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Solar Water Heater Fabrication

A Solar Water Heater uses a flat-plate collector (FPC) or evacuated tubes (ETC) to heat water and stores it in an insulated tank. The student-friendly build below focuses on an FPC thermosyphon system (no pump), with an option to add a pumped/controlled loop. Great for learning heat transfer, plumbing, insulation, and safety.

Parts Used:
  1. Storage Tank (100–150 L) – PUF-insulated, food-grade liner; hot-out dip tube; cold-in diffuser.
  2. Piping & Valves – Copper/CPVC/PEX with insulation sleeves, ball valves, NRV, air vent, drain cock.
  3. SafetyT&P relief valve, expansion vessel (2–5 L), thermostatic mixing valve (48–50 °C).
  4. Mounting Stand – Tilt = latitude ±5°, south-facing (India); wind anchors.
  5. Optional (Active System) – Small circulator pump, controller (ΔT), NTC sensors, check valves, SSR/relay.
  6. Add-ons – Electric immersion backup (1–2 kW), flow meter, thermometer gauges, PCM heat pack.

TECHNICAL SUPPORT

Advantages:
  1. Zero Operating Fuel – Free solar heat with minimal maintenance.
  2. Simple & Robust – Few moving parts (passive thermosyphon).
  3. Safe DeliveryMixing valve prevents scalding; relief & expansion protect the tank.
  4. Scalable – Parallel collectors or switch to active loop for long pipe runs/shaded tanks.
  5. Learning Outcome – Conduction/convection/radiation, insulation, and plumbing safety.