New Weil-Mclain Ultra 2 Installation

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Old 11-03-08, 11:59 PM
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New Weil-Mclain Ultra 2 Installation

Greetings,
Awhile back I posted here seeking help with installing a Honeywell wireless thermostat, which I appreciate! Just a couple of weeks ago we had new boilers installed by a local plumber and I thought I would share a few pictures. There are two Weil-Mclain Ultra 2 boilers which are replacing a an oversized Crane cast iron boiler which was about 50 years old. In addition to radiant heating, they are now handling the DHW. We also had TRVs installed (70 of them) to replace original valves on the cast iron radiators.

Here are the pictures:

http://i357.photobucket.com/albums/o...1/IMG_3076.jpg
Controls - Erie Boiler Boss relays and Honeywell wireless Tstat back in action.

http://i357.photobucket.com/albums/o...1/IMG_3074.jpg
One of the boilers with cover off during installation.

http://i357.photobucket.com/albums/o...1/IMG_3078.jpg
A look at the whole system. You can see the spot on the floor where the old Crane used to sit.

http://i357.photobucket.com/albums/o...1/IMG_3077.jpg
Close up of boilers side by side.

http://i357.photobucket.com/albums/o...1/IMG_3081.jpg
Circulators for heating.

http://i357.photobucket.com/albums/o...1/IMG_3079.jpg
The hot water heater is now being used as a storage tank.

http://i357.photobucket.com/albums/o...1/IMG_3085.jpg
Better look at the heat exchanger set up for DHW.

If you have any questions, let me know and I will do my best to answer them. I do have a question for you guys but I'll let you enjoy the pictures first.
 
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Old 11-04-08, 02:39 PM
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Nice looking job. I assume the indirect is prioritized.
 
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Old 11-04-08, 05:04 PM
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You know me, always gotta pick ... it's easy to say woulda/shoulda, isn't it ? but;

A piece of plywood behind the controls would not have been a bad idea, nor would mounting those two odd relays in an enclosure ...

That manifold is something ! Was that custom fabricated for the job? One thing I'm wondering about though... doesn't it seem as though the pump to the left would tend to get a larger percentage of the return from the right hand loop ? With both pumps running, I can see the left pump just gobbling up all the return water ... might that not tend to make that circuit run a bit cooler ? OR, is the volume of that manifold enough that it won't happen ?

SEVENTY ? TRVs ? wow ... I could put in a whole system for what just those set ya back ... but good for you... looks like a real nice job ... how's it performing so far ?
 
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Old 11-04-08, 05:58 PM
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Nice work. What kind of control runs these? Are they fired as 2-stage with lead-lag, equal runtime, or other rotation?
 
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Old 11-04-08, 06:06 PM
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The way they had it set up, the indirect was not prioritized. I had to remove a jumper on the Boiler Boss to give DHW priority. More on that later.

I agree about the lack of plywood. I'm not sure why they did that. The old controls were mounted on plywood. As far as the manifold, I'm not sure if they custom fabricated that or not, I was going to ask them though. They'll be back to do some insulating on 4" pipes that run throughout the basement, so I will try to remember to ask them then.

We were a little curious about the pumps as well, but they said the water would be moving through the manifold so fast that it shouldn't be a problem. Still, last time it was running the pipe above the left pump was noticably cooler than above the right pump. We'll have to see how that does in the winter.

We are a rescue mission (homeless shelter) and were able to qualify for some funds specifically to help reduce energy costs. If it weren't for that we probably wouldn't have been able to get the TRVs. We were also able to have all of our windows replaced, can't remember exactly how many but 120 windows rings a bell. The old windows were original to the building, almost 90 years old. In the past, when it was windy outside it was windy inside. We hope that with new boilers, TRVs and windows we will enjoy reduced heating costs this year.

Right now it is only handling the DHW but we had it on for a few days for heating about a week ago. I will be anxious to see it put to the test when it gets really cold. We've been enjoying temps in the lower 70s this week though.
 
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Old 11-04-08, 08:42 PM
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Do both pumps run simultaneously ? or is it two zones ? If it were two zones, and the water was cooler in the second, all it might mean is that the second zone would have to run for a bit after the first one shut down ... cuz then it should get full hot water ... probably will work just fine.

Bless you for helping the homeless.
 
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Old 11-04-08, 08:58 PM
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This is an interesting setup.

Why the flat-plate heat exchanger on the indirect?

Have you given any thought to sending some pics to the W-M main office or the regional W-M rep? Would be interesting to get some factory feedback.

Depending on how the boilers are staged, the left/right cool/warm issue may just be a function of control strategy, but it is interesting that the boiler is at the end of the line.

Thank you for helping the homeless.
 
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Old 11-04-08, 09:06 PM
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Originally Posted by xiphias View Post
Why the flat-plate heat exchanger on the indirect?
It doesn't look like an indirect. The FPHX keeps the domestic water separate from the boiler water.

*****************

Thanks for sharing the pix... overall, very nice.
 
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Old 11-04-08, 09:15 PM
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Originally Posted by xiphias View Post
Why the flat-plate heat exchanger on the indirect?
It doesn't look like an indirect. The FPHX keeps the domestic water separate from the boiler water.

*****************

Thanks for sharing the pix.

I'm not sure that the piping layout is ideal, but it should work.
 
 

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