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Maybe you see something I don't, but the Brookhaven test you cite confirms an indirect with purge control is only 74.9%. for a steel boiler. Cast iron in the summer with indirect at 38.3%. Purge control on DHW systems can only help so much because the purge temp cannot go lower than the DHW...

I think, for ultimate simplicity, I'd just run the recirc as the heating line. Then valve it later if you can't get the two functions to match with timing and flow adjustments.

You are on the right track with your tube layout. Down and back in each bay works well. But you don't need the fins. Just run the tubing and mount it to the side of the joists near the underside of the floor. Then insulate and leave a space above the insulation where the tubes are. Never...

By the time you size the recirc loop and route the recirc loop to do heating as well as recirc, and then install a control system, you might just as well dedicate a heating loop with it's own circulator. It seems you might be adding too much complexity only to avoid using another circulator...

The element only responds to the thermostat and cannot make the water heater "run away"

The problems with an indirect in your case are that you are not increasing the efficiency of your system, the cost for the indirect and related equipment is much higher than a conventional water heater and you seem to be worried about hot water during power failures. The indirect won't work...

You cannot combine a forced draft. 95% furnace with a gravity draft water heater in the same flue. Either the fan is forcing exhaust back down into the water heater and putting out the fire, or the room is starving for air. Be sure you have adequate combustion air. Sometimes old buildings...

You are very likely to have problems with this setup. First will be too low of a flow rate through the loops. Second will be carbon buildup in the heat exchanger as the water heater will be throttled to the lowest fire most of the time. Third is possibly the gas line sizing. What was the BTU...

The humming or moaning is caused by low flow or low pressure in the heat exchanger. Those Raypak boilers are not just low mass, they are extremely low mass and famous for moaning. Low fire is the best answer for now as long as the output is enough to keep you warm, but it's not a true fix...

You didn't mention your working pressure, but if it's a drainback system with low pressure you can use fluorosilicone hose. It's very flexible and can take stagnation temps. A little movement over time can damage collectors that are rigidly piped together. They crack at the first tee inside...

The solar collector pump is controlled by a differential controller that measures the temp of the panels and compares it to the storage temp. When the panels are warmer, the pump runs and the storage warms up. When the house needs heat, as determined by the house thermostat, the floor...