Supply manifold, dip tube done

Today billn figured out how to make the dip tube work. Even though Ergomax is the best water heater ever, they are not perfect. Their plan for the dip tube for the user to purchase a double tap bushing and have a straight pipe down to act as the return connection for the heating system (if you don't understand, don't worry). First of all, nobody seems to sell a double tap bushing and secondly, a straight pipe hits the internal coils of the unit. Billn solved this by drilling out the 3/4" sweat by 1" MPT adaptor and sweating a short length of tubing in. To solve the straight shot problem, billn used a short length of PEX with a recycled hunk of male adaptor to act as a weight.

This method threaded into the return tapping and should be just fine.

Here is the finished (boiler-water only) water heater. Billn still has to connect the domestic hot and cold water lines, but this is good progress.

Here is the supply manifold. Billn still has to connect all the distribution lines out. A prize goes to the reader who notices the problem with the pressure gages.

The wires will all bundle together into a loom, then will be butt spliced onto longer wires to go to the control panel.

Some more progress on heating, leaves turning

Here is the boiler and water heater with much of the piping done. The crooked vertical line coming out of the water heater is thanks to the not-square fitting welded onto the water heater. The domestic water piping is not done yet, but one step at a time. The board to the left of the water heater will house the domestic water mixing valve and the mixing valve and circulating pump for the kitchen radiant zone. Yes the air separator is much bigger than our 3/4" line size, but it was in the original piping system, so the price was right.

Here is the return manifold. The red and blue PEX lines on the left of the picture are the domestic water lines for the plumbing systems. We have seven zones plus a spot for a spare. The orange PEX line is the 3/4" main return line for the manifold. The water in the manifold flows from right to left into that orange line, back to the boiler/water heater. The silver valve on the extreme right hand side of the manifold is the differential pressure bypass valve. The supply manifold will live above the return, look for that picture later this week. The PEX lines make that big U-shape to prevent gravity flow (sometimes called "ghost flow"). If you really want to understand what that is all about, post a comment here and billn will expand on it. But it is boring for lay-people so billn will not post about it today.

Here is a tree across the street from billn's work. Billn took this picture early this morning, September 25, 2007. This picture reminds us why we live in VT.

Oil tank, boiler, water heater moved, some venting done

This weekend the Brooklyn Barrister visited our home and country. We were able to arrange a temporary work visa with little trouble. Here is a picture of one the key components of our boiler relocation project, the power venter and boiler vent duct (larger). The smaller duct in the back is for combustion air, that is not done yet.

Here is the power venter before billn installed the vent ductwork and control box. The drywall on the ceiling of the joist bay is insurance, the venter has a cool exterior, due to the combustion air flowing over the internal duct which contains the hot products of combustion. This is a slick setup.

Here is a shelf unit full of materials and parts we bought. Some of you may notice Grundfos pumps, these are to satisfy Tom D.

We are using the best water heater on earth, Ergomax. They designed this unit to act as both a water heater and a buffer tank. Since our house has seven small zones, a buffer tank is useful to increase efficiency (by increasing on/off times, frequent cycles are bad for efficiency. This is a home-made dip tube fitting, a 1" MPT by 3/4" sweat fitting billn drilled the stop from.

Here the Barrister and the water heater exist in the back of the garage. We moved a number of heavy items this weekend, but we lifted none. Brainpower over brawn (which was the only way we could do this, neither the Barrister or billn are particularly strong).





Here is the an interior wall we removed the drywall from to install OSB instead. We will mount the zone valves and manifold on this wall.

Here billn and the Barrister move the boiler from one part of the garage to the other. It is on a dolly. Billn previously lifted it up on blocks using prybars and patience.







Here the 1/2 full oil tank (total weight about 1,000 pounds) sits on a dolly. The other end is on a a floor jack. The pictures below capture the various stages of rolling/moving the oil tank from one part of the basement to the garage. Billn was very pleased how well this operation worked. Not a drop spilled, no heavy lifting.

Here is the oil tank, the boiler and the boiler vent duct. The boiler combustion air duct is not finished, the water heater is not in place right now, while billn completes the combustion air duct.

Friends from the Albany-Area visit

Friends of Jenm and Billn from college visited with their kids last weekend. On Saturday, JasonT and Billn constructed a new gate for Senior's school. Careful blog readers probably remember Billn built one earlier this year, but that was a temporary solution. This summer the school built a new fence. Billn built a new gate, with JastonT's help.

Here Senior helps Billn move wood for JasonT to cut.

Also this weekend, JasonT and Billn cleaned out the back of the garage where the boiler will go. There was a large, hacked-together shelf in the back. Now it is gone.

Here is our boiler and electric water heater. Of course Billn cannot leave the boiler as it was when they moved in. Watch this blog in coming weeks to see the improvements.

We insulated the ceiling above where the boiler will go, after insulating, we installed drywall. Much easier to hang drywall on a low ceiling with two people. That is a good look for JasonT, he would look at-home in Beijing.

After our friends left, our neighbor H visited and climbed the tree with Senior, Junior and Billn. Billn maxed the tree out a few minutes after this picture was taken, he feet at 25' above grade.

Senior was tired out from our friends visit. Here she rests with Billn in the shade. This nice weather and sunshine is the reason our boiler project is not complete, why install tubing, venting and oil pipe when you can relax on the front lawn?

Here is everybody:

JasonT, daughter TG, wife AleciaT, other daughter AJ, son (face obscured) K, Senior, Billn, Jenm and Junior.

A fun weekend, we hope our friends from the New York capital district visit us again soon.

The other new addition to our family

Here is Larry and Larry's sister Barry. Barry's correct name is Zulu, but Barry rhymes with Larry. Barry belongs to Junior.

Resting Cat is not certain what to do about Larry and Barry, but he glad they fight each other and not him. He rests better with them.

As a side note, none of the three cats that live in our house has caught a mouse yet. Look for Victor mouse traps appearing soon.

New addition to our family

We used to have one cat. George. George is about 13 years old, he is great. He used to be frisky, then just energetic, then when the children came, he started relaxing. Now he is so relaxed, we call him "resting cat."

We live in the country, mice come into your house. Resting cat has declined to take care of them. Billn suggested mouse traps. Jenm thought a new cat would be the answer.

This is Mya. Billn calls her Larry. Resting Cat did not appreciate Larry when Larry first came home. Resting Cat likes being Top Cat, Only Cat and Best Cat. Larry belongs to Senior. Larry is frisky and curious.

Resting Cat has come to accept Larry, we would not say he loves her, but he is not being mean to her. In fact, she attacks his tail, he just walks away. Young George would have injured Larry, but Old George just wants to sleep.

Here Larry sleeps, Resting Cat does not.