Corn Fired / Fuel Oil Back-up Boiler System Concept
The system utilizes a corn-fired boiler with a fuel oil backup to maintain optimal heating conditions. It includes calculations for flow rate, pump sizes, and control mechanisms to ensure efficient operation and prevent overheating. Check out the detailed images and descriptions provided for a comprehensive understanding of the setup.
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Corn Fired /Fuel Oil Back-up Primary Secondary Boiler System Concept
Primary Main Size Calculation Total GPM of system is 5.8 1 Copper pipe has capacity of 8GPM per Dan Holohan books
Max zone Head 9.6 Primary Loop Head 0.8 Boiler loop head 0.6 each Total flow 5.8 GPM Selected Pumps: 3 Grundfos UPS 15-58FC 1/25 HP 3 SPD Pumps W/ Check. Zone pump: Med or HI Setting Primary Loop: Low Setting Boiler Loops: Low Setting Pump Size Calculation
Corn Fired Boiler / Fuel Oil Backup Summary of Operation Corn Fired boiler consists of Cast iron pot of burning corn. When aquastat determines more heat is needed, combustion blower is turned on and corn supply augers are activated to increase water temp. (High fire mode) If no call for heat is received after a predetermined time, boiler actives combustion blower and corn augers to prevent the burn pot from extinguishing. (Low fire mode) Concern of corn boiler overheating during extended periods in which house thermostat does not activate zone pump to remove heat from primary loop. In this case, Tekmar 150 will override thermostat once water reaches a setpoint to turn on zone pump to remove heat from boiler before corn boiler shuts down due to overheat. Corn boiler and fuel oil boiler to be vented to same masonry chimney. Therefore, Tekmar 132 sequencer will ensure that Fuel Oil back-up cannot fire until Corn boiler is completely extinguished. The Flue proof on the 132 will determine whether to fire the Fuel oil boiler only during thermostat calls for heat. I have concluded that the best sensor to connect to the 132 to determine corn boiler extinguishment would be a secondary aquastat placed inside the corn boiler. This aquastat could be set at a very low water temp (such as 80F.). Since it would be quite a while before the water in the system will cool to that temperature, it can be concluded with high certainty that the burning fire pot of corn is fully extinguished. Therefore, when the thermostat calls for heat and aquatstat tells the 132 flue proof that the system water is below 80F, the fuel oil boiler will be allowed to fire. During Corn boiler start up while water is cold, I would either have a thermostat disconnect switch or reduce thermostat temp. Therefore, the 132 would not try to fire the fuel oil boiler while the corn boiler gets up to temperature. After the corn boiler reaches temp, the thermostat would be re-introduced to the system to resume normal operation. Please see follow slide for Schematic
