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Solar cooker installation
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  • 1. Parabolic Solar Cooker: Installation Instructions Watershed Organization Trust ContentsNotes Before You Begin………….....…………………………………………………..pageKit Inventory………………………………………………………………………………....pageAssembly……………………………………………………………………………………….pagePart 1: Base………………………………………………………………………......pagePart 2: Parabolic Frame…………………………………………………………..pagePart 3: Reflectors…………………………………………………………………….pagePart 4: Pot Support…………………………………………………………………pageFinal Notes, Observations……………………………………………………………….pageAppendix……………………………………………………………………………………….. page
  • 2. Notes Before You Begin…The solar parabolic cookers can be used as a supplement toconventional cooking methods that use gas or fuel-wood forcooking.The cooker works best under direct sunlight. Even if the sun-light is being partially hindered by clouds, its effectiveness isconsiderably reduced.Nevertheless, under direct sunlight, the performance of thecooker is remarkable. In most of our project areas, it has beenestimated that such clear sky days are available for 6 to 8months in a year. So this cooker should help reduce thedependence on gas and fire-wood considerably.The size of the cooker that is currently being installed caneffectively cook for about 30 adults (or 35-40 school students).As most of the household cooking takes place during earlymornings or late in the evening, this cooker might not besuitable. However, schools and Anganwadis do their cookinglater in the day for the mid-day meal scheme. Hence, thesecookers are ideally suited for them. Amongst such schools, it isrecommended to focus on the smaller schools with less than60 students.Prior to assembly, the cooker has been packed in two boxes.One contains the upper dish components, reflectors etc. Theother box contains the lower base components and wheels.While transporting boxes to the place of assembly, make surethat a proper pair of boxes has been chosen!
  • 3. Kit Inventory 4 Castor Wheels Two Cross Members (Base) Central Connecting Member (Base) – 2 pcs Two Vertical Stand Members (Base) – 2pcs 6 (3pair) Vertical Support Beams 4 (2pair) Frame Support Beams 28 Dish Flats 2 Clutch Plates 6 Connecting Flats (Dish Beams) 4 Tie Flats 2 Dish Connecting flats (mount Dish to Stand), one Clutch Side
  • 4. Kit Inventory2 Pot-Holding Pipes Grill for Pot 2 Pot-Support FlatsBOLTS B C D E F A WA Secures dish connectors and connector plates to the baseB Secures the Base componentsC Secures the pot-holding pipes and flatD Secures the dish frame and vertical support beamsE Secures the four tie flats to the dish frameF Secures dish flats to dish frame and vertical support beamsW Secures the wheels to cross members, and pot-holding flats to pot-holding pipe.
  • 5. Kit Inventory Dish Reflector Sheets Copper Wire, 2 different lengthsUtility Kit: Protective Eyewear Paintbrush Extra Paint (not shown) Pliers (not shown) 4 Wrenches of varying sizeYou may also need (not included): Scissors or a knife Metal Clippers Extra Pliers A Hammer
  • 6. Assembly Part One: The Base 3 2 11. Mount the four wheels on the ends of the two cross members, using W bolts.2. Also using W bolts, connect the two pieces of the central connecting member3. Secure the central connecting member to the center of the two cross members on each end simultaneously with the vertical stand members using B bolts.4. Make sure hooks on the cross member faces outwards (highlighted in picture above)5. You may tighten W bolts with wrench, but do not tighten B bolts with wrench yet. (will be done after mounting dish)
  • 7. Part Two: The Parabolic Dish
  • 8. 1. Using D bolts and connecting flats, assemble the 3 pairs of verticalsupport beams. The outside vertical support beams should joined using thespecialized connecting flats provided in the kit**Note that the bolt heads in the joint on the left must be facing outwards inorder to not obstruct the movement of the dish. It is recommended that forthe joint on the right as well, the bolt heads face outwards. 2. Using D bolts and connecting flats, connect the central vertical support beam to a pair of frame support beams on each end. These two frame supports will form the top and bottom of the dish. **Put all bolts in place by hand first, and then tighten them all with a wrench, after all bolts in the dish are in place.
  • 9. 3. Using D bolts, connect the other two pairs of outer vertical supportbeams to the ends of the frame support beams.4. Using E bolts, connect a tie flat to the left, right, upper, and lower framesupport beams.
  • 10. 5. Begin to connect the dish flats to the central and outer vertical support beams using F bolts. 6. The dish flats have two ends – the one with the straight edge is connected to the central support beams, while the one with the slanted edge is connected to the outer vertical support beams. Tighten bolts by hand.7. After all the dish flats have been connected, all the bolts of the dish maybe tightened by wrenches.8. Before mounting the dish onto the base, slide the full clutch plate (theone without the open space) onto the side of the vertical stand member(base) that will hold the larger of the two dish connecting flats.9. Mount the dish onto the base. Place the second clutch plate behind thelarger dish connecting flat, and secure the assembly with the two A bolts.10. After ensuring that the entire dish flips from one side to the otherwithout any obstruction, the B bolts of the base may be tightened.
  • 11. Part Three: The Reflectors1. Prepare the Reflectors. Use the shorter copper wires to thread throughthe 4 middle pairs of holes, leaving the last pair open on each end: Front Back2. For 3 of the reflector sheets, repeat step 1 using the longer wires. Thesewill be placed over the central vertical support beam.3. 2 of the reflector sheets have a hole in the center – these are meant to fitover the pot-holding pipes at the ends.4. Begin installing reflector sheets in the middle of the dish. Using pliers,wrap one of the reflectors with the longer wires around the central verticalsupport beam. This is easier with two people: one holds the reflector inplace while the other secures the wires to the dish flats. Each subsequentreflector should overlap the previous by at least the width of one finger.
  • 12. 5. The outermost spaces for the reflectors in the middle section should bereserved for the reflectors with holes in the middle, which should fit aroundthe dish connecting joints when they are installed.6. When the middle section is complete, remove the protective tape fromeach reflector.7. Repeat step 4 for the remaining top and bottom sections. For these,additional wires should be used in the top pair of holes to secure thebottom (or top) section reflectors to the middle section. It is possible thatonly one of the holes from each reflector can be used, if there is not enoughoverlap between middle and bottom (or top) section reflectors. As reflectorsare added outwards from the center, individual reflectors should be angledslightly to account for the curve of the dish (top and bottom sections only).8. When the top and bottom sections arecomplete, remove the protectivetape from each reflector.
  • 13. PartFour: Pot SupportIt is suggested that the pot-support is connected at the end(after fastening all the reflectors to the dish frame), as it mightget in the way of the person holding the reflectors.
  • 14. 1. Slide the end-reflector which has the hole onto the pot-holding pipe.2. Using a C bolt, secure the pot-holding pipe onto the dishconnecting flat. This may require theuse of a hammer. 3. Secure the end-reflector. 4. Repeat on the other side.
  • 15. 5. Secure the pot-support flats to the pot-holding pipes using W bolts. 6. Place the grill so that it rests on the pot-support flats.
  • 16. Final Notes and Observations…Once the assembly is complete, it is important to complete thesession with a proper demonstration of the complete setup.The benefits of the cooker must be effectively communicated toboth the school staff as well as the person who does the cooking. Itis important to focus on the staff as the ownership lies with them,and they are also responsible for the maintenance.The woman who does the cooking at the school is a very key personas the whole project’s success hinges on her. If she is not motivatedto make efforts to use the cooker, the project is without any doubtgoing to fail.Some other observations made during the last phase of installationsare as follows:•Pre-dispatch inspection is very important, as a number of boxeshad one or more parts missing.•We create a considerable amount of garbage while unpacking andassembling each unit. We need to ensure the school is comfortabledisposing this on their own, else bring it back in your jeep anddispose at the local raddi-wala near town area.•It is quite difficult to do the assembly on a hot day, although suchweather is better for demonstration purposes!•It is important to visit each installation regularly for a couple ofmonths after the installation to check on how well the it is beingused.•Shivaji, Devram, Pawan, Rajesh, Mihir and Arjuna know thecomplete installation process quite well and can be relied upon toprovide assembly training.