Once the system is plumbed and the manifolds are pressure tested with air, the next step is to fill the system with water and purge air from the lines, which in a closed loop system can create noise and inhibit the flow of water.
WCS Filling & Purging
installation guide
Purge Air, Fill with Water
Follow these steps to fill and purge the air in the system.
This should be done one manifold at a time. In this example, begin with Manifold 1:
Secondary Loops
- Remove any white valve caps or actuators that may be on the manifolds.
- Close Ball Valves (A-C) and ensure Ball Valve D is open.
- If closed, open the Shutoff Valve (G) for the water feed to the system. Air should begin to release from air vents.
- Thread a discharge hose to Hose Bib A and run the other end of the hose outside or to a drain.
- Open Hose Bib A and lift the fast-fill lever on the Pressure Reducing Valve (E). Water should make its way through the first manifold and out of the hose.
- Ensure the flow meters are registering flow through the manifold. If not, confirm the supply and return are plumbed appropriately.
- If any loops are not showing flow, restrict the neighboring balance valves to force flow to the affected loop(s).
- Continue filling the system until air stops discharging and only water is leaving the hose.
- Once all air has been discharged from that manifold, release the fast-fill lever and quickly close Hose Bib A. Avoid spiking system pressure with the fast-fill.
- Repeat this process on the rest of the Manifolds (B, C) until the whole system is filled.
- When done, close all the hose bibs on the system, remove the hoses, and open all ball valves.
- Reference the Lochinvar manual (Chapter 10: Start-up) for allowable mineral levels and quality of the water. Filtered water or a corrosion inhibitor may be required.
Propylene Glycol
In some situations, it may be necessary to add propylene glycol to prevent freezing. Instead of adding water from a water feed, close Ball Valve D and transfer fluid into Hose Bib D from a reservoir of glycol solution via a transfer pump. At the same time, discharge glycol solution from Hose Bib A back into the reservoir. Follow order of operations similar to the previous purge process. Once one manifold is no longer discharging air, close Ball Valve D followed by Hose Bib A. Perform these steps with Manifold 2.
Propylene glycol should only be used for freeze protection. Follow guidelines found in the WCS Plan Set for the correct mix (generally 10-30%).
To fill the system with a propylene glycol/water solution, we recommend a Liberty 331 Portable Transfer Pump, or equivalent (homedepot.com).
To maintain the propylene glycol feed for many years, we recommend plumbing a glycol feeder in place of the water feed on the Mechanical Diagram.
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