M12 nuts forexample) to the end of a long fishing line (at least14m long). Push this through the upper guide boxreturn pipe as shown. Then pass the the weightand fishing line down through the flared returnpipe (H) NOTE: the return pipe has a largerinside diameter than the riser pipe so make sureyou chose the correct one.

13. Push the fishing line rope and weightthrough the 34mm PVC connector, thenpass it through the guide box. Dont pullthe line through too far.

14. Apply some PVC glue around the outside of thebottom end of the return pipe J and push it onto the riser pipe K. Allow a few minutes for theglue to dry. NOTE:Do not put glue inside theend of the return pipe as excess glue may bepushed inside the pipe and when it hardensthe pistons may not fit through the pipe.

F

15-20cm G

Small weight

H

J

K


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15. It is important to glue the guide box 90 degreesto the upper guide box. This is to stop thepistons rubbing against the bottom of theprotection pipe. Simply make sure the holes inthe upper guide box are vertical and the pipes inthe bottom guide box are horizontal.

16. When the bottom and upper guide box arecorrectly orientated apply PVC glue to the shortreturn pipe on the guide box and then push the34mm connector on the glued return pipe.

17. Next tie a piston on every 1m with a knotabove and below the piston on to the5mm diameter rope as shown opposite.Make sure the pistons all face the sameway.

18. Then pull on the fishing line until there is about0.5-1m of the rope sticking out of the top of theupper guide box.Then thread the fishing line and weight throughthe bottom guide and through the riser pipe

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

1m

1m

90 degrees


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

21. Now check that the pistons can move throughthe pipes freely. First check that the knot tied

above is tied securely and the ends of the ropeare quite short so that they wont get caught onedges of the pipe. Pull on the rope that comesout of the riser pipe M until the knot appearsagain. If the rope is not free to move through thepipes find out the reason and rectify the problembefore moving on to the next stage.

22. Push the Elbow and reducer assembly on to thebottom end of the large PVC protection pipe.

NOTE: do NOT apply glue to this as it isimportant that it can be removed for cleaning outin the future.

23. Then push the flexible rubber pipe on to theend of the elbow assembly. The short pieceof pipe is slightly flared which helps to stop itfrom slipping off easily.

24. Use a tie wrap to squeeze the rubber pipe ontothe PVC pipe as shown in the two stagesopposite.

NOTE: Do not use metal clips to grip the rubberpipe as these will rust very quickly.

L

M


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25. Now add the float assembly to the intake pipe.Use fishing line (N) to securely tie the floatthrough the holes in the end caps. Also tie theline under and around the strainer as shown at(P).

NOTE: the strainer should NOT be glued on asthis allows it to be removed for cleaning in thefuture.

26. The guide box, riser pipe and upper guide boxassembly can now be pushed into theprotection pipe.

27. Push the upper guide box down on to theprotection pipe.NOTE 1: Make sure the upper guide box is

orientated correctly: the outlet hole on the upperguide box should be at the top (Q) and inlinewith the floatNOTE 2: Do NOT glue the upper guide box on.It will need to be removed in the future forcleaning or repairs.

28. The whole of the intake assembly can now belowered in to the water.

Keep the intake pipe and float in a verticalposition as this is done. This will take a fewminutes as the pipes will slowly fill up withwater.

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

to pass through.

N

P

R

R

Q


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30. Refit the 2 x M5 screw nuts and washers on tothe clamp S (one at front and one at rear ofclamp).NOTE: Do NOT over tighten these as it willdamage 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 theangled upper pipe T.

32. Pass the rope around the wheel as shownopposite. Hold both ends in your hands and

pull up and down to check that the rope andpistons are free to move around the bottomguide 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 therope on each side of the knot and check that it will not come undone.

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

T

S


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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 dryfirst!

34. Fit the cover as shown using the fourstainless steel M5 bolts, nuts andwashers on each corner of the cover P.

35. Slowly turn the handle to check that the rope and pistons are free to move through thepipe. Increase the speed until water comes out of the outlet pipe and that the flow rate isacceptable

Dont forget make sure that an apron(platform) should be made after the installationof the pump. This provides protection, and aclean surface to stand on when operating thepump. Key features of an apron are givenbelow:

1. Approximately 1m of apron flooraround pump (mortar finish)

2. Sloping surface on apron to leadwater to drain

3. Drain leading to a soak-away pit forspilled water

4. Raised edge around apron anddrain

Dont forget to tidy up around the area you have been working on after you havefinished

It demonstrates you care!

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

NOTE: After installation of the pond pump please read through the

RP6 Operation and Maintenance manual

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