Opitec 124.155 User manual

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E124155#1
Solar Fountain
124.155
Please Note
The OPITEC range of projects is not intended as play
toys for young children.They are teaching aids for young
people learning the skills of Craft, Design and Technolo-
gy.These projects should only be undertaken and tested
with the guidance of a fully qualified adult.
The finished projects are not suitable to give to children
under 3 years old. Some parts can be swallowed. Dan-
ger of suffocation!

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1. Product information
Article: Model in project form
Suitability: Key Stage 3 11-14 years
2. Material information
2.1 Material: Copper, non-ferrous metal
Working: Easily formed with a planishing hammer.
Joining: Glue or soft solder
Finish: Buffing or polishing
2.2 Material: Sheet metal (zinc plated)
Working: Shape with tin snips
Bend using a former
Mark out with a scriber to size, or use a pattern
Joining: Glue or soft solder
Finish: Coat with clear spray varnish
2.3 Material: Brass tube
Alloy of copper and zinc
Joining: Glue or soft solder
Finish: No special finish necessary
3. Tools
Sawing: Use a hacksaw for straight cuts in metal or for for cutting tube.
Note! the hacksaw blade teeth should face in a forward direction.
Hold the work securely in a vice and saw with smooth slow
strokes.
Use a Fret saw for all the curves and shapes that cannot be sawn with
a straight back saw.
Note! Hacksaw blades must be inserted with the teeth facing
forward
Use a Fret saw board to hold the work, saw with slow constant stokes
turning the work as you go.
Cutting: Use tin snips for cutting sheet metal.
Note! take care of the sharp edges, remove them with a file.
Cutting metal tube: hold the metal in a vice and use a fine blade hacksaw.
Note! work carefully the sawn ends will be sharp and need the
burr removed with a file.
Forming: Use a hardwood forming block and a planishing hammer.
Work in a spiral pattern from the middle outwards.
Note! do not try to work without a block.
Filing: Use a file to remove any burr or excess metal.
Note! the file only cuts in the forward direction.

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Gluing: Use two part glue (order no.300.317) or similar.
Note! read the special imstructions on the packet before using.
Soldering: Use a 60 watt iron or a soldering gun.
Note! coat the area to soldered with flux before starting.
Drilling: Use a handrill or pillar drill
Note! Take note of the safety precautions when drilling.
(all long hair to be tied back, no loose clothing or jewelry
to be worn and wear safety glasses)
Ensure that you choose the correct size drill bit and that it is sharp.
Secure all work to be drilled in a machine vice.
General:
When working with the sheet metal the zinc plating is easily scratched or removed. Corrosion can set in quickly
and therefore the metal should be sprayed with clear varnish as soon as the project is finished.
The parts can be soldered or glued together.
When gluing use a two part glue (glue and hardener).
If you are soldering use a soft solder and the correct flux. Ensure that the soldering iron is hot enough.

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4. Parts list
Part Material Quantity Diagran / Part-No Size
Fountain Metal sheet 1 0,49 x 220 x 320 mm
Pump cover Metal sheet 1 0,49 x 150 x 150 mm
Water dishes
Large Copper 1 100 mm dia
Small Copper 2 80 mm dia
Tube support Brass 1 6 mm dia x 250 mm
Cable 1 2 m
Pump:
Housing base PC (Polycarbonate) 1
Flywheel PC (Polycarbonate) 1
Pump housing PC (Polycarbonate) 1
Drive wheel PC (Polycarbonate) 1
Solar Motor 1 ø 25 x 12 mm
Magnets Ceramic 6 ø 6 x 2,2 mm
2
1
3
4
9
8
10
11
13
6
5
7

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5. Exploded diagram
1
2
3
4
4
5
5
5
6
Pump
(Teile: 7, 8, 9, 10, 11, 12, 13)

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6. Planning and Making:
6.1 Planning and making the fountain water holder
6.2 Planning and making the pump cover
6.3 Making the dishes
6.4 Making the supports
6.5 Part assembly of the tubes and water dishes.
6.6 Adding the pump and cable
6.7 Final assembly of the water dishes and pump
6.8 Assembly and connection of the solar cell
6.9 Testing and evaluation
6.1 Planning and making the fountain water holder
6 1.1 Mark out the size of the holder on to the sheet metal. Cut out the shape and remove any burr from the edges.
Note: the remaining metal will be used to support the solar cells.
1
Tab
Bend
Fold

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6.1.2 Study the drawing, firstly fold the top over through 180 degrees. Then fold the tabs and finally the sides.
Note! if you use a vice when bending make sure it has jaw protectors.
6.1.3 Once you have completed bending the shape the ends can be soldered or glued.
Note! once this stage is complete test the holder to see if it is watertight.

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6.2 Planning and making the pump cover
6.2.1 Mark and cut out the shape of the cover on to the metal sheet (2).
Drill the holes and remove any burr from the edges.
Note: to make a better contact for the support tubes we suggest that you drill the holes to 6mm diame-
ter and then widen them out with a punch to 8mm dia.
6.2.2 Fold the cover (2) as shown in the diagram
or
15 15
150
ø 8
Drill to 3mm dia. and then widen
with centre punch to 5smm dia
2

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6.3 Making the dishes
6.3.1 Beat the copper discs (3,4) in a forming block until they take on the shape of dishes.
Note: use a planishing hammer and a hardwood forming block.
6.3.2 Once you have made the shape mark out and drill a 8mm dia hole in each dish.
Note: to make a better support for the dishes, firstly drill a 6mm hole and then widen it out with a
centre punch to 8mm.
ø 8
or
5mm dia hole
widen out to 8mm with a centre punch
Forming block
34

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6.4 Making the supports
6.4.1 Mark out and saw the 3 lengths as shown from the brass tube (5) using a fine bladed hacksaw.
Note: to avoid injury remove any burr from the ends of the tube with a file.
6.5 Part assembly of the support tubes and water dishes
6.5.1 Insert the tubes (5) into the copper dishes (3,4) glue or solder.
Note: it is important that the end of the tube in the largest dish does not become blocked with glue
or solder. This is used as the water input!
Note: Seal the openings in the shorter tubes with 2 component glue.
solder or glue
5
5
5
4
4
3
input tube
Seal with
2 component glue.
5
90
50
70
50
70
90

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6.6. Assembling the water pump
Tip:
We recommend gluing the parts with two component glue or super glue
6.6.1 Glue the magnets in the drive wheel
Note: Watch the polarity ( See diagram)!
6.6.2 Slide the drive wheel on the motor shaft as far as possible, with its open side facing away from the
motor
6.6.3 Place the motor and drive wheel assembly from above into the pump housing, until the motor is flush
with the housing.
Note: When assembling the flywheel check the action of the pump, if the flywheel is lightly
turned the motor shaft should turn with it. If does not happen, remove the motor from the
housing and push the drive wheel further on the shaft , re-assemble and try it again
6.6.4 Should the motor move in the housing ( eg. be a little loose) either hold it place with a small bead of
glue, or place a small strip of sellotape around the motor, before inserting it.
6.6.5 Carefully spread a bead of glue all around the base and glue it to the housing
Note: Be extra careful that none of the glue creeps inside and fouls the flywheel etc!!
6.6.6 Testing
Testing for water tightness, once the glue has set run a brush full of soapy water around the glued
joint. Then blow down the output tube at the same time as covering the input and see if any air bub-
bles appear, if yes, it will need to be re-glued. Dry the pump and re-glue.
Drive wheel
Flywheel
Magnets
(The polarity is important!)
Magnets
(The polarity is important!)
Solar motor
Pump housing
Pump housing base
N
N
N
N
N
N
Output tube
(ø 8mm)
11
10
13
13
9
7
8

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6.7 Final assembly of the water dishes and pump
6.7.1 Insert the water dishes and support tubes into the sheet metal pump cover (2) make sure they are upright and
then glue or solder them in position.
Note: the height of the dish (3) is determined by the pump.
the height depends
on the bend
these tubes rest on
the flat surface
3
4
4

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6.8 Assenbling the solar cells
6.8.1 Join the three 700 mA solar cells (not included in the pack) together as shown in the diagram using the brass
connecting strips.
6.8.2 Make two supports for the cells from the remainder of the sheet metal (1). Use the diagram to mark them out
and tin snips to the shapes drill and bend as shown.
6.8.3 Cut the cable (6) in two. Remove some insulation from the ends and tin the exposed core. Finally connect
1

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6.9 Testing
6.9.1 Connect the solar cells and pump together as shown.
The pump does not work:- if the water wheel (motor) is turning in the wrong direction the wire connections
between the pump and cells will need to be changed over.
- if the pump housing is not watertight check the motor.
Note! we recommend joining the pump and cells together with HO connectors (no.218.027 and 218.049)
Of couse you can also power the pump with batteries (3 volts) or with a small transformer.