Making Water flow from the Sun
Dec 18, 2015
Making Water flow from the Sun
ROTOSOL: Optimum Solar Pumping solutions by ROTOMAG
The ROTOSOL Advantage
1. Technology : Ultra High efficiency BLDC & PMDC motors
2. Experience : 15 years in solar pumping
3. Capacity : 50,000 units of surface & submersible pumps/year
4. Support : 200+ Service Partners
5. Goal : High Quality Solar Pumping Installations
Technology: Why BLDC is better ?
Eff2 Eff1 IE2 IE3 PMDC BLDC74%
76%
78%
80%
82%
84%
86%
88%
90%
92%
Efficiency comparison of AC & DC motors
* AC motor efficiency is as per IS:12615 for 3 HP 4P motor
Premium efficiency- Atleast 10% higher
Rotomag DC Submersible
Leading AC Submersible
• Height : 1120 mm
• Total Weight : 52 Kgs
• Difficult to handle
• Susceptible to damage
• Efficiency : 81% (EFF2)
• 96,000 LPD @ 30 M
• Height : 740 mm
• Total Weight : 18 Kgs
• Easy to handle and install
• 300% higher torque to weight ratio
• Efficiency: 92%
• 105,000 LPD @ 30 M
Physical comparison of AC and DC pumps
70% lower weight, 50% lower temperature, 300% higher weight to torque ratio
Early Start
• DC pumps use power directly from modules• Start at low irradiance levels• Inverting DC to AC causes losses• DC pumps start early and work till late
Higher Starting Torque- reduced chances of clogging of pump in muddy/sandy water
• Starting torque in AC motors is 2 times the rated torque
• Starting torque in BLDC/PMDC is 5-6 times
• AC pumps will stall in sandy/muddy water
• DC pumps have sufficient reserve torque to clear the debris
Advantage of BLDC over AC
AC Motors
Rotomag BLDC Motor
• Exposed Windings• Sand and water ingress cause damage• Weak insulation causing drop in
performance• Considerably reduced life
• Totally Encapsulated windings• No effect of debris or water on winding• Consistent performance• Long life
Fully encapsulated winding- cannot fail
Advantages of BLDC Technology
Sealed Rotor- Life time Guarantee. 200% higher torque for operation in sandy/muddy water
AC Motor
Rotomag BLDC Motor
• Steel Laminations with AL rotor• Susceptible to oxidation due to
moisture• Heavy construction• Higher moment of inertia • Late start early stop• Drop in performance over time
• SS Shaft with rare earth magnets• No effect of moisture• Life long guarantee of performance• Lower weight – lower moment of
inertia• Early start late stop
Long Life Bearings. No replacement for 5 years
AC Motor
Rotomag BLDC Motor
• Standard ball bearings used• No Dampening of axial thrust• Axial thrust causes damage • Reduced efficiency• Higher noise and vibration• Contamination due to debris • Reduced water discharge once
damaged
• Ceramic Carbon Thrust bearings used• Effective dampening of axial thrust• Lower noise and vibration• Increased efficiency• Higher resistance to contamination• Higher MTBF• Consistent performance
Dedicated to Solar pumping for 15 years:
How does it help ?
Vast exposure enables us to build different pumping solutions
1999 2002 2007 2011 2013 2014
Development and installation of 1 HP Surface pumps
Installation of 2 HP Surface pumps 4500 Nos
Introduction of motors for export and JV for AC motors
Development of BLDC submersible pumps begins
BLDC pumps developed and approved by EQDC
2000 Surface pumps and 250 Submersible pumps installed
Rotomag’s journey in solar pumping
Designed for 10 years
Top Quality SS components. Premium quality parts
Example: Submersible pumpsRange : 1 – 5 HP Head : 100 meters• High efficiency BLDC motor• Encapsulated winding with Thermal protection• SS 304 parts for long life and corrosion resistance• Laser welded impellers for high discharge• Thrust bearing ensures dampening of axial forces• Compact and light weight• Made in India – servicing and repairs possible
Ability to withstand tough usage
• IP 65 protection
• Problem conditions shown with LED’s
Sensorless dry running protection
• 250C IGBT’s used as power stage
• Overvoltage/Thermal overload protection
• To be tested as per IEC 60068-2*
Designed for extreme conditions and user ignorance
Example: BLDC controllers
Products suited for Rural India
Example: Surface pumpsRange : 1, 2 & 3 HP Head : 25 meters
• Simple 2 wire design. No controller required
• Easy to install and maintain
• High Discharge suitable for flood irrigation
• Designed for harsh Indian conditions
• More than 5000 pumps installed till date
Fail proof, no electronics
Improper foundation Pump without foundation
Poor Installation of pump Pump stuck in ground
Installations and End user training are the key
Capacity: Can we meet the market demand?
Infrastructure
Two plants: 1.6 lacs sq feet built up factory area
Capacity : 28000 motors & 5000 pumps/month
Semi Automatic production lines
Sophisticated test equipment
Factory capacity: 50 K pumps per year
Manufacturing capability
Monthly Production Capacity :
PMDC Motors : 8,000 unitsAC motors & Geared motors : 20,000 unitsSurface pumps : 2,000 unitsSubmersible pumps : 3,000 units
World Class processes
Inhouse R & D and quality assurance
Pump testing set up
Automatic testing and plotting of pump performance curves
Solar PV simulator for automatic computation of water output/day
Sophisticated testing facilities for Solar pumps
Global reach of Rotomag products
Rotomag’s export markets
Germany, Switzerland,UK,
Italy, Poland, Norway, NL
USA, Mexico Canada
Brazil, Columbia
Bangladesh, China,
Srilanka, Yemen
Over 70% of export revenue comes from Germany, Switzerland & USA
Quality validated by TOP European customers
Support: Being close to the users
Training and Service support
• Total 200 Sales cum installation and service partners to be appointed
• Regular training being provided to partners for quality installations
• Standard work instructions and training manuals provided
• Field service centers appointed to attend complaints in villages & towns
• Master service centers appointed in major cities for repair / replacement of faulty parts
• Inhouse dedicated team for audit and supervision of installations
Professional and prompt after sales support
Sales and Service NetworkExtensive Service Coverage
‘Jalmitra’ sales cum support partners
Support Partner Training Programme
Regular training programmes being conducted to qualify ‘Jalmitras’.
Equipping ‘Jalmitras’ to solve problems
Installations: Precise, Standardized and built to last
Standardised installation process•Determine the source & depth of Water•Mark the location of PV Array•Calculate the water requirement and system suitability with micro irrigation system •Ensure that chosen pump and array combination is suitable for the site• Take site pictures for record
Site Survey
• Schedule material supply based on the site availability• Ensure proper packing and send material to the site with appropriate checklist•Confirm material receipt at site and verify that all components are availableMaterial Supply
• Schedule installation based on the availability of resources & site• Lay foundations and do the erection of structure as per WI• Take appropriate pictures during various stages of installation• Let the foundation cure for 3 days before mounting the PV modules• After 3 days, mount the modules and connect the array as per WI • Lower the pump in the bore and do the necessary connections as per WI
System Installation
•Check pump operation and ensure all the functions are operating normally•Check structure rigidity and alignment•Check the all the connections and ensure there are no open joints• Connect the pumping system to micro irrigation system and record the output • Incase of flood irrigation record water output by filling a standard container• Take site pictures for records
Site Audit
•Conduct a training program for the beneficiary to explain the basic operation and features of the pumping system.
•Explain the do’s and don’ts to ensure trouble free operation•Give information about warranty & service policy•Hand over the instruction manuals and details of local field service center•Complete the audit checklist and take final pictures of the site with the beneficiary
Training & Handover
High Quality Installations
long
Starting point for a lifelong relationship
High Quality Installations
Water that will change their lives