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http://m.youtube.com/watch?v=Xja1viotVvk youtube video of Taco circ and what it does.

http://m.youtube.com/watch?v=d6Pbrz8wwcI variable speed delta T circs and their applications/benefits

http://m.youtube.com/watch?v=-XGNl9kppR8 hydronics design basics , why you use the equipment and circs where and when you do to achieve a working system

I wasn't able to link directly from the Taco flo pro U list of videos. But it is free to register and get your learn on." How to read a curve chart to select a circ" , "how to calculate TEL,( total equivalent length of pipe) =head for circ selection" " how to calc the GPM for the zone" .....there's a lot of free accurate info for the DIY wood boiler owner. Knowing this will put you on par or ahead of many installers. At least you'll understand what's going on or why boiler systems are not as easy as they appear.

A good article explaining the universal hydronic design formula. BTUH=GPMxDTx500

http://www.fueloilnews.com/ME2/dirmod.asp?nm=&type=MultiPublishing&mod=PublishingTitles&mid=8F3A7027421841978F18BE895F87F791&tier=4&id=663F2C7F5BA543968C4AAB1732E86FFB

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Some performance data specs on logstor underground lines and recommended flow rates
http://www.urecon.com/applications/hydronics_flexible.html

Flow rates and erosion velocity, http://www.urecon.com/documents/pdfs/other/PEXFlex_losstable.pdf
90's, backside of Tee, iron pipe shoulder nipple threads and IP threads are where I see the most erosion failures from excessive flow. In lower temp applications below 160, some use cpvc to counter the growing costs of brass and copper, especially for header runs on snow melt applications.

Pipe size.         Max flow.  BTU/hr@DT20
1/2" copper = 1.5gpm            15kbtuh
3/4.    ".            4gpm.           40kbtuh
1".                   8gpm.            80kbtuh
1.25".              14gpm.          140kbtuh
1.5".                22gpm.          220kbtuh
2".                   44gpm.          440kbtuh
3/8 pex.           .6gpm.            6kbtuh
1/2".                 1.5gpm.         15kbtuh.              Note pex brand and specs differ. For ID.
5/8".                 2.4gpm.         24kbtuh.              Head loss and flow rates.
3/4".                 3.2gpm.         32kbtuh.              Uponor, viega, stadler are full IPS diameter
1". Pex.              5.4gpm.        54kbtuh.               And their fittings
1.25".                8gpm.           80kbtuh
1.5".                  11.2gpm.       112kbtuh
2" pex.               20gpm.          200kbtuh

Pressure
28" of water = 1psi of static head.  23.33'= 10psi

Strap on temp gauges are a very cheap and effective troubleshooting tool, so are IR guns once you've learned how to get consistent accurate measurements.

Another flow rate chart by Taco, includes pex-Al-pex and fitting head loss values
http://www.taco-hvac.com/uploads/FileLibrary/SelectingCirculators.pdf

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Thanks, trying to make a list of necessary info for sizing and troubleshooting.
This is a head loss chart for pex....noting as you go outside of proper design flow head loss climbs exponentially. Which just leads to problems, larger circulatory are needed.
See on the chart, the white section is 4'/sec velocity, staying below this allows for using smaller pumps. Yes upsizing pipe diameter cost more, but it can also deliver more btu if needed. Allowing for more flexibility or expansion in the future. I see why many systems use extra large and expensive circulators, because of pipe size and cost.

http://www.mrpexsystems.com/MrPEX_Install_Guide_Sections/Section_23_Pressure_Loss_And_Cv_Charts.pdf

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How to calculate circulator size links, and some design applications, system analysis

http://www.comfort-calc.net/circulator_sizing.html

http://www.taco-hvac.com/en/products/products.html?current_category=370

http://www.taco-hvac.com/en/wizard_pumps.html

http://www.taco-hvac.com/en/products/Hydronic%20System%20Solution/products.html?current_category=84

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Tap sizing, just because its 1" thread port does not mean the run of pipe should be all 1" and here's why
http://www.comfort-calc.net/pipe_sizing.cfm

Some primary secondary piping, close Tee flow diagrams, how and why the flow workx depending on exactly how you pipe your fittings. Too close, to far, using ends instead of side.....

http://www.comfort-calc.net/primary-secondary_piping_tutorial.cfm

If you have time there are definately a few real helpful tabs worth reading....

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Bump the spam