Best Of
Re: How to prevent hydronic piping from freezing?
There is a timer called ThermGuard that connects across your thermostat and will turn on your boiler for a programable set amont of time and a programable number of times per hour. It has a defult setting of turning on the boiler for 5 minutes every half hour. I purchased one for an area in the home that I didnt plan to heat but never installed it so I cant say anything about its reliability.

Re: How to prevent hydronic piping from freezing?
A word of caution, if there is any interface between your domestic hot water and the circulating heat system, then you must use only propylene glycol, never ethylene.

Re: correct gpm for open loop geothermal
Is this system a water furnace? How deep is the well, how far away is the dump point?
Check the gas pressure first before you do anything.
The well water is going to be cold 52 degrees or less so please keep that in mind when looking at the whole picture.
I guess you could flush the exchanger with strong vinegar and see how much build up is in it, you may very well have no restriction of flow.

Re: Plate heat exchanger
On the glycol side you want an air purger, pressure gauge, relief valve and expansion tank also
Maybe an Axiom fill tank

Re: Plate heat exchanger
I presume a brazed one? Gasketed likes constant temperatures.
Also you can think about filters for both sides. Not easy to clean brazed plate exchanger.
I'd just get an electric heater for that bathroom.

Re: Difficulty in Properly Sizing Equipment - 2140 Sq Ft New Construction Spray Foam House
For new construction, done to current code, in your climate, 2140 square feet, 39K heating and 29K cooling actually sounds kind of high.
Re: Difficulty in Properly Sizing Equipment - 2140 Sq Ft New Construction Spray Foam House
minis have low static ducted units that are 1-Ton or less.
Please
2 stories
2 systems.

Re: Sanity check plan new zone
sounds like you need to shop for a better brand of zone valves.😉
There is not a lot of difference between a zone valve and a zone actuator on a manifold. Often they are the exact same operator as one another
Zone valves with a short life span are often short cycling themselves to death
On the average a ZV cycles 5000 times a heating season. Quality valves, gear trains, motors and switches are designed for 100,000 cycles. Or 20 years of service.

Re: Difficulty in Properly Sizing Equipment - 2140 Sq Ft New Construction Spray Foam House
That is a problem with Oil Heat equipment. The smallest input Equipment is often too big for the building. That said, the EK has the best control to reduce the short cycling associated with oversized equipment. So explain your concerns to the nice folks at EK and they will help you to design a great 2 zone system.
And the thing about 1.5 ton cooling as the smallest available… There are some Variable speed inverter outdoor units that are usually associated with MiniSplit systems that can be connected to 1.5 ton ducted air handlers. some of the match ups are as small as 12,000 BTU or 1 ton. Ask your HVAC contractor to look into this option from their local supplier. I know that Fujitsu had one available several years ago before I retired. I'm sure the other brands have also joined in.