ITI Study-Trainers Textbook - Solar Thermal PDF

Solar Thermal Systems Module
Trainers Textbook
Study materials in Renewable Energy Areas
for ITI students
Ministry of New and Renewable Energy

Government of India
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Study Materials in
Renewable Energy Areas
for ITI students
Trainers Textbook
Solar Thermal Systems Module
(Solar cookers and Solar water heaters)
Ministry of New and Renewable Energy

Government of India
Study Materials in
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Renewable Energy Areas for ITI students
Contents
Unit 1. Introduction to Solar Energy 5

1.1 Solar energy 5
1.2 The need to use solar energy 5
1.3 Basic principle 5
1.4 Factors to consider for using solar energy 6
1.5 Measuring Solar Energy 7
1.6 Applications of solar energy 7
Unit 2. Solar Thermal Energy 9

2.1 Solar collectors 9
2.2 Working principle of a solar collector 9
2.3 What is heat? 10
2.3.1 Understanding Heat Movement 10
2.3.2 Conduction 10
2.3.3 Convection 10
2.3.4 Radiation 10
2.4 Solar thermal energy applications 11
2.4.1 Water heating 11
2.4.2 Solar cooking 11
2.4.3 Solar drying 12
2.4.4 Desalination / Distillation 12
2.4.5 Solar Pasteurisation 12
2.4.6 Solar thermal energy in architecture 13
Unit 3. Solar Cookers 14

3.1 Solar cooker 14
3.2 Basic principles of solar cooking 14
3.3 Advantages and limitations of using a solar cooker 14
3.4 Box solar cooker 15
3.4.1 Description 15
3.4.2 Precautions to take 17
3.4.3 Raw Materials Required For Fabrication 17
3.4.4 Standard testing procedure and quality control 17
3.4.5 Maintenance and servicing of box solar cookers 18
3.4.6 Customer education 18
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3.5 Dish solar cooker 19
3.5.2 Design 20
3.5.3 Material required for fabrication: 20
3.5.4 Maintenance and servicing of dish solar cookers 21
3.6 Community Solar Cooker (for indoor cooking) 22
3.6.2 Design 22
3.6.3 Material required for fabrication 23
3.6.4 How it Works 23
Unit 4. Solar Water Heaters (SWH) 25
4.1 Solar Water Heating Systems 25
4.1.1 Basic Working Principle 25
4.2 Advantages and limitations 25
4.3 Details of Solar Water Heaters 26
4.3.2 Design 27
4.4 Evacuated Tube Collector (ETC) based solar water heater 27
4.5 Domestic solar water heating system 28
4.5.1 Thermosyphon system 28
4.5.2 Forced circulation system 29
4.6 Site selection 31
4.7 Procedure for Operation and Maintenance 31
4.8 Operation of the Solar Water Heater 31
4.9 Maintenance of the SWH 32
4.10 Customer education 32
4.11 BIS Standards 33
4.12 Manufacturing of components of Solar Water Heater 33
Unit 5. Practicals 36
5.1 Engineering drawings: 36
5.2 Cross sections of solar water heater (SWH) 37
5.3 Installation Layouts 38
5.3.1 1500lpd Solar Water Heating System (SWHS) Layout at 60 c
O
38
5.3.2 1500lpd SWHS layout 70 c O
39
5.3.3 3000lpd SWHS layou: 40
5.4 Calculations 41
Annexure 42
Trainers textbook for

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Solar Thermal Systems module
Unit 1. Introduction to Solar Energy
Learning Outcome
At the end of the session, the students will have an overview of solar energy.
Time: 1 hour
Methodology: Lecture
1.1 Solar energy

Solar energy is defined as the sun’s radiation that reaches the earth. It is the most readily
available source of energy. The sun is the earth’s power station and the source of all energy
on our planet. We use the solar energy every day in many different ways. When we hang
washed clothes outside to dry in the sun, we are using the solar heat to do work, drying
our clothes. Plants use the solar light to make food. Similarly, solar panels absorb the
energy of the sun to provide heat for cooking and for heating water.
1.2 The need to use solar energy

With the growing population and fast pace of development, energy is becoming
more expensive and our cities and towns face a major power crisis. The reality is that
resources like coal, oil and natural gas will not be around forever. We all realise today,
that we need alternatives sources of energy that are renewable. Renewable energy is
derived from natural resources such as sunlight, wind, tides and geothermal heat.
Solar energy or energy powered by thic Prie sun is one of the most promising future
renewable energy sources.
1.3 Basic principle

Solar energy consists of light and heat emitted by the sun, in the form of electromagnetic
radiation. Technology today helps to capture this radiation and turn it into usable forms
of solar energy - such as heating or electricity.
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Thus energy from the sun can be categorized in two ways:
(1) In the form of heat (or thermal energy), and
(2) In the form of light energy.
Solar energy can be converted to thermal (or heat) energy and used to:
• Heat water – for use in homes, buildings, or swimming pools.
• Heat vessels – for cooking food
• Heat spaces – inside greenhouses, homes, and other buildings.
Solar thermal technologies are devices that use the solar heat energy to heat substances
(such as water or air) for applications such as solar cooker, water heaters and pool
heating. There are a variety of products available in the market that use solar thermal
energy. Often the products used for this application are called solar thermal collectors.
Solar energy can be converted to electricity in two ways:

• Photovoltaic (PV devices) or “solar cells” – change sunlight directly into electricity.
• Solar Power Plants - indirectly generate electricity when the heat from solar thermal
collectors is used to heat a fluid which produces steam that is used to power
generator.
1.4 Factors to consider for using solar energy

A few factors which need to be looked at when determining the viability of solar energy
in any given location are the following:
• Geographic location
• Time of day
• Season
• Local landscape
• Weather conditions
Geographic location
Geographic location plays a vital role in harnessing solar energy.
India is located in the equatorial sun belt of the earth, thereby receiving abundant radiant
energy from the sun. In most parts of India, clear sunny weather is experienced 250 to
300 days a year. The country has the capacity to receive 4500 trillion kWh of pure solar
energy each year. This allows solar energy in India to be a viable option.
The highest annual global radiation is received in Rajasthan and northern Gujarat. In
Rajasthan, large areas of land are barren and sparsely populated, making these areas
suitable as locations for large central power stations based on solar energy.

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Time of Day
Solar energy is at its peak at mid moon. A solar energy system works in the morning and
in the late afternoon. It however reaches its maximum efficiency around noon time.
Season
A solar energy system is more efficient during summers than in winters when the days
are shorter.
Local landscape
A solar energy system has to be installed in an open area unaffected by shade. If even
a small section of the system is shadowed, the efficiency reduces. This is the reason
why solar energy systems are placed mostly on roofs. Even in this case, care needs to
be taken to ensure that no tall trees or taller neighbouring buildings cast a shadow on
the system.
Weather conditions
Weather conditions have a large impact on the energy output of the solar energy system.
Cloud cover, rain, snow, fog and smog all reduces the amount of sunlight that reaches the
system. The system will work but its efficiency will be greatly reduced.
1.5 Measuring solar energy

Radiation data (the amount of solar energy available at a given location) for solar
electric (photovoltaic) systems is often represented as kilowatt-hours per square meter
(kWh/m2). Direct estimates of solar energy may be expressed as watts per square meter
(W/m2).
1.6 Applications of solar energy

There are a variety of technologies that have been developed to take advantage of solar
energy. The technologies are classified as passive or active depending on the way they
capture, convert and distribute sunlight. Active solar techniques use photovoltaic panels,
pumps, and fans to convert sunlight into useful outputs. Passive solar techniques uses
sunlight for energy without active mechanical systems. Such technologies convert
sunlight into usable heat (water, air, and thermal mass), cause air-movement for
ventilating, or store heat for future use, without the assistance of other energy sources.
While costs associated with operating these products may be limited or nil, maintenance
costs are very low.
This module on Solar Thermal Systems focuses on two applications of passive solar
technology, namely solar cookers and solar water heaters. These systems are discussed
in the next two units.
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Green House Effect:
The earth receives energy from the sun mostly in the form of visible light and
nearby wavelengths. About 50% of the sun’s energy is absorbed at the earth’s
surface. Like all bodies with a temperature above absolute zero the earth’s surface
radiates energy in the infrared range. Greenhouse gases in the atmosphere absorb
most of the infrared radiation emitted by the surface and pass the absorbed heat to
other atmospheric gases through molecular collisions. The greenhouse gases also
radiate in the infrared range. Radiation is emitted both upward, with part escaping
to space, and downward toward earth’s surface. The surface and lower atmosphere
are warmed by the part of the energy that is radiated downward, making our life
on earth possible

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Unit 2. Solar Thermal Energy
Learning Outcome
At the end of the session the students should have relevant knowledge and
understanding of solar thermal systems
Methodology: Lecture
Time: 2 hours
2.1 Solar collectors

Solar thermal energy is the technology used for harnessing solar energy for thermal
energy (heat). A solar thermal collector captures the radiant energy from the Sun and
converts it into heat. The most basic type of collector is the solar cooker. And the most
common type of solar collector is the roof-mounted domestic hot water system. Solar
collectors are a cheap and effective means of converting sunlight into thermal heat. This
module discusses these two types of solar thermal collectors since they are commonly
used in India.
2.2 Working principle of a solar collector

A solar collector works on the principle of converting solar energy into heat by taking
advantage of a process known as the greenhouse effect.
The basic idea is that the solar energy passes through a layer of glazed glass where it
is absorbed by the underlying material. The solar energy excites the molecules in the
underlying material resulting in heat. The glazing of the glass prevents the heat from
escaping, thereby effectively capturing the heat.
Once that heat is captured we can put it to good use. But in order to use it, we first need
to understand some of the basic principles of heat.
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2.3 What is heat?
Heat is simply a form of energy associated with the motion of molecules.
When the electromagnetic waves coming from the Sun hit an object, they excite the
molecules of that object causing them to move. This molecular movement is heat.
Heat is always moving from higher to lower temperatures until the temperatures are
equal. This is known as heat transfer. If you place two objects next to each other, the
warmer object will cool down as its heat is transferred to the cooler object. The cooler
object in turn will warm up.
This heat transfer is driven by the difference in temperatures of the objects. The heat
transfer rate is proportional to the difference in temperature. The larger the difference in
temperature between the objects, the faster the heat moves.
2.3.1 Understanding heat movement

To really understand solar thermal energy, you need to understand about heat movement.
This is especially important for passive solar energy applications.
There are three basic physical ways that heat moves:

• Conduction
• Convection
• Radiation
2.3.2 Conduction
Conduction is the transfer of heat through a solid material, or from one material to
another where their surfaces are touching. Heat is conducted more easily through a solid
material than through layers of material, even when the layers are held together tightly.
This is important as the conduction of heat through building materials is a major source
of heat loss.
2.3.3 Convection
Convection is the transfer of heat by a moving fluid, usually air or water. Natural convection
is caused by the heating and cooling of the air in a room as it contacts objects. As air is
warmed, it expands resulting in it having a lower density than the cooler air around it.
Since its density is lower than the cool air, it will rise. As the air cools, its density increases
and it will sink, starting the process all over again. This movement of air is known as
convection current.
2.3.4 Radiation
Radiation is the transfer of energy via electromagnetic waves. The transfer of energy from
the sun across nearly empty space is accomplished primarily by radiation. Radiation

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The figure given below summarises the different mechanisms
of energy transfer.
Image adopted from The Atmosphere by F. Lutgens and E. Tarbuck, © Prentice-Hall, Inc
occurs without the involvement of a physical substance as the medium. The sun emits
many forms of electromagnetic radiation in varying quantities.
Darker-coloured objects absorb more visible radiation, whereas lighter-colored objects

reflect more visible radiation.
2.4 Solar thermal energy applications
2.4.1 Water heating

The most common use for solar thermal technology is for domestic water heating.
Hundreds of thousands of domestic hot water systems are in use throughout the world.
2.4.2 Solar cooking

Solar cookers fall into two main categories – solar box and direct solar concentrators.
The basic design for a solar box is that of a box with a glass cover. The box is lined with
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insulation and a reflective surface is applied to concentrate the heat onto the pots. The
other approach is to reflect the sun’s rays onto a pot, often with a parabolic dish. The pots
can be painted black to help with heat absorption.
The main advantage to solar cookers is that wood does not need to be purchased or
collected, which is often a very time consuming activity for women.
Many variations of solar cooker have been developed from the very basic reflective
cardboard sheet box to the very sophisticated large-scale institutional and commercial
solar cookers now being used in India.
2.4.3 Solar drying

Controlled drying is required for various crops and products, such as grain, coffee,
tobacco, fruits vegetables and fish. Solar thermal technology can be used for this
purpose. The main principle of operation is to raise the heat of the product, which is
usually held within a compartment or box, while at the same time passing air through
the compartment to remove moisture. The flow of air is often promoted using the ‘stack’
effect which takes advantage of the fact that hot air rises and can therefore be drawn
upwards through a chimney, while drawing in cooler air from below. Alternatively a fan
can be used.
Solar crop drying technologies can help reduce environmental degradation caused by
the use of fuel wood or fossil fuels for crop drying and can also help to reduce the costs
associated with these fuels and hence the cost of the product.
2.4.4 Desalination / Distillation

Basic solar stills can be used to purify water in remote regions where contaminated water
is present. They can be used to remove impurities such as fluoride and salts to produce
drinking water.
The basic still is made of a glass or transparent plastic cover and a shallow tray of water
which has a black backing to trap energy. When the sun heats the water up within the
still water evaporates which then condenses on the underside of the covering glass. The
glass is at an angle so the water drains off and is captured in a trough separate to the
contaminated water.
Solar distillation can be combined with other useful functions so that a solar still may
also be used for rainwater harvesting if modified slightly.
2.4.5 Solar Pasteurisation

In pasteurization, water is heated to 65°C for about six minutes, killing all the germs,
viruses, and parasites that cause disease in humans, including cholera and hepatitis A and
B. This is similar to what is done with milk and other beverages. It is not necessary to boil

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the water as many people believe. Pasteurization is not the only way to decontaminate
drinking water, but it is particularly easy to scale down so that the initial cost is low.
2.4.6 Solar thermal energy in architecture

Providing comfortable buildings, while reducing the use of conventional fuels and
electricity, can be obtained through solar passive architecture. Solar Passive Architecture
involves blending architectural principles and solar energy to design interiors which
remain warm in winter and cool in summer, thus providing year-round comfortable
indoor environment. Solar designs can save up to 90% of the energy required to cool or
heat a building.
The benefit of solar energy is utilized through designing energy efficient buildings.
Here specific attention is directed to the site and location of the dwelling, the prevailing
climate, design and construction, solar orientation, placement of glazing-and-shading
elements, and incorporation of thermal mass.
As mentioned earlier we shall discuss two applications of solar energy which are solar
cooker and solar water heater.
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Unit 3. Solar Cookers
Learning Outcome
At the end of the session the students will be able to:
• develop an understanding of construction and working of different types
of solar cookers
• develop skills in installing, maintaining and repairing solar cookers
Methodology: Lecture, AV Material, Practicals
Time: Theory – 2 hours
Practicals: 4 hours
3.1 Solar cooker

Solar cooker is a device which cooks food without any conventional cooking fuel/energy
like cow dung, wood, coal, gas, kerosene or electricity. It converts sunlight into heat
energy and cooks the food.
3.2 Basic principles of solar cooking

Solar cookers utilise the simple principles of reflection, concentration, glazing, absorption
and the greenhouse effect to produce heat. Various types of solar cookers exist, harnessing
one or more of these principles. Basically a solar cooker is an insulated container with a
multiple or single glass (or other transparent material) cover. This kind of cooker depends
on the “greenhouse effect” in which the transparent glazing permits passage of shorter
wavelength solar radiation, but is opaque to most of the longer wavelength radiation
coming from relatively low temperature heated objects. Mirrors may be used to reflect
additional solar radiation into the cooking chamber. A double-walled insulated box can
also serve to hold the heat inside the cooker.
3.3 Advantages and limitations of using a solar cooker

Advantages of solar cooker:
1. Since the solar cooker does not consume any conventional fuel, it saves fuel.

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2. It does not emit any smoke or smell and hence does not pollute the environment.
There is thus no chance of causing cancer and affecting eyesight or lungs.
3. Since it does not require constant attention while cooking it helps saves time, which
can be utilised for other productive work.
4. As it is a slow cooking device, it preserves the nutritional value of the food
5. Simplicity of construction and operation with minimal attendance required during
the cooking process.
6. It can be used for cooking 3 to 4 items at a time
7. It keeps cooked food hot for 4 to 5 hours
8. It produces no glare and presents no risk of fires and burns. There is no possibility of
accidents like bursting of cylinders or catching fire, electrical shocks, etc.
9. It saves money.
Limitations of using a solar cooker:

1. Slow cooking process due to low temperatures.
2. It does not work in night or on a cloudy day
3. It cannot be used for frying or preparing chapattis
However, in spite of these limitations, if a solar cooker is used throughout the year it does
help to save substantial amount of cooking fuel and thereby contributes to savings.
3.4 Box solar cooker
3.4.1 Description:
The important parts of a box solar cooker are described below:
(Source: Solar Energy Centre, Faridabad, India)
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a.) The Outer Body
The outer body of a solar cooker is made of a metal sheet or fibre reinforced plastic having
suitable dimensions.
b.) The Inner Cooking Box/Tray

The inner cooking box is of aluminium sheet. All the five surfaces of the inner cooking
tray or the top surface of the cooking box which are exposed to the sun are coated with
black board paint which absorbs solar radiation. In the case of tray type cooker one may
have to apply the black paint frequently as it comes out due to rubbing of the pots with
the coated surface during loading and unloading of the cooker.
In the case of box type cooking system, the coating is not touched and hence will not be
affected during such operations.
c.) Thermal Insulation

The space between the outer box and the inner cooking box/tray is filled with insulating
material such as glass wool. This is done to prevent the heat loss from the cooker.
While selecting the insulating material, it should be remembered that the material should
be stable at least upto 200 °C. Resin bonded insulating materials are not allowed in the solar
cooker. The insulation should be in the form of a pad and should not be less than 5cm. thick.
The performance will be better if the thickness of insulating material is more than 5 cm.
d.) The Double Glass Lid

A double glass lid is provided on top of the cooking box/tray of the solar cooker. The
lid had length and breadth slightly greater than the cooking box/tray and is fixed in
an aluminium frame maintaining a small spacing between the two glasses. This space
contains air which acts as an insulator and prevents convective heat loss from inside.
The frame is attached to the outer box by hinges. A strip of suitable insulating material
between the frame and the edges of the cooking box/tray prevents heat leakage when it
rests on top of the cooking box/tray.
The inner glass of the double glass lid should be tough to avoid its being damaged due to
daily heating and cooling effects. In box type cooker single glass cover of toughened glass
is enough if the absorber is coated with selective coating material. The lid in such cases
need not have hinges and should permanently be fixed since it does not have to be lifted
during loading and unloading of the cooker.
The insulating strip between the edges of the cooking box/tray and the glass lid should
be stable at least upto 200°C and should not outgas, expand or contract between -30
and 200°C. Silicon rubber or EPDM is suggested for this strip. Gaskets used in pressure
cookers can also be used after suitably modifying the design.
e.) Mirror
Mirror is used to increase the radiation input on the absorbing surface. The sunlight
incident on the mirror gets reflected from it and enters the box after passing through the

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glass lid. This radiation is in addition to the radiation entering the box directly and helps
to achieve better results during the cooking process by raising the inside temperature of
the cooker. The reflectivity of the mirror should be over 85%. The mirror could also be in
four equal segments.
f.) Cooking pots

The cooking pots with cover are generally made of a suitable aluminium alloy or stainless
steel. The pots are painted dull black on the outer surface so that they also absorb
radiation directly. However, if the inner portion of the cooker is box type, the cooking
pots need not be painted black.
g.) Side window

A well insulated door is provided on one side of the cooker for loading and unloading
when the inner cooking space is in the form of a metal box. The insulated box should
have no leakage when it is closed.
3.4.2 Precautions to take

• The surface of the cooking box exposed to solar radiation and the outer surfaces
of cooking pots should always be kept coated with black paint/selective coating
material.
• There should be no leakage of hot air through the joints or any other portion of the
cooker.
• The lid with double glass system should be perfectly sealed so that water vapour, do
not enter into the space between the glass surfaces and get condensed reducing the
transmission of sunlight through the lid.
3.4.3 Raw Materials Required For Fabrication

G.I. sheet, Aluminium sheet, M.S. Channels, Glass, Mirror ,Asbestos fibre Sheet, Glass wool,
Caster wheel, Black board paint, Hinge, lock, Screws and other miscellaneous items.
Details of Machinery and Equipment Required For Fabrication
Hand saw, Hand shear, Portable drilling machine, Hammer, Screwdriver, Pliers, Measuring
tape Painting brush etc.
3.4.4 Standard testing procedure and quality control

Routine Test:
i) Inner box leakage test (by filling with water, then joints are examined)
ii) Cover gasket leakage test (By inserting pieces of papers in four positions in each
side of the cooker below the cover plate, after properly tightening the cover plate, the
paper pieces should exhibit a firm resistance at the time of withdrawal by hand)
iii) Leakage test of upper side of cover plate (by pouring a thin film water on the cover
plate and then by examining the cover plate for any sign of water entry between the
glass sheets)
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iv) Leakage test of lower side of cover plate (after boiling of water in cooking pots by
solar heating and then by keeping the cooker in shaded location to allow the vapour
to condense, there should be no sign of vapour entry between inner and outer glass
sheets of the cover plate)
V) Temperature test for paint on inner box, cooking tray and cooking pots at 160 degree
Celsius for one hour and temperature tests of cover gasket, cover glass and insulation
at 200 degree Celsius in electric oven. There should be no sign of damage or crack.
Degradation test
A minimum of 30 clear sunny days are required to complete the degradation test. The
cooker is kept in the sun with empty cooking pots inside and degradation, if any, of
various components is studied carefully. There should not be any degassing from any
insulating material, sealing gaskets, paints, etc. Collection of water vapours within the
space between the glasses of the lid, change in colour of the cooking pots, deposition of
water vapours or any other material on the glass lid on exposing the cooker to outside
atmospheric conditions in the sun is not allowed.
3.4.5 Maintenance and servicing of box solar cookers

• Maintenance required is an occasional coat of black paint on the inside of the cooker
and on the outer surfaces of the cooking pots.
• Replacement of gasket
• Replacement of glass and mirror
3.4.6 Customer education

A. Box solar cookers available in the market
Box solar cookers normally measure about 60 × 60 cm, and each are provided with four
pots. Smaller models are also available. An electrical heater to serve as a back-up during
non-sunshine hours is available in some models. These cookers can be procured from
manufacturers, suppliers, district and head offices of state agencies, as well as from ‘Aditya’
solar shops. National standards have been established for box type solar cookers by the BIS.
The cost of a box solar cooker varies from Rs 1200 to Rs 2500 depending on its size and
features. A normal-size box cooker is sufficient for a family of four or five members. It
has a life of 10–12 years. Its payback period is 2–3 years depending upon the extent of
use and place of use.
B. Cooking Time
Cooking time is normally about 2 to 2½ hours depending upon the kind of food and the
season of the year. It also depends on local conditions such as ambient temperature,
time of the day, latitude of the place, etc.
C. Cooking tips
Black pots work a lot better than silver pots. The pot needs to absorb as much light as
possible and silver tends to reflect the light. Dull or ‘matt’ finishes absorb more light than
‘shiny’ surfaces.

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Pots with close fitting lids keep the heat in and help the cooking process. Placing the
stove in a sheltered area stops the wind from cooling the outside of the pot
D. Trouble Shooting and Actions to be taken

Symptom Problem Action
Food not Black coating from the Paint the cooking box and
cooked even on cooking box and from pots pots with jet black paint or the
clear sunny day has faded or peeled off recommended paint.
Glass lid is broken Replace the broken glass lid
Mirror is broken or spoilt Replace the mirror or silver the
same mirror
Heat is leaking from the joints Find out the heat leakage points
and seal them
Dust has collected on the glass Clean the glass lid and mirror
lid and mirror
The absorber box has become Clean the absorber properly
dirty
Lid is being opened frequently Minimise opening the lid
Direction of the box is not Keeps the cooker always facing the
proper sun such that the reflected rays from
the mirror fall on to the cooking box
and cover its whole area.
3.5 Dish solar cooker
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3.5.1 Description
A dish solar cooker uses a parabolic dish to concentrate the incident solar radiation. This
solar cooker is commonly known as an ‘SK-14’ type of cooker, and is useful for homes
and small establishments.
3.5.2 Design
A typical dish solar cooker has a minimum aperture diameter of 1.4 m and a focal length
of 0.28 m. The paraboloid dish, made of single reflector, or by joining smaller pieces of
reflector, is fixed firmly to a rigid frame. Size and shape of the dish should be such that
when exposed to sun in the normal direction, a point focus would be formed.
The reflecting material used for fabrication of this cooker is anodized aluminium sheet,
which has a reflectivity of over 80%. The thickness of the Glass mirrors should be about
3 mm, with suitable protective layer on back to minimize degradation of the reflective
coating due to weathering.
The cooker has to track the sun and has to be adjusted manually after every 15–20 minutes.
The cooker can deliver power of about 0.6 kW, which can boil two to three litres of water in
half-an hour. The temperature achieved at the bottom of the vessel could reach 350–400
°C, which is sufficient for roasting, frying, and boiling. This cooker can meet the needs of
about 15 people, and can be used for eight to nine hours during the day.
3.5.3 Material required for fabrication:

Supporting Frame of the dish
Is made either of MS rings supported by MS strips, FRP material, or thick MS wire-mesh
structure. It should be rigid enough to resist any deformation of the dish shape due to wind
pressure or manual handling. The MS structure should have epoxy/anti-rust coating.
Stand for the dish

It is made of MS with epoxy/powder coating. It is equipped with an arrangement to hold
cooking pot of different sizes. It should have a suitable provision to secure the cooker to
the ground.
Tracking Mechanism
It is either manual or automatic, allowing unrestricted rotation of the dish along its
horizontal and vertical axes enabling its adjustment in the normal direction to the sun’s
rays. A provision of locking arrangement to hold/fix the dish at a desired position is
present. It is equipped with an arrangement (in the form of a vertical pointer) to enable
users to position the dish in a direction normal to the sun’s rays.
Cooking vessel (Optional)

For dish cooker of about 1.4 m diameter, a pressure cooker of 5 l capacity with ISI
mark is required. For larger sizes, proportionately higher capacity of pressure cooker

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is required. High temperature resistant black powder coating is given to the bottom of
the vessel.
Other requirements
• The entire structure should be able to withstand wind pressure up to a speed of 60
km per hour without damage.
• All parts/components should be weather resistant and able to withstand degradation
due to climatic conditions for a period of 15 years (except for reflecting mirrors which
may require replacement early).
• Accessories, like cap, hand gloves, goggles, manual for its installation and proper use,
and tool kit for installation are also supplied.
• The life of this cooker is estimated at about 20 years for the metallic structure.
3.5.4 Maintenance and servicing of dish solar cookers

• Maintenance required is an occasional coat of black paint on the outer surface of the
pressure cooker.
• Replacement of reflecting sheets once in 5 years
• Cleaning of the reflective panels on parabolic solar cookers should be done after
every use. All that is needed is a soft cloth and clean water to remove dust and spilled
food.
• The reflectors should never be scrubbed or cleaned with soap or an abrasive material
because that will dull the shine and reduce the temperature at which it cooks.
• Covers for parabolic solar cookers that are left outside at night will dramatically
extend their life span. They can be sewn locally.

A. Dish solar cookers available in the market
The cost of a dish solar cooker may vary from Rs 4300 to Rs 5000 depending on the type
of reflector and supporting structure. The dish solar cooker can save up to 10 liquefied
petroleum gas (LPG) cylinders per year upon full use at small establishments. Its payback
period ranges from 1.5 -2 years, depending on the extent of its use and the place of use.
B. Cooking Time
Cooking time is as low as ½ an hour for boiling water to about 2 to 2½ hours depending
upon the kind of food and the season of the year. It also depends on local conditions
such as ambient temperature, time of the day, latitude of the place, etc.
C. Cooking tips
Black pots work a lot better than silver pots. The pot needs to absorb as much light as
possible and silver tends to reflect the light. Dull or ‘matt’ finishes absorb more light than
‘shiny’ surfaces.
Pots with close fitting lids keep the heat in and help the cooking process. Placing the
stove in a sheltered area stops the wind from cooling the outside of the pot.
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3.6 Community Solar Cooker (for indoor cooking)
3.6.1 Description
Like the dish solar cooker, the community solar cooker too is a parabolic reflector cooker.
However, it is larger than the SK-14 type, and is known as a Scheffler cooker. Mr. Wolfgang
Scheffler developed the large size concentrator cooker. The unique feature of this cooker
is that it makes possible to cook using solar energy within the kitchen itself.
3.6.2 Design
The community solar cooker consists of solar concentrator with minimum 7.0 & 9.5 sq.m
aperture area, which is known as primary reflector. The shape of primary reflector is
elliptical dish shape. It is made up of multiple pieces of reflecting mirrors supported with
a rigid frame/ structure to from “Scheffler” reflector. A mechanical clock type tracking
arrangement is provided to keep the dish facing the Sun. A secondary reflector further
concentrates the rays on to the bottom of the pot/frying pan (painted black to absorb
maximum heat). The temperature attained is so high (up to 400 °C) that the food can be
cooked quickly. Thus, the community solar cooker works like a conventional cooking
device, with the difference that instead of using a conventional fuel like gas or firewood,
it uses solar energy inside the kitchen.
The dish is commonly known as “Scheffler” dish, which has been found to be useful
for generating heat to cook food for 50 to 75 persons in community kitchens especially
at religious places, hostels, ashramshalas, Govt. circuit houses and industrial canteens.
Two dishes can be installed for 100 to 150 persons cooking needs. The community solar
cooker is to be installed on proper civil structure and as per the actual requirements at
site. The secondary reflector is to be installed inside the kitchen for indoor cooking.
Due to the high temperature attained with this cooker, it is suitable for making almost all
traditional dishes, including chapattis, purees, dosas, etc. The cooker can also be used
to season (that is, ‘tadka’) dishes. When not in use for cooking, the cooker can be used to
heat/boil water.
The mechanical clockwork arrangement rotates the primary reflector outside to

automatically track the sun. The cook has to set this reflector in focus only once a day, in
the morning. By shifting two arms provided in the reflector frame, it is possible to change
the curvature of the parabolic reflector for seasonal adjustment, thus keeping it fully
tracked on to the sun during all seasons.
This Cooker is technologically far superior to the box-type community cooker, having
overcome a number of shortcomings of the box type cooker. The cooker is capable of
achieving temperature upto 250 0 C as against 100-125 0 C in box type cooker. This helps
cooking much faster. The conventional cooking arrangement within the kitchen does not
require to be changed and the cooking can be done inside the kitchen. Additionally roasting
& frying can be done with this cooker which is not possible in the box type solar cooker.

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3.6.3 Material required for fabrication
Frame & support structure
• Rigid enough to resist deformation of the dish shape due to wind pressure or manual
handling.
• Made of anodized aluminium/mild steel with epoxy/powder coating
Tracking mechanism
• Automatic, mechanical clock – work arrangement
• Designed for E-W tracking of the reflector along its polar axis to align it in the direction
normal to the sun’s rays.
• Having a provision for seasonal adjustment manually for the tilt angle.
Secondary Reflector
• Bright anodized aluminium sheet with minimum reflectivity of 80% fixed on a curved
metallic structure.
• Size & curvature of the structure is such that the reflected rays get focused on to the
bottom of the cooking pot of about 300 mm diameter.
Other Requirements
• The entire structure should be able to withstand wind pressure up to a speed of 60
km per hour without any damage.
• All parts/components should be weather resistant and able to withstand degradation
due to climatic conditions for a period of 15 years (except for reflecting mirrors which
may require replacement early).
The cooker is installed and commissioned at the site by the supplier.
3.6.4 How it Works?
System Construction
Solar Concentrating Disc (Primary Reflector) – Part A
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The Community Solar Cooker (Rotating Disc Type) works on the principle of solar energy
concentration using a Reflecting Parabolic Solar Concentrator. A 7-squaremeter area
parabolic solar concentrator is used for concentrating solar radiation on a focal area
where the cooking vessel (Part D) is placed.
Automatic Tracking System – Part B

With the help of a simple automatic mechanical tracking system the solar disc rotates in
the direction of the movement of the Sun to give continuous and accurate solar energy
concentration. This mechanical device is made up of a simple clock mechanism with
chain & gear arrangement to provide regulated tracking motion to follow the path of
the sun through out the day – from dawn to dusk and gives daily about 6 – 8 hours of
operation time.
Secondary Reflector – Part C

This opening is provided in the north-facing wall of the kitchen or the cooking place just
below the cooking vessel. This reflector receives the concentrated solar radiation and
reflects it on to the bottom of the cooking vessel as shown in the figure above.
Cooking Area – Part D

This is where the cooking vessel is kept
Installation and Working of a Community Solar Cooker

The Solar Cooker is installed in the open shadow-free area or on terrace tops facing the
South. The reflection of the disc falls on a secondary reflector housed in an opening in
the North kitchen wall. The secondary reflector further reflects the radiation on to the
cooking vessel place above in the kitchen.

A. Community solar cookers available in the market
The cost of this solar cooker is about Rs. 50,000. The payback period is 4-5 years.
B. Cooking Time
Cooking for about 40-50 persons is possible. One dish may take about 60-90 minutes.
C. Maintenance and caring for your solar stove.

When not in use, keep the stove in the dry. To store the unit in winter, remove the grill and
grill support and turn upside down. A dirty reflector will slow down the cooking times.
Clean the reflector with a dry cloth or ‘alcohol’ if available.

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Unit 4. Solar Water Heaters (SWH)
Learning Outcome
• develop an understanding of construction and working of different solar
water heaters
• develop skills in installing, maintaining and repairing solar water heaters
Methodology: Lecture , AV Material, Practicals
Time: Theory – 3 hours
Practicals: 6 hours
4.1 Solar Water Heating Systems

A Solar Water Heating System is a device that uses solar energy to heat water for domestic,
commercial, and industrial needs. Heating of water is the most common application of
solar energy in the world. A typical solar water heating system can save up to 1500 units
of electricity every year, for every 100 litres per day of solar water heating capacity.
4.1.1 Basic Working Principle

The basic principle of a solar hot water heater is that the water passes through a solar
collector or solar panels that heat the water. The solar collectors or panels are in direct
contact with the sun and this energy is used to heat the water. The water then passes to
an insulated storage tank that conserves the heated water for later usage.
There are two variations on this principle: active and passive systems. The active system
uses a pump to move the water from the collectors or panels to the storage tank. The passive
system has no power source to move the water but moves the water through gravity.
4.2 Advantages and limitations

Advantages of SWH
• It does not require extra space as they can be mounted on roof tops, windows, etc.
• It is easy to install, operate and maintain
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• SWH of capacity up to 2500 litres per day (LPD) do not require circulating pump
• The initial investment although on the higher side is fully recovered through
savings in the recurring fuel costs. A solar water heater pays back its cost in
3–4 years.
• Hot water is available 24 hours a day depending on the use and system capacity.
• SWHs last a long time (15–20 years) and require only simple maintenance.
• SWH is a pollution free system
Limitations of SWH
• The water may not heat enough on an overcast day
4.3 Details of Solar Water Heaters
4.3.1 Description
Solar water heaters based on Flat plate Collectors
Here the solar radiation is absorbed by flat plate collectors which consist of an insulated
outer metallic box covered on the top with glass sheet. Inside there are blackened
metallic absorber (selectively coated) sheets with built in channels or riser tubes to
carry water. The absorber absorbs the solar radiation and transfers the heat to the
flowing water.
Figure: Flat Plate Collector based Solar Water Heaters

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4.3.2 Design
A solar water heating system consists of (1) flat plate solar collector, (2) insulated storage
tank kept at a height behind the collector, (3) insulated hot water carrying pipes and
(4) cold water carrying pipes. The system is generally installed on the roof or on open
ground, with the collector facing the sun and connected to a continuous water supply.
The flat plate collector comprises (1) front glass glazing (2) blackened metallic (copper)
absorber sheet with built-in channels or riser tubes welded to it to carry water. The entire
assembly is placed in a flat metallic box. In certain models, evacuated glass tubes are used
instead of copper; a separate cover sheet and insulating box are not required in this case.
Water flows through the tubes, absorbs solar heat, and is stored in a tank. The hot water
so stored can be used for various applications at homes, such as bathing, cleaning, and
washing. It can also be used for a variety of industrial applications. The water stored in
the tank remains hot overnight as the storage tank is insulated and heat losses are small.
Flat-plate solar collectors are manufactured in India; however, the tubes for evacuated
tube collectors are imported. So far, about 10 Lakh square metres of collector area has
been installed in the country.
4.4 Evacuated Tube Collector (ETC) based solar water heater

Here the collector is made of double layer borosilicate glass tubes evacuated for providing
insulation. The outer wall of the inner tube is coated with selective absorbing material.
This helps absorption of solar radiation and transfers the heat to the water which flows
through the inner tube.
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4.5 Domestic solar water heating system
Most domestic solar water heaters are provided with electrical back-up. Electrical heating
elements are usually placed in the storage tank and can be switched on during cloudy
days. In some cases, the solar-heated water is led into an existing electric geyser; the
geyser needs to be switched on only in cloudy conditions. Most domestic systems are in
the capacity range of 100– 500 litres of hot water per day.
Solar water heating systems are classified in 2 types based on the circulation of water.
a) Thermosyphon system.
b) Forced flow or forced circulation system.
4.5.1 Thermosyphon system

In the Thermosyphon system, water comes from the over head tank to bottom of solar
collector by natural circulation and water circulates from the collector to storage tank
as long as the absorber keeps absorbing heat from the sun and water gets heated in
the collector. The cold water at the bottom of storage tank runs into the collector and
replaces the hot water, which is then forced inside the insulated hot water storage tank.
The process of the circulation stops when there is no solar radiation on the collector.
Thermosyphon system is simple and requires less maintenance due to absence of
controls and instrumentation. Never use a Thermosyphon system for a large set-up.

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Thermosyphon Systems
Source: www.homepower.com
4.5.2 Forced circulation system:

In the forced flow system, a pump is used for circulating water between the collectors
and the insulated hot water storage tank. The forced flow systems are more efficient as
compared to Thermosyphon systems due to higher flow rate. Generally, the pumps are
operated by differential temperature control (DTC) system, which senses the pre-setting
temperature difference between inlet and outlet of the collectors.
A) Natural Thermo Siphon (NTS):

This is the simplest way of operating a SWHS and hence is popular. Hot water becomes
lighter and has a tendency to rise. The cold and hence heavier water at the bottom of the
solar flat plate collector pushes the hot water up; it gets collected in the hot water storage
tank. The cold water due to gravity fills up the vacuum created by the hot water pushed
up. This cycle continues till adequate heat from the sun is available during the day.
Advantages of this system are:

• Cost effective
• Self operating - no attendance required
• No need to have power for operation / No sophisticated instruments
• No moving parts hence no wear & tear / maintenance
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Limitations / Disadvantages:
• Limitation of the size / capacity of system. Beyond 2000LPD, the flow becomes
sluggish and efficiency is reduced
• Rigid rules for the system construction. e.g. Overhead cold-water tank having
minimum head, hot water tank to be above the panels only etc
• Cold water is mixed in the hot water every time the hot water is drawn. This results in
less output than the capacity.
B) Fixed Temperature Forced Circulation (FTFC) System:

In this, the hot water from the panels / collectors is pumped to the storage tank, on
reaching the preset temperature only. The pump operation is automatic. When the hot
water is pumped, the cold water pumped in fills the vacuum. The pump automatically
stops on sensing the temperature at the outlet sensor point being lower than the preset
value. This way the system operates during the day.

• No limit on the size of the system
• Flexibility in system installation
• Guaranteed system output
• Better efficiency
• Reduced cost of superstructure / separate overhead tank
• Needs continuous electricity for system operation
• The electronic controls may require periodical maintenance
Differential Temperature Forced Circulation (DTFC) System:

This system works on the principle of Differential Temperature. Whenever the
difference between the temperature at the collector array outlet and the tank bottom
is higher than the preset value, the pump circulates the water imparting the heat from
the collectors ton the water in the tank. This way the total system capacity is heated
through out the day. The pump stops automatically once the temperature difference is
within the preset value.

• No limit on the size of the system
• Flexibility in system installation
• Guaranteed system output
• Better efficiency
• Needs continuous electricity for system operation, which can be connected through
generator back up / inverter
• The electronic controls may require periodical maintenance

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4.6 Site selection
Site conditions are important. Collectors should face directly south. Turning a collector
southeast or southwest can affect its performance by about 20% or more. If hot water is
needed by noon, face the collector to the southeast; if hot water is more important in late
afternoon, face the collector to the southwest.
The site should be free from shade. Collectors should be placed so that they can be tilted
from the horizon to an angle equal to the latitude of the location. For better output in
winter the angle of inclination should be latitude + 15 degree. If the latitude is unknown,
the collector can be placed at a 45[degrees] angle, except in areas near the equator). The
latitude for your area can be obtained from an atlas or globe.
4.7 Procedure for Operation and Maintenance

Before starting the system, do the following:
1. Check water in the cold water supply line and also storage tank. In case there is
no water, fill the tank with water. The system should never be operated if water is
not available. Without water the pump will be damaged. A thermosiphonic system
will not deliver hot water at the point of use if there is no continuous supply of cold
water.
2. Check the collector glazing. It should not be dirty. In case dirt is deposited on the
glazing it should be cleaned.
3. Open all the control valves as suggested by the supplier
4. Check electrical supply.
5. Check the water pump. It should not be jammed.
6. Check whether the Non Return Valve (NRV) on the cold water inlet side is working.
7. Ensure the lever of mixer in the bathroom is on either left or right side AND NOT IN
THE MIDDLE to avoid mixing of hot / cold water.
4.8 Operation of the Solar Water Heater
1. After ascertaining that the requirements indicated above are fulfilled, start the
circulating pump. The water will start circulating in the collector system and after
getting heated will be collected in the storage tank. The temperature of water in the
storage tank will rise which can be seen in the temperature indicators provided in
the system. There is a possibility of air locking in collector riser tubes and headers
which can be released by increasing the flow of water by opening control valves. As
soon as the control valves are opened beyond the limits suggested, water will start
coming out from the air vents. Keep the valves in this position for some time and
then bring them to their original position or as soon as water stops coming out of
the air vents.
2. In a thermosiphonic system hot water will start collecting in the storage tank as soon
as sunlight falls on the collector and water is available in the system.
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4.9 Maintenance of the SWH
i. Remember to keep the collector at a 45[degrees] angle if the latitude of your area is
unknown.
ii. The hot water will rise to the top of the tank. When all of the water is to be used, it
can be drained from the faucet; when only a small amount of water is needed, the
hottest water can be taken from the top of the tank.
iii. Whenever water is being heated, the water level should be kept above the tank’s
upper hose connector to allow the water to circulate or the Thermosyphon system
will not work.
iv. Lubricate the motor periodically to avoid any damage due to high friction.
v. Protect the pump from exposure to dirt and rain.
vi. The water heater works best when the connecting hoses are as short as possible.
vii. Rubber hoses may have to be replaced every two or three years. If metal other than
galvanized sheet metal is used, such as untreated sheet metal, the lifespan of the
system will be shortened considerably due to rust. Once the collector starts to rust,
it must be replaced.
viii. Untreated sheet metal can be painted with several coats of rustproof paint if it can
be obtained. However, you should check the painted area in six months to make sure
it is not peeling off. It is also helpful to wrap the tank in insulation materials.
ix. Clean the glass once a month for best results. And if you live in a hard water area,
descaling process once every year is recommended. Scaling is the build up of mineral
deposits in the pipes. Deposition of hard scales in the absorber tubes of flat plate
collectors is a serious problem. It not only reduces the efficiency of operation, but may
eventually prevent heat absorption totally. By flushing the system out periodically
scaling can be prevented (only if water is hard). Titanium micro technology coating
prevents formation of rust and scales in the piping.
x. To begin using the solar water heater, make certain the tank is 46cm above the top of
the collector. Fill the tank with clean water. Check for leaks.
xi. Use cross-linked polyethylene composite pipes, as it is a non-stick material and also
has very low thermal conductivity minimising heat loss.
4.10 Customer education

A. SWH available in the market
SWH is available from minimum 100 LPD (Litre per day) Capacity for both domestic
and commercial application. It can deliver hot water at 60 degree Celsius for domestic
application and 80 degree Celsius for commercial application.
It is available in the multiples of 100 litres in the market. For 100 LPD (Litre per day)
Capacity Solar Water Heating System, we need 1 no. of Solar Collector of 2 sq. metre area.
It requires 4 sq. metre shadow free area for installation on the roof.
B. Cost
The smallest solar water heater available has a capacity of 100 litres per day, which is

32
sufficient for a family of four or five members. It costs Rs 15 000 to Rs 18 000, and can save
about 1500 units of electricity per year.
C. Standards
National standards for flat-plate collectors have been laid down by the BIS (IS 12933:
1992) to ensure minimum quality and performance of the systems. The standards include
specifications of components of collectors such as cover, absorber, insulation, box, and
sealant1.
4.11 BIS Standards:

This is used for the types and materials of constructions. Test procedures for solar flat
plate collector- please refer BIS 12933-2003. The BIS standard can be purchased from
any Bureau of India Standards office. The standards shall be supported by Scheme of
Inspection and Testing (SIT) to plan and do the product testing.
4.12 Manufacturing of components of Solar Water Heater:

1) Solar Flat Plate Collector: The collector assembly involves the following activities-
a) Making the outer frame by cutting the Aluminium extruded sections to required
length and chamfer for frame making. Making the slots for fixing of the rubber
grommets and header pipe. Joining the 4 sections to make the frame.
b) Cutting the back sheet to required size. Fixing the back sheet to the frame by pop
up rivets.
c) Cutting of the copper header pipes to required length. Drilling of holes for brazing
of the fin tubes.
1
A sealant is a viscous material that changes state to become solid, once applied, and is used to prevent the
penetration of air, gas, noise, dust, fire, smoke or liquid from one location through a barrier into another.
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d) Flaring of the header ends after inserting the flanges for connection.
e) Brazing of fin tubes with the headers with control on the tube penetration.
f) Leak test of the absorber assembly as prescribed by BIS.
g) Placing of insulation pads and Aluminium foil in the collector box.
h) Placing the absorber assembly in the box, sealing the joints with silicon sealant.
i) Fixing the top glass cover with rubber beading, retainer angle with screws and
silicon sealant.
j) Testing as per the BIS guidelines, fixing of BIS number plate.
Precautions to be taken: Following precautions should be taken during manufacturing

and testing:
1) Raw material / component quality checks should be carried out.
2) The dimensional tolerance in the frame size should be followed strictly to avoid
breakage of glass while fixing.
3) The collector box should be air / water tight to avoid entry of water / moisture at
site.
4) No stress should develop on the glass after fixing to avoid breakage.
5) Each fin-tube assembly must be leak tested before brazing and also after the brazing
the absorber assembly should be tested @ the rated pressure.
6) Flanges should be flared to allow adjustment at site while connecting the number of
collectors without stress.
7) Finished collectors should always be stored in vertical position and not in flat
position.
2) Hot water storage tank: The hot water storage tank can be made of Mild Steel,
Galvanised Iron or Stainless Steel.
Following are the activities involved in manufacturing of the solar hot water storage
tank.
a) Cutting of sheet to required size and rolling to form the cylinder.
b) Welding the shell by ARC (Electric welding in case of M.S. or G.I.), TIG 9Tungsten
Inert Gas welding for S.S.) or MIG (Metal Inert Gas for M.S., G.I and also for S.S.)
process as applicable.
c) Welding of side dish ends/ conical ends.
d) Welding of connections.
e) Hydraulic test of tank to check leakage as well as suitability to designed system
pressure.
f) Insulation and cladding.
Precaution to be taken: Following precautions should be taken during manufacturing

and testing:
1) Raw material quality needs to be checked.
2) The tank dimensions should be decided to ensure minimum surface area / material
weight and also wastage.

34
3) Proper care should be taken while welding to minimise the heat affected zone /
damage to the parent material.
4) Leak test should be carried @ 1.5 times the operating pressure held for 30 minutes.
5) Insulation should be carried out after the leak test only.
6) Proper anti-rust coating should be provided for non S.S tanks with access for future
maintenance.
3) Stands for collector and tank: This involves fabrication activity for the stand /
supports for the collector and tank. We have to get the stands / supports designed
to ensure that the same is suitable for the load and site conditions. The fabricated
structure needs to be protected by either applying a primer coat followed by two
coats of paint or by Hot Dip Galvanising. The stands / supports should be suitable for
transport with final assembly at site.
Precaution to be taken: Following precautions should be taken during manufacturing

and testing:
1) The stand support shall be balanced and steady to avoid stress on the tank after filling
of water.
2) The materiel should be chosen after taking into consideration the corrosion
allowance.
3) The tank should have complete resting on the stand along the circumference.
4) Base plates should be provided for anchoring at site.
5) The collector stand should have a provision for height / angle adjustment to suit site
conditions.
6) The welding has to be complete, cleaned without any sharp edges and not just tack /
spot-welded.
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Unit 5. Practicals
5.1 Engineering drawings:

Blue line: HOT WATER
Yellow Line: COLD WATER
Here is a typical drawing of a solar water heating system.

36
5.2 Cross sections of solar water heater (SWH):
1) Hot water to use

2) Tank
3) Hot water to the Tank
4) Collector
5) Cold water Inlet
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5.3 Installation Layouts:
5.3.1 1500lpd Solar Water Heating System (SWHS) Layout at 60OC

38
5.3.2 1500lpd SWHS layout 70OC:
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5.3.3 3000lpd SWHS layout:

40
5.4 Calculations:
Variation in velocity with pressure difference:
P1-P2 = ½ rho (V22 - V12)
So if P1 = 1 bar
P2 = 2 bar
And V1= 0.5m/s
So, V2=0.248m/s
This shows variation in flow with variation of pressure.
So, Let us assume the diameter of the outlet pipe be 1inch.
Pressure(bar) 1 2 3 4
Velocity(m/s) 0.5 0.498 0..495 0.492
Flow(Litres) 0.00988 0.00984 0.00978 0.009723
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Annexure
List of Box Type Solar Cookers
a) BIS Certified Solar Cookers

Sl. No. Name & Address of Manufacturer Contact Details
1. M/S Universal Engineers Enterprises 0591-2493619
Garg Bhavan, Prince Road (Telefax) : 0591-2499768
Gandhi Nagar, Moradabad (U.P.)
2. M/s Rural Engineering School , Tel : 02847 294127
Rojmal, Tal.: Gadhada (SN) Fax: 02847 253535
District Bhavnagar-364750, Gujarat e-mail: ruralschool@rediffmail.com
3. Khadi Gramodhyog Prayog Samiti Telefax: 079-27552469
Gandhi Ashram, Mobile : 9825484275, 9879784255
Ahmedabad-380 027
4. Sayala Taluka Khadi Gramodyog Seva Ph.: 0281-2477226
Mandal, Motiram Building , Below Mobile : 09825074591
SBS Service Branch, Phulchhab e-mail:saylatalukakhadigs.
Chowk, Rajkot 360 001 mandal@yahoo.co.in
b) Other Known Manufacturers

Sl. No. Name & Address of Manufacturer Contact Details
1. M/S J. N Enterprises, Mobile : 2350859119
F-12, Navin Shahdara, Delhi.
2. M/s. Vishvakarma Solar Energy Co. 01826-22523
G.T. Road , Phillour, Distt. 01826-22217
Jallandhar, Punjab
3. M/s Fair Fabricators Telefax: 0731-2491488
142, Tilak Nagar , Near Post Office, Mobile : 9425316707
Indore- 452 018 fairfabricators@hotmail.com.
4. M/s Rohtas Electronics, Ph. : 0512-2305564
15/268-B, Civil lines, Telefax : 0512-2305390
Kanpur - 208001. E-mail : rohitas@vsnl.net
5. M/s Rural Engineering School , Tel : 02847 294127
Rojmal, Tal.: Gadhada (SN) Fax: 02847 253535
District Bhavnagar-364750, Gujarat e-mail: ruralschool@rediffmail.com

42
6. M/S Usha Engineering Works Ph.: 04174-73613
40-A,Trunk Road, Madanur-635804 e-mail: solltechnew@yahoo.co.in
Vellore District, Tamil Nadu
7. M/S Geetanjali Solar Enterprises 033-24420773/24424027
P/14, Kasba Industrial Estate, ( Fax ) 033-24420773
Phase-I, E.M. Bye Pass, e-mail : gse@cal.vsnl.net.in.
PO East Kolkata Township,
Kolkata-700107
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Solar Thermal Systems Module

Ministry of New and Renewable Energy

Ministry of New and Renewable Energy

Unit 1. Introduction to Solar Energy 5

Unit 2. Solar Thermal Energy 9

Unit 3. Solar Cookers 14

Trainers textbook for

1.1 Solar energy

1.2 The need to use solar energy

1.3 Basic principle

Solar energy can be converted to electricity in two ways:

1.4 Factors to consider for using solar energy

Trainers textbook for

1.5 Measuring solar energy

1.6 Applications of solar energy

Trainers textbook for

2.1 Solar collectors

2.2 Working principle of a solar collector

2.3.1 Understanding heat movement

There are three basic physical ways that heat moves:

Trainers textbook for

Darker-coloured objects absorb more visible radiation, whereas lighter-colored objects

2.4 Solar thermal energy applications

2.4.1 Water heating

2.4.2 Solar cooking

2.4.3 Solar drying

2.4.4 Desalination / Distillation

2.4.5 Solar Pasteurisation

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2.4.6 Solar thermal energy in architecture

Methodology: Lecture, AV Material, Practicals

Time: Theory – 2 hours

3.1 Solar cooker

3.2 Basic principles of solar cooking

3.3 Advantages and limitations of using a solar cooker

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Limitations of using a solar cooker:

3.4 Box solar cooker

The important parts of a box solar cooker are described below:

(Source: Solar Energy Centre, Faridabad, India)

b.) The Inner Cooking Box/Tray

c.) Thermal Insulation

d.) The Double Glass Lid

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f.) Cooking pots

g.) Side window

3.4.2 Precautions to take

3.4.3 Raw Materials Required For Fabrication

Details of Machinery and Equipment Required For Fabrication

3.4.4 Standard testing procedure and quality control

3.4.5 Maintenance and servicing of box solar cookers

3.4.6 Customer education

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D. Trouble Shooting and Actions to be taken

3.5 Dish solar cooker

3.5.3 Material required for fabrication:

Stand for the dish

Cooking vessel (Optional)

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3.5.4 Maintenance and servicing of dish solar cookers

3.5.5 Customer education

The mechanical clockwork arrangement rotates the primary reﬂector outside to

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