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Author Topic: New System - Solar, WBS, Thermal Store & CH  (Read 1773 times)
feeta
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« on: January 07, 2011, 08:06:46 PM »

Hi everyone!

Well finally, over a year since planning began, the system is almost completely finished! extrahappy

I'm very happy so far even though there's still quite a bit to do, it seems to be performing exactly to my expectations.

I was originally planning to post updates as the project progresses, but you know what these things are like...you start the project and then everything else goes on the backburner until it's finished! (which in my case was everything between July and December!)

Anyway, over the next few days I'll post a load of photos of the work that's taken place so far.  In case you didn't follow my initial planning here, basically, I'm starting from scratch with it all.  I pulled out the old night storage heaters, re-wired the entire house electrics, pulled down ceilings, put in a new thermal store, solar panels, multifuel stove and flue, as well as radiators and all pipework.  Finally, I built a false chimney breast through the living room to give the authentic fireplace look.

So here goes... (please feel free to ask any questions / post any opinions on the work) - Click photos to load full size version.

Bits and pieces start arriving.  This is in the living room before any work starts.


The living room is now all emptied.  The first thing to be done is to get the ceiling down...


First section of the ceiling down.  I'll just give a little info here.  Our first floor is 10" concrete lintels with hollow cement bricks in between them.  The cement bricks have 4 x 12mm reinforcing iron rods running the length of the house through them and have then had concrete poured into them.  On top of that is a 1" cement screed onto which the floor is laid.  The Ground floor ceiling is suspended around 24" below the first floor, leaving a crawl void between the two.  This is where all our current wiring and pipework is.  To add complication to the matter, there is a honking great 12" wide by 20" high steel girder with concrete moulded around it and on top of that rest 5 x 12" girders, again, moulded in concrete.  As I'll explain later, these things are the bain of my life.  I used every tool i could get my hands on to try and drill holes through them for cables and pipework but absolutely nothing worked.  I think I could safely say that the ground floor of my house would be bomb-proof!


Finally, the old artex'd plasterboard is all down!


Here you can see the giant concrete covered girder.  Before the ceiling came down, it actually protruded around 2" below the plasterboard.  It was "boxed in" but it meant the ceiling was divided by this boxing.  I think I'll probably drop the height of the ceiling a little to compensate for this so when it's all plastered, it should look much nicer.


Living room all cleared of broken plasterboard (that was messy!) Now the solar panels start arriving...




When I picked up the solar panels, I also collected the thermal store from Navitron.  It's custom built to the spec in my previous thread (linked to above)


The stove has also now been delivered.  It's a Stratford Eco-Boiler.  Very nice!  Grin


It seems to be multiple large deliveries each day now!  The plumbing bits have all arrived, as have the rads, all the fire-proof board and plasterboard, the flue bits and the rest of the electrical stuff...


The first major job is the re-wiring of the entire house.  Here are a couple of pics of the wiring going in...


Upstairs in the office, the new power points, phone socket, TV aerial and satellite points go in.  Notice the cables going under the carpet, these are heading through the floor to downstairs (for the media centre)


Security system going in...






After a week of drilling, digging, running cables and wiring, the electrics are done!


Up next is the installation of the thermal store...coming soon!
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swestsparky
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« Reply #1 on: January 07, 2011, 08:16:46 PM »

Can we assume you are qualified to sign the electrics off or are you getting building control in?
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feeta
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« Reply #2 on: January 07, 2011, 08:23:13 PM »

No, I'm not qualified myself.  After I had got everything in place, an electrician came in to connect up at the consumer unit and do all the necessary tests on the system.  He was happy with everything and signed it all off  Smiley

everything else I've done myself and BC have been in at regular intervals to check.  They will sign off once I've finally commissioned everything.
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desperate
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« Reply #3 on: January 07, 2011, 09:39:20 PM »

Hi feeta,


Why is there so much steel in your house? are you near a mainline railway line, or unstable ground, by the way was that artex on your ceiling? you know it has asbestos in it.

We havew a system pretty similar to yours, WBS, solar, and T/S with gasser for back up, this years gas consumption about 20% of last years Grin


Good luck, keep us posted.


Desperate
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feeta
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« Reply #4 on: January 07, 2011, 09:55:57 PM »

Ok...so next set of photos...

First job to do... take out old tank and get airing cupboard ready for all the new bits.
Draining the tank out into our 1000L rainwater storage container.


Up in the loft, and the current F&E setup is looking nicceeee!  Lips Sealed






This is what was left in the old tank.  I drained all the good water out into our storage container and once it was nearing the bottom of the cylinder, I took it out and turned it upside down over the bath to get the rest of it out.  Its not nice to think that all this was in the water that we were showering and bathing in!  What even is it? (all the white lumps!)




Old tank out, new tank ready to go in.


So after a hell of a lot of shoving and grunting, i eventually got the store in.  I had designed it so it would fit with 2mm each side but hadn't bargained that the doorway was lower than the cylinder and I hadn't allowed any space to angle the cylinder to put the top end in first.  Nevertheless, I got it in...just!


I was originally planning on mounting the store on top of 10' of blocks to allow for drops in the pipework coming out of it.  But again, I didn't think of the space needed to allow the top connections.  And when I put the cylinder on the blocks, the top connections were inaccessable.  So out the blocks came.  At this point I've packed rokwool under and around the cylinder for extra insulation.


Plumbing connections starting to be made... cold feed for coil and F&E connections made.


Tundish in place ready to be connected.  Heat circulation circuit also in place.


Looking inside one of the immersion holes, you can see the DHW coil, the top solar coil, and some of the diffuser pipes inside the cylinder.  Also, just below the diffusers is the mid-height baffle place.


EV and catch tank ready in place for the solar.


That was the tank all in and ready.  All the connections on the cylinder were either blanked off (the spare connections for the future) or had the first section of pipe connected up to the iso valve.  The immersions were then put in place and the tank filled.

The next "instalment" will be the solar install...  Wink
« Last Edit: January 07, 2011, 09:57:40 PM by feeta » Logged
feeta
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« Reply #5 on: January 07, 2011, 10:05:14 PM »

Desp, It's because the building used to be an agricultural storage building.  The walls are actually reinforced with steel rods too!  Not quite sure why the building needed to be this strong, i don't know what was stored in here.

Yes, it was artex on the ceiling.  I used a heavy duty particle mask when removing the ceiling.  Having grown up on a farm, putting many asbestos roofs on sheds, I'm sure if I have done any damage, it was already done long before this project  Undecided

The solar has been running since August and according to the controller, we've already generated over 2MWh and not switched the immersion on once!

Grin

Hi feeta,


Why is there so much steel in your house? are you near a mainline railway line, or unstable ground, by the way was that artex on your ceiling? you know it has asbestos in it.

We havew a system pretty similar to yours, WBS, solar, and T/S with gasser for back up, this years gas consumption about 20% of last years Grin


Good luck, keep us posted.


Desperate
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Stuart
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« Reply #6 on: January 08, 2011, 01:32:58 AM »

Excellent stuff, On day i think i will enjoy the fact we did it all on our own too! thankfully i didn't need to live in the dust and dirt.

Whats the naughty spur off circuit 7? tisk tisk
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8kw woodburner, Big piles of wood, 20 tube solar panel, custom tanks, back up gas boiler, North walls internally insulated
1968 landy that runs on anything and a currently wild meadow garden.

Nr. Tow Law
feeta
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« Reply #7 on: January 08, 2011, 09:34:14 AM »

hehe, where a night storage heater was before, we have reused the existing cabling for a single socket outlet.  Grin
Whats the naughty spur off circuit 7? tisk tisk
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feeta
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« Reply #8 on: January 10, 2011, 06:14:12 PM »

Hi David,

Not exactly.  I have only one tank.  The small tank I had has now gone (to be used on other projects).  Think of the large tank (the thermal store) as a large battery which gets charged by various means (solar, woodburner and occasional immersion)  The tank keeps the same water in it all the time (water that has been mixed with various inhibitors and chemicals)  The heated solar water flows through coils inside the tank heating the water.  The stove has a direct connection to the tank (so the same water flows through the wood burner and the tank)  The large tank is 320 litres.

In the design stage, I was pulling my hair out trying to source all the parts and get it to all work correctly in theory.  The practical side of putting it all together was much easier.  The big thing i would say when taking on a project this big is have very detailed plans.  I followed my plans to the letter and everything works really well.

My wife and I have been living in the house while all the work was going on, but we actually got the heating side of it finished by mid November.  The house is very well insulated anyway so it wasn't too cold.  Currently, the project is almost completely finished.  As I update the pictures, you'll see the stage that we're at currently.

Feeta  Smiley
So, I am trying to understand this, you are storing both solar and woodburning stove (back boiler pipes) into the one very large water tank? and then that provides a feed to your smaller water tank? That large tank is huge, is that over 300litres?

This looks like a brave project, although I hope you are not having to live in it during this winter while the work is going on!
==davidnc
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feeta
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« Reply #9 on: January 10, 2011, 07:47:21 PM »

Soo, it's mid August and the solar install starts!

Starting to get the scaffolding towers erected. I didn't fancy ladders, the house is pretty high and the roof is steep!


Scaffolding up...time to start getting the panels together






Panels ready to go up


Panels up, now to fix them to the roof.




As you can tell from the pictures, it wasn't the nicest of weather when putting the panels up, so I decided to call it a day and wait for the sun to come out!  I managed to get all the plumbing done inside during the evening.

Day two and the sun's out!


Panels connected


Got some friends to come over and we created a chain up the scaffolding passing the tubes from one to another.  Worked really well and pretty fast too!




Tubes in and roof cleaned.  Just in time as the weather turned bad again!


Thought I'd give the windows a clean while I was up there!


Panel in place and working


Some of the pipework inside in the control cupboard for the solar.




This is the 2 way diverter valve which directs the solar flow through either the top or the bottom coils.


So that's it... Panels up, plumbing done.  It's all good to go!


We've had many days like this since!


Next up will be the installation of the new flue and multifuel stove.

Feeta  Wink
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