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First high efficiency boiler on my own...short cycling! Help!
I have piped a lot of boilers for companies I hjave worked for and feel confident in doing so. I recently last year went out on my own, at first things were slow but momentum is finally moving my way! Im scheduling work a week out and it feels great to earn.
I understand the concepts of a mod con boiler, outdoor sensor, primary secondary loops etc. I have heard several times in my career that the greatest plumbers are lousy heatguys and vice versa, but I am determined to be great at both. The onset of the heating season has brought in a lot of boiler inquireies/estimates and the first estimate i gave wanted me for there boiler...(Most likely because I priced it to cheap...)
So I know that Burnham Alpines are very popular with plumbers in my area so I thought that would be a good choice. The boiler there was...odd. It was a steam boiler converted to hot water (never saw that before) and it was. their hot water heater was in rough shape so I suggested adding on some tees for a future indirect and I inquired with the one of the sales guys at the supply house about the sizing. He said that the sq ft and baseboard of the condo only called for 60-70k BTUS and that it was customary to add 100k for the indirect....ummm ok that sounded a little ridiculous.
I figured I would put in the alpine 105 and leave an extra 30 or so for the indirect. So fast forward...all done with the boiler. (pic attached) So I had a friend of mine who is also a licensed plumber help me. Honestly he is not so confident with high efficiency systems but he has more experience than me. First off, I installed a programmable thermostat that was sent to the homeowner from the state as part of their rebate. My friend and I went through all the settings. Adjusting anything we knew for sure needed to be changed, outdoor reset:on indirect:off priority:off etc. And the ones we were unsure of we left alone like the set points. I went up and turned the thermostat up to kick the burner on, which it did. When I turned it up, i turned it all the way up to 90's which might have confused the boiler a bit since the temp outdoors was in the 70's. The boiler short cycled a few times up to 140...off...down to 120 or 130, back on up to 140...It was late and not cold out so I left the boiler off and took the book home to read up. So went back today and tried turning up the thermostat a little above the room temp
and the same thing...short cycles. Called burnham, first off I was scolded for oversizing the boiler. the tech said you never add anything for a indirect set on priority...he asked me if my tees on the primary loop were spaced appropriately and yes they were. He suggested jumping out the TStat on the boiler to eliminate that as the problem. I jumped it out, fired it up and it actually went up to 130 as limited by the outdoor sensor and then I heard it "Modulate down and maintain the temp" just like the burnham guy told me...it stayed there for about two minutes before shutting off and then started short cycling again....I am extremely frustrated. I will be calling the burnham guy again tomorrow but was hoping some of you heat experts could give me any tips. Thank you in advance!