DIY Solar Heater:

Top 20 Tips How to Build and Use a Solar Air

Heater

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 Table of content
Table of content
Introduction
Chapter 01: Benefits to Build a Solar Air Heater
Chapter 02: Types of Solar Air Heaters
Chapter 03: Important Components of Solar Heater
Chapter 04: How to Build and Use a Solar Air Heater?
Chapter 05: Screen Absorber Solar Air Heater
Conclusion
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Introduction

Are you looking for the best heating mechanism for your house that is inexpensive and
energy efficient and you can design by yourself at home then solar air heater is one of the
best option for you?

Sun is the source of solar energy, without it live on earth is not possible. The use of
solar energy is taken seriously in last few years as it is a significant source of free
energy.

Usage of solar energy for heating purposes is most simple and efficient use. Solar
collectors are used for converting solar heat into thermal heat.

Solar air heaters were invented for using solar energy efficiently. Solar energy heaters
eliminate the need for conventional heating devices during spring and fall as well as
reducing the use of traditional heating systems in winter as well.

The solar air heater is simple to design and use. It works on a particular mechanism. It
is cost efficient. Solar air heaters work on the latest technology. It utilizes solar energy.
We get natural energy by sunlight which is wasted, and we use other conventional
systems for heating that costs more while the manufacturers of solar air heaters
recognized the importance of solar energy and worked on utilizing it and reducing the
cost.

A solar air heater uses active heating process rather than passive heating process. In
passive heating systems, a structural material is used for heat absorbing while in active
heating system, solar panels are used for collecting solar energy.

The solar air heater does not replace your heating system but supplement it. Solar air
heaters can be mounted on wall, windows or roof. It must be mounted with its face
towards south region, so that it can efficiently absorb the heat.

A small unit can be installed on the window, therefore vents or ducts are not required
for air flow. The small units do not have any storage for heat so it does not work during
the night time.

In the large air heater systems, there are heat sinks and other materials that will collect
and save heat for further use.

In the upcoming chapters, you will get to know about the benefits of solar air heater as
well as how you can design one for your home in an easy and simple way.

Chapter 01: Benefits to Build a Solar Air Heater

Solar Air Heating

As the name depicts, solar air heating is the process in which solar radiation is
converted into thermal heat. Air absorb and carry this thermal heat to the working or
living space. Air does not simply transfer it to the working space; it needs a technology
and proper mechanism for it. The technology or mechanism used for this transference is
known as solar air heater.

It uses a renewable source of energy. It is mostly used for industrial and commercial
applications. Solar air heaters are built using the latest technology with decreasing the
heating loads, and for providing heat, it uses renewable energy source. While the use of
solar air heaters is not widespread but increasing with time.

Solar radiation

The sunshine reaches the earth throughout the year. The amount of sunshine varies
throughout the year. On the brightest days, the heat collector will collect plenty of heat.
While even on cloudy days, it will collect solar energy but in less amount.

Solar panels absorb solar energy in three methods as

Diffused Radiation- It is a scattered form of the rays. These rays come to earth in an
unparallel manner.

Direct Radiation- These rays are received by the earth in a parallel way direct from
sun. This type of radiation casts darker shadow on clear days.

Reflected Radiation- Radiation is reflected by surface of the ground and other

buildings, solar energy received by the collectors. The color, texture and shape of
surfaces that are surrounding affects the amount of radiation absorbed by the sun.

As the heat travels from one place to another, much of the heat is lost. The dust, vapor,
smoke content present in the atmosphere as well as the purity of the atmosphere affects
the amount of radiations. The angle of sun also affects the amount of radiation. The
amount of radiation received by the sun is reduced when the sun is lower in the sky.

Benefits
Solar Air Heaters are a useful source of heat. Solar air heaters do not replace
conventional heating systems, it just stimulates the heating process of those devices.
Most of the solar air heaters are wall mounted that makes them capture a significant
amount of solar radiation. They use 20% less conventional heat as compared to other
heating devices. Some of the worth mentioning benefits of solar air heaters are given
below.

• System

The method of heat transference used by the solar air heaters is quite simple. The heat is
directly by air as it is primary heat transferring substance in solar air heaters. The need
for a transference of heat from working fluid to another fluid as that in other heating
items is eliminated. Solar air heaters are easy to use.

• Energy

It does not consume energy from any virtual power source as it uses the sun energy for
heating the home. It saves energy and independent from energy. As the sun energy is
natural. Sun is the best source of energy, and its energy must be utilized, solar air heater
is utilizing its energy rather than using any other source.

• Safety

It is safe to use as even the air leaks out; it does not freeze out your home. As freezing,
can cause damage to your place, it prevents that.

• Cost

Solar air heaters not only save energy but it also saves your money. As traditional
heating systems for house cost a lot. You have to pay the energy bills as well for heating
your home while on other hand solar air heaters use natural energy saving cost. The cost
of a conventional heating system is increasing day by day. A traditional air heating
system can cost up to $500 per annum. Solar air heaters are simple and cheap to design.
Well the exact amount of the cost that it saves differs as the climate is different from one
are to another.

• Environment

Conventional heating systems cause damage to the environment as well, as they

discharge CO2 in the high quantity that can cause climate change. The methods like
processing, Mining/harvesting, burning fossil fuels, transporting and other fuels used for
heating can cause drastic changes in your environment leading it to global warming that
has adverse effects on living beings. On the other hand, solar air heaters do not emit
CO2 that saves our environment.

• Health benefits

During winter, many urban and rural areas face smog as a result of burning fuels for the
purpose of heating. Smog and other similar air pollution issues can cause breathing
problems, increase in asthma attacks and also affect the developing fetus. Air pollution
is responsible for hundreds of deaths per year whereas solar air heaters eliminate
danger to health by removing smog and not increasing air pollution.

• Automatic

Solar air heaters are automatic. You do not need to turn them on and off every time. It
automatically turns on during cold weather and when a significant heat is transferred to
the working space, it turns off automatically.

• Lifespan
Solar air heaters can live for almost more than 20 to 25 years without needing any
additional maintenance. Once you installed it, forget about maintain from time to time. It
works for many years efficiently.

• Availability

Most of the area of the earth is exposed to the sunlight and receives a significant amount
of sunlight that can be used for energy purpose. Therefore, using solar air heater is
beneficial as you will lack the energy.

• No transportation cost of fuels

Solar energy is received and transported to almost all the area of Earth, you do not need
fuel for transporting it from one place to another. By eliminating the cost of
transportation fuel, the overall cost decreases.

• Great for household use

Solar energy is a useful for household purpose. The amount of heat or light that is falling
on a single house is enough for fulfilling the heating needs of that specific house.

• Zero dependence on the fossil fuels

Solar air heaters by using solar energy reduces the dependence over the fossil fuels as a
result reducing their use. Fossil fuels can cause air pollution as well as increase in cost
that is balanced when using solar energy

As, solar air heaters have many advantages over the conventional heating devices, as
mentioned earlier. The benefits are increasing the use of solar air heater over time.

Chapter 02: Types of Solar Air Heaters

Solar air heaters are divided in to various types on the basis of

• Absorber

• Collectors
On the basis of absorbers, solar air heaters are divided into two types

1. Porous solar air heater

2. Non-porous solar air heater

1. Porous solar air heater

A porous air heater contains expanded plate and a slit, that are overlapping the glass
plate absorber. A separate passage is used for air flow. Air slows in the middle of the
solar air heater and below the air plate.

In porous solar air heaters, the loss of radiation is reduced. Solar radiation in porous
penetrates to a considerable depth and also absorbed to that extent. The drop of pressure
in porous is lower.

Porous solar air heater has optimum plate thickness equal to 0.05 m. If the right
thickness of the plate is not used in it, can decrease the efficiency of the solar heater.

2. Non-porous solar air heater

In non-porous solar air heater, air flows above or behind the plate of the heater. In this
type, no separate passage is installed for flowing of air. As the air flow above the
absorber in non-porous therefore the cover of the heater receives much of the heat and
loss this heat to the ambient. As there is more loss of heat in this solar air heater,
therefore, it is not the best choice.

In some of the non-porous solar air heater, air flows form below the absorber plate that
decreases the loss of heat. It is commonly used type of non-porous heater. In some of the
non-porous air heaters, air streaming process is used for cooling of the absorber plate.

As the transfer of heat and flowing of air in this type is low, it decreases the efficiency
of the air heater. You can make the performance better by using vee-corrugated plate as
absorber plate or by roughing the absorber plate. Air transfer can be made better by
inducing turbulence in the air flow.

In terms of collectors, solar air heaters are divided into two types

1. Unglazed air collectors

2. Glazed air collectors

1. Unglazed air collectors

It refers to the heating system in which the absorber is without any glazing over its top.
These air collectors use outside air rather than circulating the inside air. One of the most
common types of unglazed air collector is transpired solar collector. Transpired solar
collectors are mounted on the wall that helps in capturing sun heat at a lower angle
during winter. As a result, increasing its performance. In this type of air collectors, air
flows at the rate of 5 and 9 CFM per square foot of a collector room.

The exterior surface of the transpired solar collector consists of tiny micro-perforations.
These micro-perforations capture heat and distribute it uniformly in the inside cavity. In
transpired air collectors, the heating load is decreased to 10-50% as compared to the
conventional heating system. The unglazed air collectors can also be roof-mounted.

2. Glazed air collectors

It has the same mechanism as that of traditional air furnace. In glazed air collectors, heat
is provided by recirculating air in the room. It is a simple air collector that collects sun
energy and condition it.

A simple glazed air collector has an absorber material that captures heat from the sun
and transfers it to air using conduction heat transfer. The heated air is transferred to the
room and utilized it for heating of that specific space.

Size of solar collectors

The bigger the size of the solar collector, that much efficient it will be. Many of the
building loses a large amount of heat that can be reduced by installing a big collector.
Even during cloudy days, your large collector has some heat stored in it. it does not
mean that your collector will be overheated, as you can close the upper vents.

Efficiency of solar air heater

Efficiency of the solar air heaters is at the highest point when a temperature of the air
that enters into a solar panel is equal to the ambient temperature.
In space designed for heating, the air that enters solar panel is returned for heating the
room. In winters, the energy may not be sufficient; the efficiency is reduced. While any
during any heat gain, the rise in two or three degrees can increase the amount of energy
hence increasing the efficiency of solar air heaters.

Performance example

As given in the table below, suppose

The Solar radiation= 1000 W/m2

The temperature outside the plant= -10°C

The air temperature of plant = 20°C

Solar panels recirculate the air of the plant=

X-axis intercept (20-(-10)) /1000 = 0.03

Hence, the efficiency of the solar air heater is 30% for air recirculation from graph

While the air ventilation outside the plant=

X-axis intercept (-10-(-10)) /1000 = 0

Hence, the efficiency of the solar air heater is 60% for outside ventilation from graph
Disadvantages of solar air heaters

• The solar air heaters are not suitable for summer season or during cloudy days,
as there is less amount of sunlight that will have effect on the efficiency of your
heating device.

• As it has low density it cannot handle a large amount of air.

• If your solar air heater is not designed perfectly, your cost can increase.

Chapter 03: Important Components of Solar Heater

Working of Solar Air Heater

The panels of the air collector have installed near the wall with several inches away
from it and create and air cavity. When metal cladding receives heat from the sun, and
heat is absorbed by the perforations on the exterior surface of the panel. As a result, the
fans create negative pressure in the cavity.

The manufacturing design and equipment used for panel and frame both control the ratio
of airflow by the panel perforations. This maintains that cooler air does not come in
contact with the air stream and keep a consistent air drawn along the surface.

The air collected is taken off from the top of the wall and collects all of the solar heat
that is produced. The heated energy is then ducted in the building and is connected to
HVAC intake. The air that is entered through the air handle is heated from 40-100
degrees Fahrenheit. It reduces a load of energy on a traditional heater. During summers
or warm day, the conventional heating would not be required during the day time. This
quality makes it suitable for industrial use as most of these buildings are utilized during
the day time. The collected solar heat is then distributed into the room.

When you do not want to install exterior cladding, or want to increase ventilation in the
chamber, solar air heaters are helpful for this purpose as well.
Design basics

There are some of the common features and components that are found in almost all
models of the solar air heater. Most of the solar air heater have frame equal to 4′ x 8′
while you can change the size depending on your need and space you have.
Some of the standard components that solar air heaters contain are

Frame- The frame is the central part of solar air heaters; all the solar panels are
installed within the frame. The frame holds the solar panels and provides protection to
them. A standard solar air heater frame is made up of 2 x 5 or 3 x 5 lumber. The interior
depth of the frame is equal to 3 to 4 inches. You can change the depth and dimensions of
the frame depending on your needs.

Insulated Back- Most of the heat is wasted from the back of the solar air heater.
Therefore, back of the solar air heater is insulated. Polyisocyanurate in 1 to 2 inches is
recommended. Polyisocyanurate is a thermoset plastic that covers the heat. The side
insulation is more important than back insulation.

Matte Black Interior- The interior surfaces of the solar air heater must be great
absorbent of heat, for that purpose all the interior surfaces are painted with heat tolerant
in matte black paint. Matte black paint absorbs the most heat from the sun.

Solar absorber- A solar absorber is the main component of the solar air heater. The
solar absorber collects the heat and transfers it to the area through heated surfaces.

Air intake/outlet- The cooling air enters in the unit, heat is picked by the absorber.
After absorbing heat, air exits from the top of the premises. The process of air intaking
and exit is sometimes done naturally, or a fan is used that is thermostatically-controlled.

Glazing- The front of the solar air heater is sealed by using an explicit material that
allows the sunlight to be absorbed by the solar absorber and increase the interior
temperature. The conventional materials used for glazing are polycarbonate, tempered
glass or acrylic.

Collector- The collector plays a significant role in solar air heaters. Collectors absorb
radiation from the sun and convert it into thermal heat.

Collector angle

Many of the solar air heater designers suggest that the perspective of the heater collector
must be more than 10° to 15°. When the collectors are installed at a slope, they will
absorb maximum radiation. The collectors that placed at slope are better than the
collectors that are vertically mounted.

• The installation cost of the sloped collector is less than that of the vertical
collector.

• The vertical collectors absorb less heat as compared to the sloped.

• The wind loads are not added to vertical collectors.

Chapter 04: How to Build and Use a Solar Air Heater?

Building and using solar air heater is easy and simple but it needs some basic
knowledge that will help you in understanding the use of solar air heater. Some of the
basic tips for building solar air heater are as under.

1. First of all, measure the length of the south wall of your house. This measurement
will tell you about how will you adjust the collector.

2. While measuring pay attention to the spacing of stud and height of the wall.

3. After measuring, expend the vents.

4. Leave enough space between wall and vent for vertical frame that would be
installed away from the studs.

5. After laying out vent, lag-screw them from inside of the building.

6. For proper installation of electric wires, mark the location of the vent from
inside and outside of the building.

7. After marking the location, cut the vent. Cut the top of the vent by at least 1 inch
and cut back in such a manner that it is sat slope of 10 degree that will help
during rain.

8. Cut the verticals in such an angle that it matches with the slope. After cutting line
them and for supporting glaze cut two notches horizontally equal to 1 inch each.

9. After you are done with cutting, paint and prime everything. Paint in the interior
in dark color so that it can absorb more heat. The collector screen will show
some of this color therefore use such color that fits with your creativity.

10. After the paint is dried, take verticals and mount them to the siding that will
support it. If the siding is not able to hold the weight of the verticals, make sure
that you use strong and large lag screws from outside as well.
11. Make sure that everything you screw must be straight and in line. Attach the
bottom and top beams.

12. You can also place a metal sheet above it for saving it from rain. Use silicone
caulk for sealing the frame of collector. Mount it tight and install the window
screen absorber over it. Fold and wrap the corner of the screen.

13. Now start constructing glazing panels equal to 5-by-9 foot, for making it join
pairs of corrugated panels equal to 25-inch-by-9 foot. Use one corrugation for
overlapping panels by applying silicone caulk between the sheets.

14. Strengthen the joint between two overlapping sheets by using 2-inch-long
wooden strips from inside and use screws for reinforcing joints that contains
washers made up of EPDM. EPDM is a rubber material that is not sensitive to
temperature or weather changes.

15. Now install the strips created for supporting glaze in the space created on the
collector frames. The surface of the frame and surface of the strips must sit
straight to each other.

16. Do all the caulking, cleanup or any other thing you want to do inside the
collector frame, as after installing the glazing you will not be able to reach the
frame.

17. Now install the glazing panels.

18. Install the strips for sealing that will fit in top and bottom beams.

19. On first set of the verticals, move the caulk beads and install first glazing panel.
Use screws with EPDM washers for fastening the panels.

20. Repeat this step and overlay all the glazing panels. Use caulk for overlapping
another panel on the previous one by using corrugation 1 by 1.
Solar air heaters uses

The solar air heaters can be used for several purposes. Some of which are given under.

Heating

Solar air heaters are used in residential and commercial areas for heating of the space.
This is the main purpose of installation of solar air heater. Solar air heaters absorb the
heat and air from outside. After absorption air is passed through the collector and gets
warm, after which it is supplied to the room.

Process heat

Solar air heaters are also used for drying of crops, laundry and other things. It reduces
the moisture of the item by absorbing air, that is heated and then passed to the thing that
need to be dried. As a drying application, solar air heaters also work efficiently.
Cooling

Many of the solar air heaters are also used for cooling the homes. It transfers the cool
air during the evening or night time from outside to inside of the home. The cool air is
collected and then transferred to the space, as a result lowering down the temperature of
room.

Ventilation

Solar air heaters are also used for ventilation purposes as it absorbs the fresh air and
transfer it to the room. It also reduces the heating load.

Filtration

The air transferred to the space from outside is free from dust, pollen and other
particles. The air enters in the room in a method that is controlled and only transfer the
filtered air as compared to the air that is entered by the windows or doors.

Applications of solar air heater

The heat produced by the solar air heater can be used for several purposes that are given
as under.

• Industrial purpose

It is heating for space like factories, warehouses etc. It is also used industries for drying
of coal, paper, minerals, bricks and food industry products. Drying of the brown coal is
very important for the industries.

• Agricultural purposes

In agriculture sector, solar air heaters are used for heating warehouses, animal farms and
greenhouses. Solar air heaters are used for drying crop like fruit, grains, meat and
vegetables. You can get benefit from solar air heaters can be obtained by harvesting your
crops early and use solar heat for drying it and protect it from mildew, rodents etc. After
drying, you can get space for second batch of crops.

• Household purposes

In residential applications, solar air heaters can be used for heating and cooling
purpose. It can also be used for air ventilation and air filtration in your homes.

• Community and commercial purposes

For commercial purpose, it can be used for heating office buildings, shopping centers
and public buildings.

• Camp or camping purposes

For camping purpose, it can be used for heating up military camps, emergency relief
camps, or recreational camping.
Chapter 05: Screen Absorber Solar Air Heater

The solar air heaters with the screen are easy and inexpensive to make. The solar air
heaters with screen allow contact with a large surface for transfer of heat. The air flow
resistance in the screen absorbers solar air heater is quite low.

The screen absorber solar air heaters are built on the concept of screening used for
absorbing heat. Like the screen, will consume a significant amount of heat and transfer it
to the area.

Before designing it for your home, make a sketch on the paper and rethink that whether
you are satisfied with the design or not. After making the plan, start construction of your
solar air heater.
 1. Building wooden frame

The process of construction of screen absorber solar air heater starts from building the
wooden frame. For this purpose, you will need

Acrylic Sheet

Pine 1x5."

Hole Jig (Kreg)

Plywood 1/3."

First of all, bought the acrylic sheet for the frame in your desired dimensions almost
equal to 35"x70"x1/4 (a standard length). The size of acrylic sheet will determine the
size of your frame.

For routing the edge, make the frame almost 1/3" larger to the sheet. Use Kreg jigs for
drilling the screws into the frame that will hold the frame. Combine the plywood and
pipe clamped in the unit. You can cut holes in the plywood equal to 3” for airflow.

2. Build foam

Silver HVAC Tape

1/2" Foam Board

1-2" Foam Board

The two foams are used for better insulation of the unit. One of the foam 1/2” foam is
used for the purpose of insulating the sides and bottom of the unit.

The other foam 1-2” is also used for insulating the sides and bottom of the unit as well
as it will provide the support to the backer board. The second foam will also help in
creating waves on the screen.
The backer board is not directly installed on the wood as it can lose some of the heat
while placing a foam between them can save heat. Use adhesive material for sticking the
wood and foam together.

3. Vents and Air Channel

Aluminum Foil

Silver HVAC tape

Construction Adhesive

5" Aluminum flange tubes

It is a difficult step, tape the 5” vents into the foam. The vents will create a seal that will
keep the air tight closed without losing.

Cut down various strips equal to 2” from the foam board and create air channels. Stick
strips with one another using glue and cover strips with silver tape. Seal all the gaps that
are left behind.

Take aluminum sheet and attach it on top of the air channel.

4. The Heat Sync

2 Concrete Backer-Boards 37" x 62" x 1/2"

Adhesive

A Silver Tape

Measure vents and cut them out. Drill holes in the vents. Take silver tape and apply it to
the edges of the vents. Use adhesive material for joining the seal. Secure the backer
board on beneath the foam strips.
 5. Paint it up

Exterior Paint- Black Oil-Based

Spray Paint- Matte Black

Paint the exterior part of the box with the black oil-based paint. Use various coats of the
paints so that weather change has minimum effects on the paint.

Spray the interior of the box with the matte black paint that will increase the absorption
of heat. Also, paint all the exposed surfaces of the box with matte black.

6. The Screen

Thin Copper Wire

Matte Black Hi-Temp Paint

Silver Tape
Adhesive material

Screws / Staples

Black Fiber Screen - 38"

Cut down the foam board for forming the borders inside. Cut triangles for side strips.
The bottom triangles are attached to the backer board. Paint these triangles into the
black.

Make sure that foam triangles are enough that will create waves on the screen.

Place the screen and cut it down to the size that it will fit the wooden frame. Install
wires using the screw and put the screen right on it. Use adhesive material for locking
the screen in its place.

Conclusion

Solar air heaters are energy efficient and profitable that makes it a better heating device.
It is easy to use and install. You can design it at home by following the tips given in the
chapters.

Solar air heaters use the latest technology and utilize sun radiations for heating purpose.
Solar air heaters are not only used for a heating purpose, but it can also be used for
cooling, ventilation, filtration, and for drying applications.

This e-book contains all the necessary information about the uses as well as designing of
the solar air filters. Follow the steps given in the chapter for constructing a solar air
heater for you home.

You can use it for commercial purpose or for household use. Share your feedback with
us that how this e-book increased your knowledge and helped you in designing a solar
air heater. Thank you again for downloading this e-book.
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