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New Lochinvar Knight Questions / Concerns
Second time typing this so it's going to be shorter than the original which was lost somehow...
We had a new Knight KBN 211 installed two weeks ago. The house is staying warm at 68, however I have two concerns with the system and its installation.
Heres some quick info about the house and system first. ~4100 sq ft. 1920's Brick / block / plaster / concrete floors. No insulation at all and the original windows. Original 27 radiators and piping over three floors as a single zone. Original system in the house was coal, the Knight is replacing a 50's cast iron boiler, BTUs were 266k I believe, may have been 290k.
#1. My dad and I are concerned that the boiler is piped incorrectly. I will add pictures below but first will try to diagram and explain. The system return line dumps into the primary loop prior to the system supply line. Very roughly, without any valves, gauges, checks etc. it looks like this
Boiler Outlet ---> Capped DHW ----> Capped DHW ---> System return --- > System Supply ---> Boiler Circ pump ---> Boiler Inlet
In our opinion, this is cooling the boiler output water with the system return water before it even has a chance to get out to the system supply. So instead of 160 degree water going out into the system, that 160 water is mixing with the the system return which is cooling it to whatever temp. before it even gets to the radiators.
Boiler circ pump is a grundfos super brute set to high and system pump which is on the return is the grundfos equivalent of the Taco 0011, also set to high.
#2. The system cycles a lot. At 97 run hours, there have been 595 system cycles. It seems like the boiler will run for 15 minutes, rest for 10, and then repeat that. Now they have not been back out to program the boiler yet, but this still doesn't seem right. The thermostat calls for heat even though its already 68 degrees. My uneducated theory is that this relates to issue #1 in the radiators aren't getting that 160 degree water to begin with so they are cooling off much quicker and the temperature in the rooms drops much quicker.
Those are my basic concerns, I am going to add the pictures below, but if there are any details left out or pictures needed I will be happy to provide what I can. The house is warm and comfortable, but I am just concerned that the Knight isn't running efficiently and/or as it is designed to run.
Edit: The pictures are coming up way way too big on the message board, let me provide links instead
shows primary loop piping
system and expansion tank piping