New System Control(jalcoplumb)

Unknown

The system is circa 1975. It had a powers pneumatic control system with outdoor reset, 3 way mixing valve, pneumatic controlled pressure differential bypass, about 8 unit heaters, 8 duct coils, 8 zones of perimeter baseboard, 500gal domestic hot water tank with a Taco bundle, two 1.6MBTU input boilers with Preferred Utilities Burners.
It was ugly. Over the years they had replaced the roof top A/C units that had the duct coils with gas fired ones. They left the duct coils in and shut the valves. AAAAGGH!!!! This reduced the load heating load a lot. The pneumatic system was shot. It needed more work than it was worth. Compressor died, leaks throughout the building, no one knew how to maintain the system. To top it off they removed all the balancing valves and inserted straight pipe.
When I arrived the system was running on boiler limit and a T-87F thermostat in one office to run the system pump. Unit heaters worked once in a while. The boiler limit was set at 180 low and 200 high. They ran both boilers all summer long to keep the domestic tank hot.
I just completed the first phase. I built and installed a new system control panel. I installed a Tekmar 262 and 362 to run the boilers and operate the mixing valve. To operate the zones I installed 8 taco ESP zone valve and a two taco zone control panels. As for the system pumps they run off the Tekmar 262 boiler control and will shut down during WWSD. I added a auto rotator and a timer for the pumps as well. I still have to balance the system. The pressure differential bypass is not big enough now. It is wide open and just isn’t cutting it.
I can’t wait to see the fuel savings with just the first phase.
Second phase is installing a Munchkin VWH water heater.
Third phase it to rip out the two 1.6MBTU boilers and install two Munchkin 399 boilers. All in good time.