How to DIY a Flat Panel Solar Thermal

Solar thermal heating systems use the sun's energy to heat water which is then used domestically as hot water, or passed through a radiator to provide heating for the building. Black panels are placed on the roof of the building to collect the sun's energy by heating water. The hot water is then allowed to flow down to the furnace or hot water where it is passed through a heat exchanger to warm domestic water or heat air.

Sheet of 3/4-inch plywood
Thin-walled copper tubing
U-brackets
Screws
Screwdriver
High-temperature flat black paint
Thermocouple
Roofing mounting brackets
Caulking
Thick-walled copper tubing
Radiant heat exchanger
Water circulation pump
50 percent water, 50 percent anitfreeze mixture
Water reservoir

Instructions

- 1
  Lay out the thin-walled copper tubing along the plywood in an S shape. The parallel sections of tubing should be 1/2 to 1-inch apart and the tubing should be at least 1 inch from the edge of the plywood.
- 2
  Use a U-bracket, screws and the screwdriver to secure the ends of the tubing to the plywood. Place U-brackets every so often along the length of the tubing to make sure it stays in place during mounting and operations.
- 3
  Paint the plywood and copper tubing with the high temperature black paint. Typically the paint is available as spray paint, which is the easiest to apply to the odd shape of the solar panel.
- 4
  Mount the thermal couple onto the solar panel so that it is touching the copper tube near the center of the panel.
- 5
  Mount the solar panel on your roof or other direct sunlight area using the roof mounting brackets. The panel should be directed towards the south to get the most direct light during the day and should be in an area without any tall trees or building blocking the panel.
- 6
  Plumb two runs of the thick-walled copper tubing from the solar panel down to the furnace. This will transport the hot water created on the panel down to the heat exchanger where it can be distributed throughout the building.
- 7
  Install the radiant heat exchanger in front of the furnace fan then connect the tubing running to the output of the solar panel to the input of the heat exchanger.
- 8
  Connect the input of the heat exchanger to the output of the water circulation pump then connect the input of the pump to the output of the reservoir.
- 9
  Connect the output of the heat exchanger to the input of the reservoir. Fill the reservoir with a 50 percent water and 50 percent antifreeze mixture. Run the circulation pump then refill the reservoir with the water-antifreeze mixture.
- 10
  Wire the thermocouple to the power supply of the pump and the furnace's fan. When the thermocouple gets hot, it will turn on power to the water pump and the fan, moving the hot water from the solar panel down to the heat exchanger which will heat air being blown throughout the building.

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