Solar space heating for shop
 

Here in Ontario Canada fall weather is beginning. Nice weather for working outside. For fellow Eco-renovator that have been following and remember 2 yrs. ago I had built and installed a homemade Ground source heat-pump under the tutelage of AC Hackers Manifesto in the shop. I would say the GSHP was a resounding success. Reduced my shop heating bill (furnace oil) from $2800.00/yr. to less than $500.00

Many may also remember the solar hot water heating system we had installed to my home also a very successful adventure. Reducing energy costs by a min of 1/3. If we receive a good solar fraction in-excess of 1/2 of the heating energy. Dollar wise $1200.00 approx.

Now I would like to install a solar heating system in the shop. The south facing wall is perfect for the application. I know what you maybe thinking, at a cost of $500.00 /year for heating why bother. 1./ the position of the shop is perfect. 2./ I still have a lot of copper left from the home system I had assembled as well as recycled tube. 3./ Windows have rotted corners I have to open the wall anyway to replace. 4./ Already have a hot water system ready for implementation. 5./ May reduce my shop heating bill to near zero. 6./ Electricity will always increase in cost therefore solar hot water is an excellent investment Sunshine will always be free!!.

In the photos is a captured typical temperature of glycol (solar collector)circulating in the system. When the sun is shinning minimum 6 hrs. per day is a lot of heat!!

So far the steel siding has been removed and the copper tubing that was used to convey the furnace oil from the tank to the furnace (removed 2 yrs. ago) has been pulled from the walls and readied to be recycled into riser tubes for the solar collectors. Boy I enjoy this type of recycling. I have a very simple method to straightening the tubing- give it a tug with the lawnmower and tree. It makes the tubing as straight as an arrow. The steel siding was replaced with couple screws to keep the insulation dry. In the photos is a pic. of the simple copper form tool that puts a groove in the copper strip stock to solder the copper riser tubes.

A little side note: I had stopped into my previous furnace oil sales office and the cost of furnace oil has increased to the price that would have pushed my costs for keeping my home and shop comfortable for the heating season to $10k WOW.:eek:

I would say the extra efforts and capital costs of Solar Hot Water and Geo thermal have well been justified. So if any other Eco-Renovators are on the fence It does work well!!:thumbup:

Randen

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Randen, you are a machine... I'm really looking forward to seeing this project progress. :)

Randen, I have 3 sheets of solar glass (46" x 96" x 1/8") if you need them. Good price, give me a call. It's hard to ship the glass and it is available to anyone but local will be easier.

Are you planning on using heat storage of some form? If not, why not just go with hot air panels?

Solar hot water space heating for the shop
 

Well yes on the storage.

The office portion of the shop has in-floor heating. Its made up from 6" of concrete so it stores heat nicely. The shop however was built before I gathered much wisdom and knew nothing of efficiency. However the shop is full of machinery that do hold some heat. If the heating is shut off for a long weekend in cold weather I've never seen it below 5 Deg. C.

Here is a photo of the ceiling air handler that is already plumbed for the solar hot water. I believe that the solar hot water may even thermal-syphon we may require only a slow running fan motor.

And a photo of the manifold for the concrete in-floor heating. Originally the in-floor heating was done with an oil-fired hot water heater. It was fabulous. Many times I would see my secretary with her shoes off warming her feet directly on the floor.

As I had mentioned financially it isn't making any sense to install this solar hot water being heating the shop with the home-made Geo thermal is so economical, But we're on a roll. :thumbup:

As storage goes I do have another additional option. The original 1000 gal fiberglass storage oil tank that once supplied my home is slated for removal. One could have it spray-foamed and buried again for storing hot water. :eek:

We'll have to consider that a little longer.

Randen

http://ecorenovator.org/forum/attach...1&d=1382537530

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The Hard work has begun
 

I was a beautiful day here in Ontario. In fact the last couple have been. We have begun the task of replacing the shop windows with new narrow windows. This will increase the number of copper risers I can install for the width of the south wall. All the steel siding was installed with screws so its made it a non issue to remove. The bottom of the 2 x 6 studs have been drilled to make way for the 1" copper pipe. This will supply the lower manifold with the propylene glycol mix to then rise through the copper finned risers and gather all that free heat to keep the shop warm.

I had built the shop in 1987. I was 27 yrs. old Wow has time flown. The original windows were purchased in a lumber yard sale. Got them cheap. They are wood framed sliders. Not a great performer but did the job for a nice well lit shop.

By the end of this week should have the windows in and sealed up from the weather. More importantly the rough in for the Solar hot water. After which let the soldering begin on all those riser-tubes. (about 80 pcs.)

Randen

http://ecorenovator.org/forum/attach...1&d=1382537566

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Randen, I have more glycol and I have to come out your way in the next 2-3 weeks, if you need some.

Yes please I'll run some calculations for the amount required.

Randen

So you're building the collector into the wall? What are you going to use for insulation behind it?

I'm intending on using Thermax insulation with the aluminum foil face. I will spray them black and fasten them with plastic washers and screws.

Randen

How much are you going to be able to put behind? 1"?

Solar Heating with GSHP Backup...
 

Wow randen, Solar Heating with GSHP Backup.

What a luxury!

Another angle on this setup is that you'll be drawing less heat from your loop field, and the replenishment solar energy falling on the loop filed will bring the temperature up.

BTW, do you have any plans to store the solar energy that you will be gathering, but not needing throughout the summer?

That would raise the ground temp and really increase the efficiency of your heat pump when you do need to use it.

Remember this graph:


It indicated a COP 6 down to COP 4, ultimately depending on the delta T, but most understandably it relates very much to the source temperature (loop field temperature).

Is you house set up to work in that manner? Mostly a matter of plumbing, and some sensors, and a little Arduino magic (hint! hint!).

Best,

-AC

Solar hot water space heating for the shop
 

AC Hacker

The heating of the loop field is very easy in the shops system set-up. I will include a drawing of the circuit a little later. The whole system uses the same propylene glycol. Meaning its all connected. The glycol solution can circulate through the solar panels then by-pass the air handler then through the 4-way valve in the heat-pump and back to the solar panel. Daox asked about the insulation. The shop currently has 6 in. r20 fiberglass and yes will be adding 1" thermax sheeting to the exterior. I've been a little anal about the sealing of the plastic vapour barrier and other ideas on how I can make it better and I have to keep reminding my-self (its a shop)

It's the 28th of Sept another beautiful day. A good day for more out-side work. will be framing in the last window.

Check-out the photo any idea what these two items could have in common?? My plate is now more than full with projects!!

Solar hot water space heating for the shop
 

The air-conditioner is fairly new. I was installed in the window incorrectly. PUSHED CLEAN OUT. OPPS. Condenser absorbed the fall.:eek:

Randen

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An up-date
The south wall has both the new windows framed. We needed to have a narrower window so we could increase the amount of solar collector area. The 1' copper tube supplying the bottom manifold with glycol is installed. Insulation and Thermax back board is next.

Randen

Randen, remember that the stud wall has to be able to breathe, either to the inside or to the outside or the dreaded rot will come. I think the 1" sheeting may constitute a vapour barrier.

Mike
Thanks for the heads up. But it is a shop, and I'm making an effort to stem most of airflow. But in no way will the wall be air-tight in any stretch of the imagination.

Randen

Another donor unit!

-AC

Solar hot water space heating
 

The last window is installed and the copper tubing for the lower manifold is in and soldered. The plastic vapour barrier has been improved greatly from when I first built the shop. Its just a little thing but the receptical boxes never had been enclosed with plastic to prevent air infiltration so we'll do that now.

The circulation pump has arrived and we'll install that in the next day or so as well do a pressure test.
I will use the fiberglass insulation in and around the copper tubes. The exterior Thermax will be painted a flat black and installed on-top of the 2 x 6 studs doing double duty. More insulation for the envelop and the back of the collector risers.

I'm having some stainless sheet stock bent up for drip and corner flashing as well as retaining the Suntuff corrugated plastic collector covering. Its a little more expensive and tuff to drill and work with but you only do it once. and it always looks good.

Randen

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How is this going to be plumbed? Im guessing its a antifreeze setup, not drain back. So is it going to be plumbed directly into the floor loop?

Solar hot water space heating for the shop
 

We're forging ahead with the solar heat for the shop. Today the polyiso insulation board was sprayed a nice flat black. This insulation board would be seen as a shiny aluminum surface between the black copper risers/fins if not coated.
The next order of business will be the custom bent stainless steel drip/flashing strips to mount the Sun-tuff clear covering. After that the polyiso board then copper riser/fin.

Hopefully all before the weather turns.

Randen

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Almost ready for the copper
 

Fall weather is starting to settle in to Ontario Canada. Wind rain, cold , soon it will be too in-climate for this Canuck to work out side!! Today was a good day and much progress had been made. The wall had all the insulation tucked back in and windows squared and shimmed. The custom stainless drip flashings had been fastened. As well the poly-iso that was previously painted a flat black is fastened into place. The paint will need to be touched up here and there but it all went on real well. I need to change some of the old ratty fiberglass insulation at the extreme ends and trim additional poly-iso board to fit. All the Suntuf acrylic sheet stock had been ordered and should be here in a few days.

The really fun stuff is about to begin. THE COPPER stuff. And that's going to be a lot of copper. Making the copper tube risers and fins about to start. The exterior can now take some rain therefore one can begin to cut & form copper on the bad days and only install on the good days. OOh can almost feel that free heat already!!:thumbup:

Randen

http://ecorenovator.org/forum/attach...1&d=1382537255

This is a great project you are presenting here... I understand in theory what you're going to do, but the details will be very enlightening.

Keep your camera close at hand.

Best,

-AC

Great progress. I'm looking forward to hearing more about how you do the copper work. :)

Solar hot water space heating for the shop
 

Just an update. Today the Suntuf acrylic had arrived and this is probably the most expensive part of the project. I think by the time we have everything together it might be a littlee north of $1k.

Solar hot water space heating for the shop
 

Just an update. Today the Suntuf acrylic had arrived and this is probably the most expensive part of the project. I think by the time we have everything together it might be a little north of $1k.

I need to get moving now on the copper but the day job is extremely busy.

On a side note the little 2 Ton homemade Geothermal was cranking out the BTUs (Calories) Shop started in the morning at 11 DegC. Noon a comfy 20 DegC.
Can't wait to get the two together- the solar with the Geo back-up.

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Solar hot water space heating for the shop
 

Today, Saturday is very wet as its been raining for the past 3 days. I had some time to work on the solar collectors. Drilling the holes in the stainless to pass the manifolds from enclosure to enclosure below the windows. The manifolds will pass below and above the windows thru 3" of foam. The walls already have R20 so the areas above and below the windows will have close to R45 and I believe the wall will now have R28 and better sealed. The copper manifold will be insulated around with the foam so as to not lose any heat from proceeding enclosure.

In one of the photos the manifold can be seen with a section of risers and fin to give an idea of the near completed assembly.

The foam will be latter finished with a stucco and I added an outside receptical. When ever the lawnmower needed the battery charged the cable always had to run though the open window. How handy now!!

Some of the copper work has began. Winters coming!!:eek:

Randen


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Any updates on this, or has it gotten too cold?

Randen is in Argentina for a couple weeks so I guess we'll see when he gets back. Lucky bugger, warm, dry and good beef dinners......

Just thought I would report in. In the shop I have begun to make the risers. As Mike solar had mentioned we are in the south. The beef here is world famous. So much for Canadian Beef. No eco-renovators here, its always warm in B.A. Argentina. No solar panels no insulation. Although they do sport the instant water heaters, compact florecent lights.

The home-made Heat Pump is keeping the shop well above the freezing point Floor temp 14 Deg. C.

Randen

I am building one of these for my house. But instead of using copper . I am doing mine with an air space heatin.

Solar hot water space heating for the shop
 

Here it is, a new year and the Canadian is dragging his feet on the project. Jan 09 is a sunny cold day with an expected high of -6 Deg. C. Mikesolar was curious if any activity had occurred. Not. Except for a few risers nothing has been done.

Again the day is sunny and the house is getting the free heat for the day. Only if the shop could make the same claim. Other little odd time-consuming jobs are being knocked off.

Something cool happened this morning. I apologise for not getting a photo, the eco-renovators may be able to mentally picture this. Yesterday, full sun heated the house as well as the garage. As a daily occurence my wife parked her car in the garage last evening. She had expressed her like to have a warm car in the morning and I find that a floor temp of 21 Deg. C. room temp. 16 Deg. C. is warm enough.

With this floor temperature the accumulated ice and snow melts over nite and the car and garage floor is dry in the morning when she leaves.

Upon opening the garage door this morning with the outside air temp -16 Deg. C. a plume of warm moisture laden air condensed and made a cloud of vapour.
She was amazed as the car emerged from the sauna. I believe she now agrees the garage is warm enough.

I like that its a fine display of solar heating.:thumbup

Randen


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Solar hot water space heating for the shop
 

A little light production is made. The copper risers for the solar collector. It is a mundane task and its going to take some time. I've about 90 pcs to make. You guys probably know what I mean. Those jobs when you just need to go though the motions with your mind shut off. One after another till one day, Hey I've got them all finished, On to the next step.

The copper tube was recycled from the old oil furnace that was removed from the shop and I believe some more was donated. The copper fin material was purchased for the collector I had made for the house. Believe it or not it was cheaper to make a minimum order for the slit copper and scrap what I didn't use than buy the quantity I required only.

Still a little cold and snowy for out-side work anyway. Its a little disappointing too that we haven't seen a lot of sun this season. Its been very cold lots of snow and more cloud than one can stand.:(

Randen


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Solar hot water space heating for the shop
 

A nice sunny day in Ontario -7 Deg. C Some serious work is progressing on the solar hot water panel for the shop. These jobs of tedium seem to take forever and one must be in the right frame of mind.

The risers are being silphos brazed to the upper and lower manifold tubes. Not difficult just need the steady hand. After this panel is brazed we will place it outside on a nice day and give it a coat of flat-black selective coating. Then we'll put in place and start again on the next section. These things are large and take up a lot of room.

The all important pressure test is now being made We'll confirm tomorrow if all is well. To skip this test would result in a possible leak when the panel is all assembled resulting in disassembly and a few choice words.

In one of my builds a pressure test was made however in some part of assembly a cold joint was opened and a world of pain was made. Removal of the glass and re brazing trying not to start the foam insulation a blaze.

This section will be one of 4 assemblies adding up to about 300 sq.ft. of collector

Randen

Solar hot water space heating for the shop
 

A nice day here in Ontario. The temp rose to 2 Deg C. perfect for a selective coating for the copper risers. In the direct sunlight out of the wind proved ideal for the job. The coating dried quickly and allowed us to hoist it into position allowing more room for the next section to be manufactured next.

The sun-tuff glazing is under 3 ft. of snow. It may be a few weeks before any can be installed over the collector.:thumbup:


Randen

Cover it so the elements don't bugger up your coating

Project seems to be comin along nice.

Hi Randen, how did this project turn out?

Pletby

This project for the time has taken a back seat to some other projects. However from time to time some pieces do get soldered into place. Last week I had some time to rout the piping inside to the air handler.
The 5T DIY geothermal shop heating is working extremely well and keeping the cost of heating the shop to meir pennies by comparison to furnace oil heating. So the urgency to have this up and running is not there.
The solar resources here for the last two years had been disappointing. Very little sun a lot of overcast skies.

Randen

Hello, What is the "AC Hackers Manifesto" ? I can not find any reference to this.