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HELP: Problem Triangle Tube ModCon + Radiator System
I was dumb. I didn't insist on a Manual J heat loss calc from my installer. I went with a nice guy, but I don't think things got done right, and now I need help. Some preliminaries:
Location: Olympia, WA 98502 (not very cold in the Puget Sound region)
House stats: 1200 sq. ft., 1.5 stories, built 1937, insulated walls, floors, ceiling
Replaced aging gas forced-air furnace and gas water heater with:
-Triangle Tube (TT) Prestige Solo 60 gas mod con boiler
- TT Smart 60 indirect water heater
- Runtal radiators in most rooms except kitchen which uses a "Toester" toe kick heater
- Two-zone setup with Taco, what, switch, zone controller?
We are trying to resolve a problem TT is aware of with some controllers on this unit. They are sending a new controller out. Actually, they already sent one, but it didn't help. We found out they sent the wrong one (an uncorrected controller unit apparently).
- Frequent "thud" noise. I don't know whether this is delayed ignition or other improper ignition or what. It is disconcerting, and I am hoping a corrected controller addresses it.
- Failure to ignite lockout resulting in boiler lockout error. We have to press the reset button to get out of this. Again, hoping a corrected controller addresses it.
- Slow recovery. I am wondering if the radiators were spec'd too small. I know that radiators do not heat up a house as fast as forced air, but this is pretty slow. Also, from what I can tell, there is only a slight 4-degree difference in the return heat compared to the outgoing heat.
- HIGHER, not lower energy bill. OK, so we only have one heating season bill to look at, but it shows that the average temperature was the same this year and last for the same billing period. I'd expect the new high-efficiency unit to be significantly cheaper to operate, not MORE expensive. Again, I wonder about the delta-T and inefficiency resulting from it.
- Setback thermometers were installed, but I am reading about how they might be inappropriate for mod con boilers.
We are awaiting the new corrected controller to arrive. I expect that will cure the thud noise and the failure to ignite consistently. I remain concerned about the other problems, however.
Was a modcon boiler a bad choice for our small house? Do they make units that modulate lower than 16K?
Was it _technically_ wrong to have two zones in terms of dumping heat even though we are only upstairs for sleeping?
I realize mistakes I made out of ignorance, and need to know what advice _at this stage of things_ do you folks have. THANKS!