The background: We know a solar water heater can be made, but making it work everyday without requiring constant adjustment and fiddling is the tricky part. I'm lucky, my mother owns a hardware store (awesome place to grow up) and she decided to fund the project. She let me build it at the store and agreed to deal with the ridiculous time line I often fall into on pet projects like this. This will be installed to provide warmer than ice cold water to the hardware store bathroom and will only really be used for washing hands and cleaning etc...
I've broken the project into three phases:
1- The Collector: A heat exchanger that will collect the sun heat energy and efficiently transfer it to whatever fluid media we end up using to carry the heat to our desired location.
2- The Emitter: Yet another heat exchanger that will deliver the heat from my carry fluid to the water the end user will come into contact with.
3- The Install: making it all work as maintenance free as possible... probably the hardest part.
This 'ible covers Phase 1. I will not be as long winded in the steps as I was here.
Step 1: The Box
A picture speaks a 1000 words, so I'm not going to step by step the box construction. I've opted not to go into great detail about quantities and sizes because I think those metrics would be governed by the specific application. There is so much to say about each picture that this 'ible could end up being a royal pain to read; so I'll keep it nice and general for the sake of easy reading. Hopefully the photos do the talking.
Step 2: The Coil
-Cut your runs so they'll fit inside your box taking into account the the " qty 2 elbow lengths" you'll add to each end.
-Dry fit everything together and put the coil into the box, see how everything fits. Adjust as necessary.
-The initial and final run of the coil are slightly longer so they'll exit the box and allow access for plumbing the rest of the system. I saved my longer pieces for the end so I could estimate where to drill the holes.
At this stage, I began planning how I would suspend the coil off the back of the box to maximize the surface area of the coil and air flow in the box.
Step 3: Paint
As with any paint job, the success of the finish is determined in the prep. Clean smooth surfaces take and hold paint better than rough, dirty, oily, greasy, sandy, dusty... you get the point.
The Box- I primed the entire box and then sprayed on two coats of black. I think more would have been better for water proofness etc... time will tell.
The Coil- This was an important step for me. I wanted the collector to have the best efficiency possible in all weather conditions. So I chose to paint the coil. I just felt a few of you cringe... yes, the heat resistant paint is a barrier in the convective heat transfer process. But I believe the radiative gains I'll get on the less that scorching hot days will out weigh the convective losses. There is a bit of math that could be done to quantify this. But I didn't do any of it because this is an experiment for fun and I chose to go with my gut.
Step 4: Prep Coil
This task was tedious, luckily I had a two trusty sidekicks that volunteered to help. We set up an assembly line. We wire brushed/sanded every single piece of the coil then washed them in soapy water .
The sanding and wire brushing removes dirt and grit, but more importantly scores up the surface of the copper enough to take and hold paint well and helps with soldering. The soapy water removes oils and grease... which also helps with soldering.
Step 5: Assemble Coil
I made sub-assemblies first: each straight piece gets one of each type of elbow on it, facing opposite directions. Finally, solder all of your sub-assemblies together and your coil is complete.
If this doesn't make sense, look back to the pictures of the fit up and visualize how it will all go together.
Step 6: Leak Test Coil
I got it all hooked up, purged the air, the sealed the end. I let it sit under city water pressure(~35psi) for around 30 minutes.
No leaks, good to go.
Step 7: Assemble Collector - Coil in Box
Step 8: Assemble Collector - Glass on Box
I made a handful of the modified clips, then applied a bead of silicone and placed the glass onto the bead. Once I was happy with where the glass was resting I used the clips to keep it in place until the silicone dried.
Step 9: Testing
Heated water moves up the coil and through the hose into the bottom of the bucket. The same water then rises in the cooler temperature water bucket and is recirculated back to the coil out the top port of the bucket to the lower end of the collector. Hopefully that process repeats.
It worked! for awhile... The heated water began to soften the garden hoses so much they collapsed under any bend radius at all.
Before they collapsed I added food coloring that shows the water circulating and being pulled back into the circuit. Then all of a sudden everything stopped. I used my infrared thermometer and checked my outlet temp at the box and got a reading of ~250 degrees F... I thought this couldn't be right so I used a few other thermometers and got similar results...
I think the water in the coil may have vaporized and turned to steam (water boils at 212 F) which caused a vapor lock and halted my circuit flow. Over all I'm happy, better plumbing setup and less hasty testing will really tell me how well this thing works, but for now I'm satisfied.
The collector works very well, during dis-assembly of my test rig I ended up draining the coil onto my hand and burned myself pretty significantly. Blisters and the whole deal. just a heads up, be careful.
Anyhow, this was the build and a tid-bit on the testing. I'll come back through here some day and go into more detail so if someone wants to build one they can improve off what I've done.
Thanks for reading.
Feel free to shoot me questions if I've completely skipped something you want/need.