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Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
I did a lot of pipe thawing back when we had the shop in the mountains
Infiltration was the biggest cause of freeze up. Windy days at below freezing conditions, we were always frozen pipe days. That’s when I got sold on spray foam, even a 1/2” layer with batts over it would seal a building against infiltration.
Underground piping froze when we had years with little snowfall to insulate the yards

Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
The seal around the bottom of the wall and the plate and the floor is usually poor. pipes usually freeze not when it is the coldest but when it is fairly cold and there is a wind to push air in through openings in the building that are close to a pipe.

Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
How much work are you doing and how much piping is in the exterior wall? Perhaps moving it will solve numerous problems. Glycol needs maintenance of the inhibitor. Placing the insulation between the exterior and the piping would seem to be an amount of work where re-routing the piping would be a negligible additional step.

Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
hot water does NOT freeze quicker!

Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
I would think that if the wall bay insulation is placed between the outside wall surface and the piping, then the piping would remain at or near the indoor ambient temperature, so it would not be much more vulnerable to freezing than any other interior piping.
Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
In general, the efficiency hit of glycol is way overstated. It doesn't make your burner burn any less efficiently. What it means is that slightly more fluid needs to be pumped to get the same heat transfer. Your system will have a slightly lower maximum output, but unless it's undersized that shouldn't be an issue. The circulator pump will consume slightly more energy having to pump more fluid but that's the extent of the energy penalty.
Re: Another cold climate home with hydronic piping in exterior walls. Who does this??
It is an ongoing fallacy that hot water freezes faster than cold water. Personally, I believe the fallacy is developed from the fact that hot water cools faster than cold water. People without any intelligence then extrapolate that hot water must freeze faster because its temperature is falling faster. Nothing could be further from the truth.
With regard to piping in the exterior walls, I restored one house to get the iron piping out of the living space. The look is less than desirable.
Since the wall was open, I utilized 2" styrofoam, 14.5" width for the entire height of the bay. The styrofoam was cut slightly large so it was pressing on the studs without any gaps. The copper lives in the 1.5" space between the sheetrock and the styrofoam. The copper is not insulated and the intention is for the line to warm the fairly small space left in the bay.
The system works perfectly down to -3F. However, it has never suffered a power outage at that temperature to verify that it would be successful under those conditions. I highly doubt that even interior piping will survive more than 24 hours in the event of an extended power outage at -3F ambient.

Re: Flame Retention Head for Weil Mclane Boiler
Sadly that oil burner was manufactured by Weil Mclain in an unsuccessful attempt to make a "BETTER" oil burner. And this particular part 643-900-110 no longer shows up on any supply house inventory searches and no longer shows up on the Weil McLain Parts Finder. You are SOL trying to find that thing. You will most likely need to replace it with a Beckett or Carlin or Riello burner that is approved for that boiler. I even looked on eBay for the part. NADA!
Sorry for the bad news, but your contractor is correct, you can not operate that burner without that part. My son is currently operating that particular burner in his Buderus boiler. I can ask him if he may have one in his junk oil burner pile.
Re: Correcting my 2 Zone Monoloop System (Need Help)
You are correct. His system has the diverter T's on the "supply" side, which is counter to the recommendations. However, it is correct and the system should function properly. Of course, the arrow on the supply side will be opposite to the direction of flow.
Since it is piped correctly based upon the T's, the problem remains. It simply cannot be attributed to the circulators on the return. That's not sufficient to cause the issues that he has.
To the JW:
There is no benefit to repipe the system to flow the opposite direction. The system was originally designed properly, although a bit unconventional. Ed is correct.

Re: Viessmann cast iron boiler replacement.
I believe that is a Verticell indirect water heater