SolarHeatCollector

BuiltbyDustinStucki alankorskey@gmail.com BeginningNotes: Irent,soIwantedadesignthatcouldmovewithme.IalsowantedamodulardesignsoIcouldmakeafewpanelsto testthedesignandifitworked,addmoreintheFall.MywifelovesaVERYwarmhouse,eveninthesummer,soIdidnt feelbadstartingsolateintheseason.Ialsowantedittobesimple,fromeasytogetmaterials,andofcourse,cheap.I amsomewhathandy,butbynomeansdoIknowalotaboutconstructionorengineering,etc.Ireliedalotontheadvice andresearchfromtheSimplySolaryahoogroup(http://tech.groups.yahoo.com/group/SimplySolar). OverallDesign: Dimensions:8x4x6(Ibuilttwomodules,andwilladdacouplemoreintheFall) Frame:2x6outsideframerestingonplywood.1x6innerseparatortocreateairflowchannels. Backing:3/4Plywood(NexttimeIwilluseathinnerpiece,maybeevena1/8withafewsupportstomake lighter) Glazing:Twinwalled6mmPolycarbonate(boughtlocally) Screen:Fiberglass(CharcoalColored) InsulationBacking:3/4CorningInsulation.(IamgoingtousetheStyrofoamwithfoilreflectornexttime,itis cheaperandwillworkjustaswell,plusitalreadyhasareflectivebackingsononeedforaluminum flashing. Framestoholdscreen:1x2wood Fan:FlowProUtilityBlower8in.,1/4HP,1575CFM,Model#39008(Itisnotpowerfulenough.Iwanttoendup with300+CFM,evenwiththeextramodules,andthisonlygivesme135CFM,Iwillbegettingamore powerfulblower.) ConnectionsBetweenModules:Iusesimpleweatherstrippingtogetaprettygoodsealbetweeneachmodule. OverallCost:$481(IncludingEverything:Fan,Switch,andDucting) IndividualModuleCost:$130

 OverallDesign

FRAMEOnlyVIEW

ThreeSCREENLAYOUT: TwolayersofScreenlaidoutinAccordionPatternandathirdlaidflatintheback.Only12.5%oflightenteringthe collectorreachthebackthroughthe3screens.Thereflectivesideoftheinsulationthensendsitbackthroughthe screensagain.Only1.5%ofthelightescapesbackoutthecollector.Thepointistohaveasmuchheataspossiblebeing storedinthescreen.Runningairthroughtheaccordionpatternthenensuresthatthereisalotofsurfaceareaforthe heattotransfertotheair.Itturnsouttobeaveryeffectivedesignforheattransfer(atacosttoairflow,meaninga morepowerfulfanwillbeneeded)

PicturesofConstruction:

MydaughterlovestohelpwithwhateverIdo.Shejustlearnedtowalkandgotakickoutofwalkingthepaththatthe airwilleventuallytravelupanddownthechannels.

 IusedSiliconeCaulkingtosealtheedgesoftheframe.Iwanttohaveahighflowofair,soagoodsealwillbeimportant (nottomentionforheatretention).Ialsousedsiliconecaulkingtoattachthepolycarbonateglazingdirectlyonthe2by 6s.Thereisnothingelseholdingiton,andthisallowsforexpansion.Timewilltellifitholdsup.

Puttingintheinsulation.IthinkforthefuturemodulesIwilluse1x6sinsteadof2x6sfortheframeandputinsulation ontheinsidesides.Thiswillmakeeachmodulelighter.Iwillalsoconsiderusingathinnerpieceofplywoodbacking. Thisthingonlyholdsscreensandair,itdoesntneedtobetoostrong.(Unlessyouhaveachildwholovestorunaround alloverit)

Igotajigsawtomakethesecuts.A12x2.25x6EndRegisterboxwillfitintotheseholestomakeconnectingtheintake andtheoutputeasier.

Figure1

Iputaluminumflashing,butitreallyisnotneeded,andIwillnotdosonexttime.Alltheheatisideallyinthescreen, andthealuminumisonlyusedforreflectingthe12.5%oflightthatdoesgetthroughbacktothescreens.AtHome DepotInoticedsomeStyrofoaminsulationwithareflectivematerialononeside.ThatiswhatIwilluseforthe additionalmodules.

Ihavethescreensinplace(seescreendesignabove).Imadethefirstpassalittlelongerthantheotherssotheintake andoutputairwouldnotbehinderedasmuch.Iwantedaclearpathtothoseholes.

Irentsocuttingholesintothewallsforductingwasnotpossible.Hereisanextbestsolution.Thedoorstillopensand closesallthewaywhenthecollectorisnotinuse.

HereisthefanIthoughtwouldwork.FlowProUtilityBlower8in.,1/4HP,1575CFM,Model#39008.Itonlyoutputs 134CFMthroughthesystem.IthinkIwillneed1/2HPormaybeevena3/4HPblowertogetthekindofairflowIwant, andtotakeadvantageofthethreescreendesign.(Wheremoreairflow=moreheattransfer.)Thiswillespeciallybe trueintheFallwhenIaddacouplemoremodules.

 DOESITWORK? 64sqftofcollectorarea.Thehotairtravels37feetin6R6insulatedducting.Outsideairis66.2degreeslocatedin NorthernCalifornia. Airflow:135.7CFM IntakeTemp:66.2 OutputTemp:147 SolarIntensity:245at45degreeangle(gottaloveCali!) BTUsperhour:11836 WattHourEquivalent:3468(3.5Kwh) EFFICIENCY:75% EndNotes:Itwasawarmerday,soIamcurioustoseehowthisperformswhenthetempsgetloweroutsideandmore oftheheatescapesthroughtheglazing.Buttheefficiencyisquiteamazing.Ireallywanttogetsomeairflowing throughthiswithamorepowerfulfan(butwillhavetopaymoreinelectricitytorunthefan.) Iamalsoimpressedwiththeglazing.Itistwinwalledpolycarbonatefor$55asheet(4x8)boughtlocallyata plasticsstore.Itsealswell(flat)andisinsulatedbecauseofthetwinwall.IlikeitalotbetterthanSuntufanditcomes outtoaboutthesameprice.Adownsideisthatitletsin9%lesslightthanSuntuf. ComeFallIwillbuildanoffthegroundframefortheseandacouplemoremodulesandbetterinsulatethe registerboxesandupgradethefan.Overall,Iamveryhappywiththedesignandfindthatitworksverywellinmy circumstances.