Job questions

Dave0176

Last year I got a call from a VFW hall to give a proposal to replace their old Hydrotherm boiler because it was leaking. I gave my price and waited, but was never called back. Apparently a member who claim to be an HVAC guy said he'd do it and used my proposal. Long story short, he did a terrible installation job and now the commander wants me to fix it right. He never wired the circulators or even ran wiring to the boiler, it was wire nutted to a 50ft ext cord.

So far I've redone all the wiring, used a Taco 6 zone pump controler and wired in all the safety's. The boilers running good it's a Weil McLain EG65

Here are my questions, he obviously didn't have a big threader. The supply he ran 2" to the existing 3" header were 5 B&G 100 series pumps take off. They return to a 3" header and he reduced it down again to 2". They were asking me if this was correct to do. The WM install manual says 2" minimum. But I was wondering if a 3" riser and return would serve better? Plus half the pump flanges are leaking.

Also 4 of the pumps come off the header on 2 "Y"s is this sufficient??

SWEI

Begin at the beginning. What size is the boiler? What is the design day heat loss (total and for each zone)?

We are finishing up a replacement of two boilers in a church (one 840k and one 480k) and four B & G Series HV circulators (next size up from the Series 100.) Three of those were replaced by a single MAGNA3 32-60 and zone valves. The fourth was replaced with a Taco HEC-2. The trustees were slack-jawed at the difference in size and noise -- just wait 'till they see the gas bills.

Dave0176

SWEI said:

Begin at the beginning. What size is the boiler? What is the design day heat loss (total and for each zone)?

We are finishing up a replacement of two boilers in a church (one 840k and one 480k) and four B & G Series HV circulators (next size up from the Series 100.) Three of those were replaced by a single MAGNA3 32-60 and zone valves. The fourth was replaced with a Taco HEC-2. The trustees were slack-jawed at the difference in size and noise -- just wait 'till they see the gas bills.

The boiler is already installed, they want me to get it working properly. I just need to know about the pipe sizes if I should upsize tgem to 3"??

Zman

It looks like the eg65 is 250k/btu input.
There is no reason for piping larger than 2" for the supply and return. It sound like the headers are oversized to allow for even distribution to the circs. Post pictures if you are looking for more specifics.
Carl

Robert O'Connor_12

DaveO said:
"Apparently a member who claim to be an HVAC guy said he'd do it and used my proposal."
How could someone use your proposal? I'm confused.

SWEI

My point was that the system is almost certainly overpumped, likely by quite a bit. I would check the ΔT on both the zone pumps and the boiler before I started making changes. At a minimum, the Series 100's could easily be replaced with properly sized zone circs (perhaps a 006?) but the best answer would likely be a single ECM circ with zone valves.

Dave0176

Robert O'Connor said:

DaveO said:
"Apparently a member who claim to be an HVAC guy said he'd do it and used my proposal."
How could someone use your proposal? I'm confused.

It's funny, at the time that person was the quater master (person who handles all the money) since then they had a takeover from Washington due to all the theft and the club nit showing any extra cash flow. The guy (Mike) was the one who called me because I had done some refrigeration work previously. He told me he was a retired HVAC tech plus a boiler mechanic on his Navy ship, anyway he called me for a proposal, I gave it, and basically talked the members into letting him do the work at my price. He is no longer in charge of anything but a regular member. Thing with the veterans clubs is they won't go after a member even though he basically robbed the clubs money. The new quater master told me that was old way of doing things and this is the new way.

Anyway since the takeover I done a lot if work for the new people, including a new rooftop A/C install.