IBC Boiler wiring help

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hamel01

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Hey all,
So I am installing a IBC HC 20-125 in our new house. So far i have it all plumbed based off the information from some helpers and the guys that sold everything but i am at a loss for how to get it all wired. I think i know what needs to be done to correct it but i am looking for some insight. Here is the components i have to work with. IBC HC 20-125 boiler that has DHW call and pump connections as well as space heating connections for tstat, Caleffi 6 zone relay box that has connections for a zone 1 (Priority) pump, Secondary pump and system pump, (2) 007 circ's and (1) variable speed circ. In my system i have a DHW tank as one zone, garage in-floor as one zone and then 4 zones in the basement in-floor all fed from one manifold with Reahu zone valves on the manifold. I have attached a pic to show how it is plumbed current. the first pump is for DHW, 2nd is for garage in-floor and the 3rd is the basement in-floor. The combination of pumps and zone valves for the basement infloor don't seem to jive with the controls i was given. If i hook the DHW to the boiler and the in-floor to the zone control there is no way to tell the zone control that the DHW is running and not to run the in-floor heat due to the temp being too high. If i use the zone control for everything i have no way to separate the pumps for all 3 different heat zones. So after looking at this and thinking about it here are the options i have come up with:

#1 - Pull the middle pump and right pump and move it (Right/Variable Pump) to before the tee's on the supply line for the in-floor but after the tee for the DHW. Then install a zone valve for the garage in-floor. In the zone control wire the first pump to zone 1 along with aqua-stat from DHW tank. the other pump would go the sec terminal. Zone 2 would be the newly installed zone valve and 3-6 would be the basement in-floor which is zoned at the in-floor header. From there wire the xx terminals on the zone control to the space heating terminals on the boiler and the zone 1 output terminals from the zone control to the DHW terminals on the boiler.

#2 - Pull all the pumps and reinstall the variable pump before any tee's. Install zone valves for DHW and Garage in-floor and repeat most steps as above.

#3 - get another pump control unit to slave off the first one and leave it all the way it is.

To me #2 seems like the best option but not the least amount of work which I am ok with. I would rather have it right and spend some more time vs getting it to work as quickly as possible.

Does anyone else see any other way to do it?

Thanks!!
 

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