This is my first ever boiler installation. I knew nothing about boilers two years ago and because of the people here I believe I pulled it off. I'm just a home owner who learning things like this. I could have made it simpler but at least it's done now.
I'm posting this because past installation threads really helped me. There have been a number of members here who have also helped so thanks again.
This was the final design. I spent a lot of time working this out and it changed many times while I was building it.
I used two moving dollies and two car floor jacks to roll the boiler into place. I moved this by myself and it worked. It almost tipped over once.
Had to put in an 8" flue. I used a diamond blade circular saw to get through the cinder block and a 4" diamond blade cut off wheel to get through the terra cotta liner. I've used hammer drills in the past but I found the cut off wheel much easier.
These were old 3/4" supply and return manifolds I scavenged from an older boiler. Everything worked so I cleaned them up with
ketchup.
Building out the supply side. Paid attention to the 18" before the air scoop. I overbuilt this with (3) 1" supply and returns plus the (3) 3/4" supply/returns.
Front view with return lines mocked up.
Worked on the return manifold. The electrical was started. Painted the masonry wall too.
I added this picture. I read a post where someone said to install an overhead light. That made a world of difference with the rest of the install.
It's starting to look like I'm making progress here. The 3/4 manifolds were added from the scavenged boiler. Had to redo some of the copper pipe though. I used a few unions to remove the 3/4 manifolds if/when needed.
The tricky part of the piping was the hot air furnace duct above.
Wired the aquastat. Rather than wire the stoker and circulator directly I put ran wires to the junction box below so I can unplug either one and plug directly into the outlet nearby. Just have to remember not to mix them up.
Working on the water supply. What a waste of time trying to reuse 1/2" valves.
I was able to salvage the back flow and pressure reducing valves. Neither worked so I pulled them all apart and cleaned the insides. They worked after that.
Electrical done and the return is nearly complete.
All the black iron and copper work is completed. Next it's time to install pex......the color of the boiler looks different in this pic.
Pex install.
Color coded the circulator and stoker plugs with paint. That aquastat cover is wrong so bungee corded it on. Also have a barbque thermometer in the chimney stack and another thermometer to see what return temps are. Probably didn't need the purge/fill valve but it works well.
Circulator pump did not work initially. I found it in a junk pile at my oil friend's company. I pulled it apart and gave it a spin to free it up and it works. I like "free" when it comes to plumbing. Hopefully I can get a few seasons out of it.
Supply and Return complete. There's a 1" supply line with manual valve coming off the manifold that goes to my modine-style garage heater. I didn't want to spend an extra $150 putting in a zone valve and thermostat. Not many members here approved of it but for now it works. I'm only going to use when I'm working in there. I'll have to plug in the heater fan manually also when I use it.
Boiler install is completed.
I am still working on a coal bin and a delivery system to fill it.
I need to familiarize myself with air and tooth counts, hi lo settings on the aquastat, and the settings for my fan limit switch for the radiator in my furnace plenum.
I'm also playing with furnace fan settings to pull off enough heat from the radiator while keeping total external static pressure within furnace specs.
Overall this was a fun project. What I like best is that I know everything about this system and can now work on it. Thanks everyone for all your help.
