Joined on February 27, 2010
Last Post on December 11, 2013
@ November 19, 2013 8:39 PM in Is there a truly graphical heat-loss program?Wrightsoft! You draw the blueprints and change your parameters. Easy, peasy, lemon squeezy.
@ November 19, 2013 8:35 PM in My Shiny Old ToyThe trap looks like a band-aid for keeping steam out of a dry return, instead of dropping into a wet return.
I've seen the "bypass, short circuit" arrangement once before. It had no appreciable effect on the system. Although, when I saw it, there was a cross below every radiator run out.
The spigot is another band-aid. Somebody didn't know how to use a level, and the spigot is their way of removing water from the main.
@ November 19, 2013 7:39 AM in Another Twin System - 6" Drop HeaderThe lag boiler cuts out at 12. Lead boiler cuts out at 16. When both boilers run, it builds pressure steadily, and maintains system very well. When only the lead boiler runs, it doesn't maintain enough pressure to keep the unit heaters running.
I'm planning to go back soon to add modulating fan controls to the unit heaters (as recommended by SWEI). If the blowers run at 50% speed, they should more closely match the lead boiler's output.
@ November 17, 2013 8:30 PM in Another Twin System - 6" Drop HeaderYou're right that it will. However, we needed to keep the Gifford Loop high enough to keep all of the wet returns wet. There is also about 2 cups of water that lays inside of each tee. In fact, every header, no matter what size, has water trapped in the fittings.
@ November 17, 2013 7:48 PM in Another Twin System - 6" Drop HeaderWe were out of wicking, or else we would have used it. The last 6" 90 faces down at a 45 degree angle, and reduces down, going to the equalizer in the back left. There is surprisingly little steam carryover between boilers.
@ November 17, 2013 4:17 PM in Another Twin System - 6" Drop HeaderThose are for the circulated zone. The water level in the boilers equalizes because the returns are connected.
@ November 17, 2013 6:04 AM in Smith G-8 with New Style Carlin EZ-GasCheck out the Honeywell R8845U relay. It has a Common terminal for the WiFi thermostats and a control fuse.
@ November 16, 2013 6:56 PM in Another Twin System - 6" Drop HeaderSo, I spent the afternoon skimming and testing. Here's what I'm seeing...
The staging and unit heater controls are very fickle and hard to fine tune. I'm going to scrap the Vaporstats for pipe-thermostats to control the heaters. I will also set up another relay to turn off 2 of the 4 units heaters when the 2nd stage boiler reaches pressure and shuts down. The idea is that when 2nd stage isn't needed, neither is the full capacity of 4 unit heaters. In a sense, I will be modulating the heat emitters as well as the heat source.
More to come as I play around with this system.
@ November 15, 2013 8:23 PM in Another Twin System - 6" Drop HeaderI refuse to weld a header. I'd much rather struggle with threaded fittings than have a rigid header that's going to stress out and bust open in the future. We have 36" chain wrenches that just barely fit 6" fittings. A 5ft pipe wrench is on our wish list.
@ November 15, 2013 8:02 PM in Another Twin System - 6" Drop HeaderThe 6" fittings really kicked our butts. Embarassingly, we had a few leaks from being too conservtive with our teflon/dope. We remade the fittings by using dope, teflon, and more dope. The big threads of the 6" pipe digs deep and tears up all of the teflon tape. Lesson learned!
The system still needs some fine tuning and plenty of skimming. I'm debating whether or not to remove the Vaporstats on the unit heaters and install temperature controllers.
@ November 15, 2013 7:27 PM in Another Twin System - 6" Drop HeaderHere's the new system.
Steamhead, it was a Becket. I'll check what model number tomorrow.
@ November 13, 2013 8:14 PM in Another Twin System - 6" Drop HeaderThe boiler room is through one door, about 5 feet from our trucks. Can't ask for a better work environment than that!
The original header was only 4", which is what we use for single 5 section boilers. Being piped wrong, they probably spent 2x on fuel than they should have. Add to that, a major lack of main venting, and our fuel savings are going be easily predictable.
@ November 13, 2013 7:48 PM in Another Twin System - 6" Drop HeaderWe'll be installing 2 SMITH series 8 boilers with CARLIN gas burners. New 6" drop header. Controlling the boilers with a 2-stage tstat and High/Low Vaporstats. The system has 4 steam unit heaters and 2 small radiators. There's also a small circulated hot water loop.
Pictures of the new system coming tomorrow or Friday.
@ November 13, 2013 7:45 PM in Another Twin System - 6" Drop HeaderHere's an old TACO heat exchanger. Keeping this in the museum-piece collection.
@ November 13, 2013 7:44 PM in Another Twin System - 6" Drop HeaderWe seem to be doing a lot of twin steam systems lately. Possibly one more in the near future...
Here's a few photos of the old National Radiator Co. boiler, and poor piping.
@ November 13, 2013 7:31 PM in Header sizing****Header Size per Maximum BTUH Output****
(Based on Velocity of 15 ft/sec. to 20 ft/sec.)
2" Header = 48,384 - 64,512
2.5" Header = 68,832 - 91,776
3" Header = 106,416 - 141,888
4" Header = 183,312 - 244,416
5" Header = 287,856 - 383,808
6" Header = 416,016 - 544,688
@ November 11, 2013 8:58 AM in I lost a job to a company that did this:They converted the old header into a steam to hot water heat exchanger.
@ November 10, 2013 5:05 PM in Hydronic Replacement Boiler SizingI suppose that I'm just used to seeing very poorly designed air systems. And we would never install a hydronic coil system from scratch unless it was the absolute only option. We hear nothing but complaints about this type of arrangement. We'll actually be converting a hydronic coil system to radiators for somebody this year.
@ November 10, 2013 2:55 PM in Hydronic Replacement Boiler SizingCool/warm air feels uncomfortble, even if it's the appropriate temperature for the heat loss.
@ November 10, 2013 1:39 PM in Hydronic Replacement Boiler SizingIf the boiler is feeding hydronic coils in an air system, a modulating boiler is a gigantic waste of money. The coils will need a constant 180F water supply; completely defeating the purpose of a modulating boiler.
@ November 10, 2013 1:35 PM in What to do: false water line, loop, pump, trapsCan the dry returns be converted into wet returns?
@ November 10, 2013 10:22 AM in Only 1/2 of my house seems to get any heat - help?Definitely 2-pipe.
Water hammer and uneven heating? The survey says....bad traps!