Yellow Flame, A Christmas Stoker Boiler

Today I finished cleaning and painting all of the stoker mech parts, assembled it on the bench and tested it. I was trying to upload a video, but even my 20MB videos wouldn't load because they are mpg files, whatever that means. That being the case, my next post will a series of pairs of photos that show the grate linkage and the grate plate at both ends of there motion. Hopefuly that will be a good discription of how this crazy thing works.

The linkage on this one has a LOT of wear. which again makes me wonder how it could have maintained a fire, same thing I thought when I saw the crusted up blower! The grate plate was so far down the ramp that during most of the stroke, the bottom of the grates were exposed, air was blowing right out the front instead of the grate holes!

Anyway, this is what it looks like now. -Don

Don, is there a bearing on that cam that rides up and down in the slot?

Yes, it has a shoulder bolt through it so it rides against the lever and spins freely as the transmition truns. That's one part that isn't worn out!

-Don

Good. I think it would be a good idea to hit that with a very light oil once in a while. Enough to keep it lubed, but not enough to accumulate dust...otherwise you create a lapping compound.

First pair of photos, notice the lever connect to the transmition. The yellow part on the linkage is the feed dissable, for when you are lighting the stoker.
Grate plate stroke at the bottom of the ramp.
To be continued...

Grate stroke, this is more difficult to see.
I'm think'in with it adjusted like this, it will put out a lot of BTU's!!!

-Don

Rob R. wrote:Good. I think it would be a good idea to hit that with a very light oil once in a while. Enough to keep it lubed, but not enough to accumulate dust...otherwise you create a lapping compound.

Good point Rob, I was going to put grease on it, but your right, lapping compund!

Her are the plumbing parts that I ordered today. My credit card hurts now!

From http://www.badgerinsulatedpipe.com/
Items

Qty Item # Description Price Each Total
4 valves:pex3/4 x 3/4pexbv 3/4 pex x 3/4 pex ball valve
6 valves:pex x pex ball valve1 1 Pex x Pex Ball Valve
1 bp units:bp50 BP-50 50K BTU Hanging Heater
1 coils:inkitair Water to Air installation kit
1 coils:12 x 18 12 x 18 Water to Air Exchanger
50 clamps and rings:ring3/4 3/4 Crimp Ring
20 clamps and rings:ring1 1" Crimp Ring
2 tools:Crimp Tool 1" 1" Crimp Tool
2x1" OB + 2x3/4" x 100' INSULATED PEX BUNDLE

From pexsupply.com

3/4" 374A Relief Valve (30 psi)
SKU: 0358553
Brand: Watts
In Stock! Ships in 24-48 Hours

3/4" Quarter Turn Boiler Drain (Drain Cock)
SKU: 0820956
Brand: Watts
In Stock! Ships in 24-48 Hours

SX-30V Extrol Expansion Tank (14 Gallon Volume)
SKU: 118-27
Brand: Amtrol
In Stock! Ships in 24-48 Hours

1/8" Hy-Vent
SKU: 400-4
Brand: Taco
(1)
In Stock! Ships in 24-48 Hours
(2)
In Stock! Ships in 24-48 Hours

1" IPS Isolator Flange (Pair)
SKU: 40404
Brand: Webstone
In Stock! Ships in 24-48 Hours

1" Air Scoop
SKU: 431-6
Brand: Taco
In Stock! Ships in 24-48 Hours

3/4" Sweat Thermostatic Mixing Valve (Lead Free)
SKU: 75103W
Brand: Webstone
In Stock at Supplier! Ships in 24-48 Hour

1" Full Port Threaded Ball Valve
SKU: HV100T
Brand: Hydrovalve
In Stock! Ships in 24-48 Hours

1-1/4" Full Port Threaded Ball Valve, Lead Free
SKU: HV125TLF
Brand: Hydrovalve
In Stock! Ships in 24-48 Hours

1" Threaded Swing Check Valve
SKU: SC100T
Brand: Hydrovalve
In Stock! Ships in 24-48 Hours

1/4" NPT, 3-1/8" Face, Long Probe Temperature & Pressure Gauge (Tridicator)
SKU: TD-165
Brand: Honeywell-Sparco
In Stock! Ships in 24-48 Hours

1" x 1" SharkBite Coupling (Lead Free)
SKU: U020LF
Brand: Cash-Acme
In Stock! Ships in 24-48 Hours

1" x 1" SharkBite Elbow (Lead Free)
SKU: U260LF
Brand: Cash-Acme
Box of 6
In Stock! Ships in 24-48 Hours

1" Sharkbite Disconnect Clip
SKU: U714
Brand: Cash-Acme
Box of 12
In Stock! Ships in 24-48 Hours

1" Sharkbite Disconnect Tongs
SKU: U715
Brand: Cash-Acme
In Stock! Ships in 24-48 Hours

Shipping (UPS Ground): FREE
Tax: $0.00

Gotta love that free shipping!

So, as fare as the 1" vs 1.25" PEX wars go, I decided that 1 80KBTU will work OK for this season with 1" PEX. Next year I will put the boiler in the basement and feed the 50KBTU in the garage with the same 1" PEX. What do ya think of $396.95 for 100' of 2x1" OB and 2x.75" insulated PEX!. The place in Falston was $1000 for just the 2x1"!

I also decided that I will buy a new pump for the 1" run up through the attic to the duct heat exchanger, I just don't know which one to buy.

-Don

Pexsupply.com is great - Rob pointed me in that direction too for my install. Saved me a ton of money .... which I then wasted on multiple F -ups ...

Their customer service is second to NONE. They're FAST, and they'll take stuff back, no questions asked. Does cost return shipping though. I paid for my F -ups more than once ...

Nice paint work on that thing, btw.

Thanks Smitty,

I'm just sit'in here hav'in a beer wonder'in what the heck I did today.

-Don

I do that alot meself ...

I'm sure your credit card is hurting after all that. But the savings in real, significant dollars is right around the corner. You will never regret it.

With all your DIY sweat equity invested and low initial boiler outlay, you'll be in the plus column in short time!
Then it's smooth sail'in
Will there be a used coal stove sale coming sometime in the future?

coalkirk wrote:I'm sure your credit card is hurting after all that. But the savings in real, significant dollars is right around the corner. You will never regret it.

Buying and installing the EFM is on the short list of my greatest accomplishments.

PUMP SIZING;

I got my brain working on the pump sizing calcualtion this morning. Using the "Taco Radiant Made Easy Application Guide
Selecting Circulators" that Rob R. posted earlier in this thread ( thank you again Rob) I was able to do the following calculations;

Target flow = 80,000btu(exchanger) / 500(water) X 20(delta T) = 8 Gallons Per Minute

Using 200 feet of PEX pipe for the circuit

Target Operating Point = 0.00223(1"PEX) X 1.0(water) X 200(feet) X 38.055(flow rate to the power of 1.75) =
16.973 Feet of Head Loss.

Using the Pump Selection Chart; 8GPM by 17 Feet = Taco 0014 = $287.95 (ouch)

I will get that ordered today with some o-rings for the 007.

-Don