Attack Boiler w/ 550G open storage install

[3fordasho]

Thought I would document my 2nd boiler install here, will add updates as the install progresses.
Back of the boiler plumbing underway, Dirt separator and relief valve on the bottom, Alpha 2 circulator, LK823 return protection upper right.

 

[3fordasho]

Boiler will replace this Tundra, just not enough horsepower for my 39x60 shop (quonset style buiding), especially when starting with the building at 35-40F.

 

[3fordasho]

Yes you need lots of fittings and valves $$$ ;-)

 

[3fordasho]

550 Gallon Stainless Steel tote from work for open storage, 100K btu rated heat exchanger next to it. Tote was free because someone at work hooked up a positive displacement transfer pump and did not vent the tote. Pretty impressive to see it suck in like a crushed pop can.
(since been straightened)

 

[3fordasho]

Room prep where the tote will go. Had to cut a 4' wide opening from the main shop area into a small office area.

 

[3fordasho]

American Solartechnics 100k BTU heat exchanger sitting in the SS tote.

 

[maple1]

Cool, will be watching this one.

Your first pic - no iso valves at the boiler openings? Also if the LK823 has those little built in iso valves like the LK810 does, I would pretend like it didn't and put ball valves there too. I had to isolate my 810 to get the circ unstuck once, and tried to use the built in ones. They turned hard as heck and one seeped out the top for a while afterwards.

 

[3fordasho]

Cool, will be watching this one.

Your first pic - no iso valves at the boiler openings? Also if the LK823 has those little built in iso valves like the LK810 does, I would pretend like it didn't and put ball valves there too. I had to isolate my 810 to get the circ unstuck once, and tried to use the built in ones. They turned hard as heck and one seeped out the top for a while afterwards.

Good to know the LK valves are marginal
On the return I don't like to put a valve in between the boiler and the pressure relief valve, somebody could shut the valve effectively eliminating any pressure relief safety.
The two uppermost valves shown should provide enough isolation, no big deal to drain the boiler to service anything shown in that pic.

 

[andym]

Cool project. Is that a Lambda boiler like your other one? I almost bought one last spring, but the whole setup was more $ than I had to spend. Ironically i got a Drolet instead!

 

[3fordasho]

Cool project. Is that a Lambda boiler like your other one? I almost bought one last spring, but the whole setup was more $ than I had to spend. Ironically i got a Drolet instead!

Yes, the Lambda version. The Drolet owes me nothing, quite happy with it actually. I am hoping 550 gallons of hot water storage will keep the building above freezing between firings. (still have propane back up so I don't freeze anything)

 

[3fordasho]

Tank moving time. Capable moving equipment helps a lot for projects like this. Need to drill some pass through holes in the ceiling before I push the tank into final position.

 

[3fordasho]

Not much progress tonight, positioning storage tank and fitting copper piping to the storage HX connections.

 

[Hydronics]

Nice work, nice score on that tank. Don't forget to pipe that relief valve towards the floor.
Only install issue to reconsider is that sign on the wall that says Ford Country...

 

[brenndatomu]

Only install issue to reconsider is that sign on the wall that says Ford Country...

Shoot, I assigned bonus points for that!

 

[3fordasho]

Finalized storage HX connections, started piping run towards boiler:

 

[3fordasho]

more progress on the piping runs, fan coil under the steps, need to mate the blower housing up next:

 

[3fordasho]

Air flow for the HX- cut off the blower box from a decommissioned propane furnace and mated to the water to air HX. It also provides for a 14x25 filter.

 

[3fordasho]

Finalized control wiring for the WAHX blower box - basically just a 24vac transformer, relay and thermostat to run the circulator and blower (switch is to go from auto to manual operation of the circulator). In the summer I put the circulators in the manual position and then select "summer" mode on the Alpha 2 circulators - this prevents them from locking up from non-use.

Tundra on its last coals before the swap, and finally the Attack boiler in place leveled and connected to the flue.

 

[3fordasho]

Completed piping runs. Boiler and rest of the system is pressurized with compressed air to 17psi for leak checks. 3 or 4 found and sealed so far. Electrical completed at the boiler. The Attack is a 240 v boiler so a 120v to 240v step up transformer is required. (can not use typical 240V 2phase or 2 hot US power, so the transformer is used) The output for the boiler to storage circulator is also 240v so instead of purchasing an odd ball 240v circulator, the output goes to a solid state relay that will switch the desired 120v for the circ.

 

[3fordasho]

Flushed and filled the system tonight. I had to remove the thermostatic element in the boiler return protection valve because it prevents flow through the boiler when the water is cold. Flushed for a good 10 minutes and used a filter sock to catch any particles.

 

[maple1]

Did you catch much?

 

[3fordasho]

Did you catch much?

I'll check later today and post up a pic. Ran out of time last night.
Also need to swap out the solid state relay that controls the alpha 2 circ. The alpha doesn't seem to like the SSR so I will have to switch to a standard relay. On the plus side the system seems to be holding pressure, no leaks as of this morning.

 

[3fordasho]

Did you catch much?

Not much of substance inside the filter sock, but lots of small particles. Surprise leak once the system got hot at a sweat fitting, sometimes the flux seals things up when cold and then lets loose once things get hot. Project for tomorrow night.

 

[3fordasho]

Pipe and storage tank insulation install:

 

[3fordasho]

Connecting the overheat protection valve (watts sts-20) to the overheat loop in the boiler and the other side to cold domestic water, drain connection not completed yet. The Watts valve opens if boiler temps hit 97C and floods the overheat loop with cold water - the typical european overheat protection scheme in case of power failure or some other failure causing over temp.