HTP Pioneer Versaflame E03 code with cascading setup

Of course now that it is 10 degrees outside one of my pumps died. Its a B&G and from the looks of it not cheap. lol. Guess we will see how that turns out. Either way here are the photos I have.

Hopefully you can read it, but this is t he plate from my coal furnace.

Here is my pressure gauge on the coal furnace. It was at 13 last night. This morning I found out a pump died on me so not sure if that is part of the issue or not.

This is the first pipe that goes from the water storage is the coal furnace to the two HTP in the other room.

This is the first pipe that comes FROM the HTP and goes out to the radiators.

This is the next pipe that goes to the HTP boilers, the big iron one coming from the top of the coal boiler. Behind it with the 3/4 copper pipe is the inlet and what you cannot see here is one of those low pressure valves that lift up manually and you can fill the system up with more water when the pressure is low. Not quite sure what those red things are (are they air removal thingies?), but we do have a combination of copper for baseboard heaters and iron pipes for radiators. So I am sure that somehow those go out to baseboard heaters and probably to the largest area which is about 6400 sqft in total.

I guess you can see the low-pressure valve in this photo here. It goes into one of the return pipes from the one pump that broke on me today (it was making some noise, I was hoping oiling it would fix it, but it didn't help). It is really hard to say what most of that is, but I am sure some of it is a return to the radiators and some of it is pulling in from the radiators.

This is the next room. You can see my pressure/temperature gauge there that I am worried about and the first of two pressure tanks at the top there. The huge valve is coming from the first pipe in my second photo

This is an underneath photo but that valve is the second pipe coming from the coal furnance. You can see my system sensor zip tied to the return pipe there. You can also see my second pressure tank there in the very back.

This is the piping going to the secondary furnace.

Here is a picture of the details for the furnace.

This is a closeup of my pressure / temperature gauge.

This is my pump that just died on me. It is not looking cheap when I find it online. We will see what the local guys do to me.

Well, it turns out I just forgot to turn that switch back on last night. I have five pumps and the building is 13000 square feet. That pump and there is one larger pump that go out to the radiators. The three taco pumps I have all work with the newer baseboard heaters that I have honestly.

Thank you so much! This is exactly the part I am looking for!

In PA we have deregulated energy, but unfortunately when there is a COOP you don't get choice. Literally two miles away the cost of natural gas is 1/2 the cost of what I pay. It is very frustrating. So my natural gas bill is over $1000/mo during the winter months right now, which if they had the same prices as Peoples then it would be way less daunting to keep running Natural Gas. I am seriously thinking about just going back to coal which I can guarantee is significantly cheaper, even if it is way more labor intensive to keep it running. For some reason the old coal furnace is still tied into the hot water heating system as well (even though it is only running 1/2" through it) so it screws up the water pressure and takes already hard water and just puts more rust in there. So I know I would at least like to get that out of the way.

I have a bunch of PEX and this house is OLD. So I would like to get rid of the all the current plumbing and replace it with that to be fair. Was thinking about doing radiant floor where the current radiators are, at least in the show room areas where it is easy to get to the floors on the second floor. I notice a huge difference when running that big iron pipe for the radiators compared to the 3/4 copper for the baseboard heaters. Not sure if it is just more effient carrier of heat. I just look at the cost of materials for baseboard and it is about $6k without all the accoutriments. I am just not sure if I trust myself with all the soldering for them myself.

Either way we will see how it goes.

So they were complaining it was cold again last night so I went down there to look. I did put more water in the tank as you had mentioned and not change on the guage by the boilers. Thinking it was the pressure again I was down there and lightly tapping on the glass for the gauge and for some reason I turned it counter clockwise and the needle shot up to the same pressure as what was on the coal boiler. So somehow that guage was off because of how tight it was in there. Either way that was good. But their radiators were still not warming up. So I got out my electrical tester. For each of the boxes that controls the pump from the thermostat there is a light switch to help make it easier to maintain everything. Well power was going into that switch but it was not going out of the switch no matter where it was. So I replaced the light switch and low and behold that pump started working again. While I was pulling the switch out of the box the pump came on and went right back off a few times, so it just had a really spotty connection. That switch was from the 70's/80's era so it had a good life. Either way they had to turn the thermostat down this morning because it was hot up there. Hopefully everything is moving along in a good direction.

Either way I seriously appreciate everyones time and attention here! I still have a ton to learn about these systems but they are super cool and very interesting for sure! Going to carve out the time to watch the video training I found on here. Can't think you guys enough. If you ever need some technology support happy to pay it back that way! lol.

I called them out one time and this is literally the only system they installed like it. The guy who installed it came out and he brought three other guys with him. Those three guys started tearing into these things and had no idea what they were doing. I mean these are maintenance free boilers, but you definitely need to maintain everything else around it. After that is when the issues started happening for me. So I just don't trust him and ultimately they were not very helpful in the long run. Hard to find good people these days and with where I am located the options are limited.