|
HOW TO SET UP AN IRON MAN WATER PUMPING WINDMILL™ AND TOWER
|
Frequently, Iron Man WindmillTM are setup by the dealer who sells the windmill or by associates whom the dealers work closely with. However, anyone familiar with construction work can setup an Iron Man Windmill, even if they have never done so before. The smaller sizes of windmills (generally up to 12ft - 3.6M diameter) can be set up in one or two days on towers up to 40 - 50ft or 12M -16M height by an experienced installer. Large windmills with deep wells can take a week or more to set up depending on equipment available. The Iron Man Windmill can be completely assembled by hand, or if power equipment is available, time can be saved using cranes, hoists or even well drilling rigs.
Here are the basic procedures of installing a windmill by hand. Full details instructions and details are included with every windmill and tower. 1. The location of anchor holes is laid out according to the charts in the instructions. 2. Four anchor holes are dug or drilled. 3. The bottom section of the tower is assembled horizontally on the ground and is tilted up into the vertical position with the anchor legs in the anchor holes. 4. Level the bottom section of the tower using steel corner posts from the upper sections by clamping or tying the corner posts in position with heavy wire or strong “C” clamps to the anchor legs bolted below the bottom section and then use wood blocks, bricks, jacks and shimming material under these steel pieces to level the tower. 5. When the tower is roughly leveled, measure from each corner post to the well casing and be certain that the bottom section is accurately centered on the well. This should be to within a 1/4 inch. Then check the level again and level the bottom section as well as possible. Time spent doing this work will result in the rest of the work going much easier and result in the windmill being located directly over the center of the well, which is necessary for proper operation. 6. Place cement in the anchor holes until the cement covers the cross pieces bolted to the bottom end of the anchor legs. The cement should be as shown on the installation diagram. There is no need or value to using more cement than is shown in the installation drawings. It is not recommended that the entire anchor hole be filled with cement. 7. While the cement is setting up, it is a good time to prepare materials for the balance of the installation work. Then fill the anchor holes and compact the earth well as the holes are filled. Do not bump or allow the tower to move. When the anchor holes are filled and compacted, place planks across the top girt and assemble the second section according to the instructions. Continue assembling tower sections until the entire tower is assembled. Install ladder steps as the tower progresses. Install platform and pipe mast in top section of tower. 8. Install windmill gearbox. When installing a windmill by hand, a small crane or "Gin Pole" made of pipe is commonly used to lift the gearbox into place, especially with the larger sizes of windmills. 9. Bolt the vane to the tail and the tail, vane and install the related tail hardware. The tail can also be installed using the Gin Pole. 10. Install the wheel arms in the hub and then the pre-assembled wheel sections according to the instructions. 11. Install the pump rod with swivel in the gearbox. Turn the gearbox over and inspect the operation. Be sure the windmill turns easily without any binding. Fill the gearbox with good clean light oil. Good 10W hydraulic oil is fine. Never use automotive engine oil. Never use heavy gear oil. Never use Detergent oil. These automotive type oils tend to thicken and plug up oil passages when used in windmills. Only use light 10W hydraulic, which works fine in all temperatures and provides excellent lubrication. Check that the oil ring on the guide wheel shaft makes good contact with the large gear and carries oil up to the upper mechanism. When you are confident that everything on the gearbox is working correctly, place the helmet on the gearbox and tighten the nut that holds it in place. Do not use any type of sealing compound on the base of the helmet. It is designed to allow a small amount of air to flow through the gearbox preventing the accumulation of moisture and condensation while keeping dirt and sand out. 12. Turn the wind wheel until the pump rod is at the bottom of the stroke. Then use a good rope to tie the wind wheel to the tail, so that it cannot rotate and the tail cannot open. 13. When the installation of the windmill is complete, Hang the first section of pipe in the tower. REMOVE THE PISTON FROM THE PUMP and be sure the foot valve is in position in the pump cylinder. Install the pump cylinder on the end of the pipe being sure to use a good pipe joint sealant. Use just enough sealant and avoid allowing excess sealant into the pipe. Use good pipe clamps to hold the pipe in place while it is being lowered and to hold it in place when the cable is disconnected to allow connecting the next length of pipe. NEVER hold the pipe with pipe wrenches, clamps, chain, rope, etc. Use only professional pipe clamps and elevators (Available from Iron Man Windmill CO.) to avoid dropping the pipe down the well. Continue lowering the pipe, holding it with the proper clamps and getting the pipe joints tight with good sealing compound. Consider using chain wrenches for tightening the pipe when installing the larger sizes of pipe. 14. When the pipe is in position and is being held by the pipe clamp / well seal, you can place the piston on the end of the first piece of pump rod and begin lowering the pump rod the same way the well pipe was lowered. Be sure the pump rod joints are tight. Continue adding lengths of pump rod until the piston enters the pump cylinder and carefully lower it till it touches the bottom – the top of the foot valve. 15, Be sure that the necessary pipe fittings – “T’s”, Pump Rod Seals, Stand Pipes, Etc are in place as required. Set the length of the pump rod and connect to the pump pole in the tower and to the windmill according to the instructions and diagrams. 16. Connect piping to the tank or to where the water will be discharged. 17. The Last step is to connect the shut off wire from the handle or winch to the furling linkage. Be sure the furling handle or winch is set so that the windmill is turned off and remove the rope around the wind wheel and tail. Turn the wind wheel over and be sure the pump rod moves up and down without bumping or hitting at the ends of the stroke. When you have looked everything over and are confident the work is complete and correct, open the furling handle and let the wind wheel begin spinning in the wind. The pump rod should be moving up and down freely and without any binding or hitting either end of the stroke. It can take some time for the water to reach the surface, especially when pumping in deep wells. Be patient. The water will come and then you can give thanks and be proud of your god work! |
|
|
|
Pricing |
|
Main Office: 1-541-359-0859 |
|
China Office: 86-27-8349-6716 |
|
|
|
РУССКИЙ |
|
|||
|
ALL CONTENT RIGHTS RESERVED WORLDWIDE ©2010 - IRON MAN WINDMILL™ CO. LTD
|
|||||||