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Workbench Creations is the place for conversation and discussion about do-it-yourself (DIY) projects. This DIY blog will feature projects completed by its owner as well as projects completed by other do-it-yourselfers. Workbench Creations is the place where DIYers can discuss ideas, learn about what others have done, and share their expertise.

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Solar Hot water Update

Posted September 07, 2011 5:05 PM by user-deleted-1105

I first did my solar hot water system in Feb 2008. The water in the solar panels was common to the central heating water and I had to shut off and drain the panels every winter.
My upgrade is to add a second coil to my hot water cylinder. The solar heating will then have it's own header tank and can be filled with antifreeze and it will be completely isolated from the central heating hot water.
It will be able to run all year and will be more efficient as it will be heating the water lower in the tank and not competing with the gas boiler.
Luckily my hot water cylinder has an inspection plate near the bottom and with a lot of sound advice from the CR4 crew, (they dissuaded me from using cheapskate plastic fittings) I made myself a coil and installed it in a few hours (While Mrs Cat was out).


Total cost about £40, whereas a new twin coil cylinder would have cost about £300.
I can complete the plumbing at my leisure now without much disturbance to the hot water supply.
When I removed the inspection plate I was surprised to recognise the gasket material, which was still sound. Last time I'd removed the plate, I'd made a new gasket from a piece of old Wellington boot!
The connectors are 10mm compression to 1/2" BSP fittings reamed out to allow the tube to pass right through. The plate is nice thick brass which allowed me to tap it to take the fittings. Rubber wellington boot washers and a smear of silicone sealant finished the job.
In the final shot the cylinder has been refilled and there are no leaks.

My top tip for bending the coil is to crimp one end, fill the pipe completely with fine, dry sand (sold as block paving sand) and then crimp the other end. It was then bent mostly by hand by wrapping it round a bit of plastic drain pipe. A pipe bender was used for the start and finish.

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#1

Re: Solar Hot water Update

09/07/2011 8:24 PM

Awesome, Del!

I might try that since we get lots of sun here.

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#2

Re: Solar Hot water Update

09/07/2011 11:38 PM

Nice post and excellent work!

Good to see you keeping your hand in, Del

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#3
In reply to #2

Re: Solar Hot water Update

09/08/2011 2:56 AM

Cheers, ...like the retired bra designer who liked to keep his hand in?
Del

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#5
In reply to #3

Re: Solar Hot water Update

09/08/2011 3:31 AM

Hi Del,

The old adage "If it looks right" seems to to apply here. A really neat job.

Best regards,

John

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#4

Re: Solar Hot water Update

09/08/2011 3:30 AM

At least the tank was large enough to fit that nice coil straight in. I was envisioning having to turn the coil 90° and weasel it in past/around/through the preexisting coil.

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#6
In reply to #4

Re: Solar Hot water Update

09/08/2011 3:59 AM

Yeah the existing coil is a couple of inches above the top of the hole, so it was pretty much a straight in job. I had to squirrel weasel it around the door jamb a tad.
Actually, this morning there was about a teaspoon of water beneath the plate, I've wide it away, if it comes back I'll go round the bolts again. But I don't want to risk overtightening 'em as they are brass.
Del

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#7

Re: Solar Hot water Update

09/08/2011 5:31 AM

Proper job. Well done, Del.

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#14
In reply to #7

Re: Solar Hot water Update

09/09/2011 7:18 AM

Well done Del, this has made me try to do my own heating panel, before the winter comes.

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#8

Re: Solar Hot water Update

09/08/2011 10:38 AM

Very nice design, very nice work!

Occasional progress photos of the (future) piping would be great!

Regards - KJK

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#10
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Re: Solar Hot water Update

09/08/2011 11:47 AM

Occasional progress photos of the (future) piping would be great!

Fear not a big softy show of like me will be doing just that prrrrr prrrr
Del

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#9

Re: Solar Hot water Update

09/08/2011 11:34 AM

Have a "Like", young man.

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#15
In reply to #9

Re: Solar Hot water Update

09/09/2011 7:25 AM

Ooooh, I like the like.
Del

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#11

Re: Solar Hot water Update

09/08/2011 10:32 PM

Del, what a nice job, and thanks so much for hanging out here to show us your work. Don't forget to put a pressure relief valve in the coolant circuit, as it will no longer be able to get emergency pressure relief through the potable water PRV.

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#13
In reply to #11

Re: Solar Hot water Update

09/09/2011 2:18 AM

The coolant circuit will be open to the atmosphere in a small header tank in the loft.
It's all done the weird old fashioned UK way.
The only circuit under any real pressure is the cold water mains feed which gows to domestic cold water, the ball valves in the header tanks (and mrs Cat's secret electric shower room...the shower room even has a mirror with lights around it ...I deren't go in there as my reflection is too awful)

I'm going to fit a new efficient gas boiler next year, but I'm keeping the same low pressure system.
There are pros and cons, but I think modern systems with DHW and CH under mains water pressure are asking for trouble if there is a leak. Less plumbing but harder to fix it yourself (IMO)
Del

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#12

Re: Solar Hot water Update

09/09/2011 2:09 AM

Now we need some data!

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#16

Re: Solar Hot water Update

09/12/2011 11:02 AM

Nice Job!

Thanks for sharing.

Appreciate the bending tips using sand.

Milo

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Users who posted comments:

Anonymous Hero (1); edignan (2); jesw55 (1); JohnDG (1); KJK/USA (1); Milo (1); PFR (1); PWSlack (1); Tornado (1); user-deleted-1105 (5); xanasax (1)

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