KA6 Is Plumbed and Ready for Coal

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Hollyfeld
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Post by Hollyfeld » Sun. Oct. 19, 2008 8:42 pm

Almost.

Yesterday and today a good (great) friend and myself plumbed the KA6 into my system. The problems I was having understanding the purpose of the bypass were solved when Phil (the great friend) devised a plan of running the bypass through the oil boiler. This made the install a helluva lot easier and very straight forward. We decided to the existing circulator where it was on the feed from the oil boiler and take that and connect it into the return of the KA6.

If I'm running oil, then the water flows from the oil boiler into the KA6 and then out to the system for heat (or to the boilermate for DHW). In this case then the bypass loop would be closed.

If I'm burning coal, then the water flows from the KA6 into the system and then returns thru the oil boiler (which will not have power because I will not have the flue connected) and then into the return of the KA6. The bypass loop is open so if the 4006B turns on the circulator, the water will flow the loop and the oil boiler before returning to the KA6.

After having the oil boiler going and trying to get all of the air out of the system, which may take some time, I'm thinking that either my current Taco 007 circulator cannot push the water through the KA6 and into the baseboard, or I still have air to get out. I don't hear any gurgles anywhere, but I'll be bleeding the radiators a little more.

Tomorrow night we'll be doing the controls and if all goes well, then I'll be lighting the coal on Tuesday.

Question/concern - I noticed the temp in my oil boiler was going to around 190 and then went over. The temp on the KA6 was getting closer to 160 and finally reached it, but I'm concerned about the temp in the oil boiler. I shut off the thermostats for the night and will turn them back on tomorrow when we're doing the controls. Can anyone see a problem with the design we did? Why is the water in the oil boiler getting that hot? If the oil boiler is supplying the heat, I assume the bypass should be closed. With it closed, the temp in the oil went high, when I opened it, it dropped.

Thanks.

 
gregolma
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Post by gregolma » Sun. Oct. 19, 2008 10:50 pm

From what it sounds like, your use of the oil boiler in the plumbing as a "bypass" has instead made the oil boiler the only radiator.

Both boilers should be piped separately into the system. Use primary-secondary piping with the system having a circulator and each
boiler having a pump to move the boilers output into the system.

 
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Hollyfeld
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Post by Hollyfeld » Mon. Oct. 20, 2008 7:34 am

I don't understand how that would make the oil boiler the only radiator? If the zone valves for the 2 zones are calling for heat, they will open and start heating the baseboard. If the zone valves are closed and the KA6 gets too hot, then it will cycle the water thru the loop and the oil boiler giving the water more room to cool down. Or am I mistaken?

I woke up this morning and the floor in the mech room was wet. :mad: The old gate valve drain on the return to the system was leaking. We had a hose hooked up to this and I wouldnt be shocked if yesterday was the first time that valve was turned in over 30 years... drained it down and then ran out for a new ball valve. No leaks now.


 
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Hollyfeld
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Post by Hollyfeld » Mon. Oct. 20, 2008 10:20 am

gregolma wrote:From what it sounds like, your use of the oil boiler in the plumbing as a "bypass" has instead made the oil boiler the only radiator.
In theory, this is what we did, but it's only going to be used in the case of the coal boiler overheating and turning on the circulator to cool it down.

 
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Post by gregolma » Tue. Oct. 21, 2008 7:27 pm

The Taco 007 (which has a pretty high flow and head) or any pump will seek the easiest path. The easiest path is the oil boiler. I think its mainly circulating through the boiler and back and setting off the limit switch.

 
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Hollyfeld
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Post by Hollyfeld » Tue. Oct. 21, 2008 7:58 pm

Gregolma, you are correct. I have a ball valve on the by pass and have throttled down the loop a lot. If I can get this system to perform and get me through the winter, I will be making some changes come spring.

There was a large pocket of air stuck up in the baseboards on the first floor and the loft. I'm thinking there might still be some air in the system somewhere because I am not getting decent heat coming off the radiator in the loft.

I am burning coal and the oil is off! Woo Hoo!

Pressure is reading about 16, and the temp is around 175.

I'm 11 turns out on the red nut and the timer is set with 5 pins of running every 15 minutes. Keystoker recommended starting with the 11 turns when I called them this morning with some questions.

Thanks to all for the help and the advice.

edit: 3 minutes for 5 pins.


 
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vtec350
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Post by vtec350 » Tue. Oct. 21, 2008 10:55 pm

Congrats. on the new boiler Hollyfeld :cheers: You'll love the heat from it and know you're not using any more oil :dancing: . I had mine installed durring the summer and fired it back up a week ago, still messing with the setting with the warmer days and cool nights here. You might be able to back the feed nut off a few turns depending on how many zones you're running and DHW. Mines at 17 turns rite now, small idling fire but I'm only running 2 zones and not a big call for heat yet.

Dave

 
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Post by djackman » Tue. Oct. 21, 2008 11:13 pm

Hollyfeld wrote: In theory, this is what we did, but it's only going to be used in the case of the coal boiler overheating and turning on the circulator to cool it down.
Congrats on the new boiler, I've had mine up for only a week and butt is still sore from kicking myself for not doing this 3 years ago.

One of the heating zones should be the "dump" zone - oil boiler will only have a finite capacity to absorb excess heat since it's not radiating it anywhere.

Also makes more sense to dump excess heat into house instead of "wasting" it into the oil boiler.

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