Thermal Solar Fill and Flush Tips

[David Coley]

Thermal Solar

I have installed the above in my 3 bed simi
with22mm pipe and an E and WEst panels into a cylinder with solar h/E and boiler H/e above .
Is there and DIY way ( am not a proffesional) of filling and flushing , without buying and expensive fll and flush station please ?

I used a SEcon Solatr Triple Line System.

 

[centralheatking]

Thermal Solar

I have installed the above in my 3 bed simi
with22mm pipe and an E and WEst panels into a cylinder with solar h/E and boiler H/e above .
Is there and DIY way ( am not a proffesional) of filling and flushing , without buying and expensive fll and flush station please ?

I used a SEcon Solatr Triple Line System.

I like it when someone steps out and has a go themself...if you post a diagram ...and some piccys (that will be ace) then we can give you more info...I read somewhere you can hire the nec. chking

 

[David Coley]

I like it when someone steps out and has a go themself...if you post a diagram ...and some piccys (that will be ace) then we can give you more info...I read somewhere you can hire the nec. chking

I like it when someone steps out and has a go themself...if you post a diagram ...and some piccys (that will be ace) then we can give you more info...I read somewhere you can hire the nec. chking

Thanks for your kind encouragement .My computer skills for attaching photos are poor so it will take some time but I will send them. I intended to pour in the Glycol through the fill hose and pressurise with bike pump then set the pumps in the system going , and bleed them from time to time but since these are at the bottom of the systen migh fit an extra fill pint in the loft .Does this sound ok . Pictures coming in a few days
Regards


David


David

 

[centralheatking]

My expertise in this area is that I designed a solar thermal collection system for others and I am now non exec, dir of this solar thermal start up. However my experience of commissioning a system is limited to a laboratory rig and test roof outside. I hope others might be able to assist you as well. A diagram would assist. centralheatking

 

[Brambles]

David,

You don’t need an expensive or specialist pump - but you do need a pump capable of filling and pressurising the system. Ebay or Machine Mart are good sources for cheap single use pumps.

First recheck the hydraulic configuration of the circuit to ensure that you have the correct flow rates and no gravity circulation (unless designed to be so).

Ideally you need to know the system volume - it takes the guess work out of mixing and filling.

In the winter I pressure test the circuit with air at 0.5bar for 15mins to ensure that the circuit is tight. It does not work in the summer - the air expands too quickly.

Charge and check the airside of the expansion vessel to the correct pressure ( use a compressor or bicycle pump.

You need a decent pump two large buckets and three hoses (washing machine type) to flush and fill the water/ glycol side of the circuit. The system needs to have a pressure gauge readable from the pump point.

Connect flow, return and the pump to the permanent pump station. Connect the third pipe to the flush drain point.

Flush the system at least twice with a 10 percent glycol (don't use car antifreeze). There is always a risk of freezing any dead legs if you flush with just water in winter.

After flushing, fill with the correct mix and pressurise to the correct level to suit the expansion vessel with the pump.

Do not try to pressurise the water/glycol side with an air pump.

Do not try to use the permanent pumps to fill and pressurise the water /glycol side.

Close valves, check for leaks and commission the permanent pump(s)

Be aware that the Secon Triple line will only operate with the Secon controller ( an MRW I think) - unless the design has changed.

 

[David Coley]

My expertise in this area is that I designed a solar thermal collection system for others and I am now non exec, dir of this solar thermal start up. However my experience of commissioning a system is limited to a laboratory rig and test roof outside. I hope others might be able to assist you as well. A diagram would assist. centralheatking

Many thanks , I am working on it . I had some photos on sd card of the old system I replaced but think I deleted before copyihg to computer .Will take new ines iof current system today .

Regards

David

 

[David Coley]

David,

You don’t need an expensive or specialist pump - but you do need a pump capable of filling and pressurising the system. Ebay or Machine Mart are good sources for cheap single use pumps.

First recheck the hydraulic configuration of the circuit to ensure that you have the correct flow rates and no gravity circulation (unless designed to be so).

Ideally you need to know the system volume - it takes the guess work out of mixing and filling.

In the winter I pressure test the circuit with air at 0.5bar for 15mins to ensure that the circuit is tight. It does not work in the summer - the air expands too quickly.

Charge and check the airside of the expansion vessel to the correct pressure ( use a compressor or bicycle pump.

You need a decent pump two large buckets and three hoses (washing machine type) to flush and fill the water/ glycol side of the circuit. The system needs to have a pressure gauge readable from the pump point.

Connect flow, return and the pump to the permanent pump station. Connect the third pipe to the flush drain point.

Flush the system at least twice with a 10 percent glycol (don't use car antifreeze). There is always a risk of freezing any dead legs if you flush with just water in winter.

After flushing, fill with the correct mix and pressurise to the correct level to suit the expansion vessel with the pump.

Do not try to pressurise the water/glycol side with an air pump.

Do not try to use the permanent pumps to fill and pressurise the water /glycol side.

Close valves, check for leaks and commission the permanent pump(s)

Be aware that the Secon Triple line will only operate with the Secon controller ( an MRW I think) - unless the design has changed.

David,

You don’t need an expensive or specialist pump - but you do need a pump capable of filling and pressurising the system. Ebay or Machine Mart are good sources for cheap single use pumps.

First recheck the hydraulic configuration of the circuit to ensure that you have the correct flow rates and no gravity circulation (unless designed to be so).

Ideally you need to know the system volume - it takes the guess work out of mixing and filling.

In the winter I pressure test the circuit with air at 0.5bar for 15mins to ensure that the circuit is tight. It does not work in the summer - the air expands too quickly.

Charge and check the airside of the expansion vessel to the correct pressure ( use a compressor or bicycle pump.

You need a decent pump two large buckets and three hoses (washing machine type) to flush and fill the water/ glycol side of the circuit. The system needs to have a pressure gauge readable from the pump point.

Connect flow, return and the pump to the permanent pump station. Connect the third pipe to the flush drain point.

Flush the system at least twice with a 10 percent glycol (don't use car antifreeze). There is always a risk of freezing any dead legs if you flush with just water in winter.

After flushing, fill with the correct mix and pressurise to the correct level to suit the expansion vessel with the pump.

Do not try to pressurise the water/glycol side with an air pump.

Do not try to use the permanent pumps to fill and pressurise the water /glycol side.

Close valves, check for leaks and commission the permanent pump(s)

Be aware that the Secon Triple line will only operate with the Secon controller ( an MRW I think) - unless the design has changed.

Dear Brambles Here is the schemaic diagranm for my t system. I am trying tio send ophotios but the attachment system here cannot find the 4 I have upoloaded for you but , the plumbimng is all done with separatye pipes for east and west as per shematic diag attached . However my expansion tank is in the loft where it was in the bad system I replaced but the Secon system has it by the cylinder in the bedroom where the whole module pumps , cotroller and sight glasses , temp guages and vent valves and flush and fil valves are ,. But the ty say I can have ithe expandsuion tank any where but I think I need to put the PRV valve in line with it because it is on the contol board in the cylinder cupboard at present and wioould vent into the cupboard if it hit the pressure reliefe value so I must alter that .

Thanks for the advice of flushing with 10% glycol. I was going top use just water . I think I can borroew a pump from church which pumps out our baptistry .

Hope the diagram helps to give you a picture

 

[Brambles]

If your hot water cylinder is unvented, there are two separate systems that are under pressure and require their own pressure relief valves:

The cylinder is ( if unvented ) needs to be installed and configured by a G3 qualified engineer. The G3 regulations specify the configuration of the safety relief valves for the domestic hot water side.

The glycol side. If you have more than one glycol side PRV, all need to be correctly plumbed in. You cannot second guess which one will vent if the system over pressurises.