Best Of
Re: Small DIY radiant bath heat
More crucially, a HPWH pulls heat from inside the building. Using it for space heating is like a perpetual motion machine.
Re: (Updated with pictures.) Likely gas leak after installing new thermocouple?
Hi @Lashen , I agree with what @mattmia2 said. If you look closely, there is some whitish buildup between the nut and what I'll call the body that the gas tubing is attached to. It suggests a leak. If you have some skill and tools, you could do this, or get a handy-person, but I'd back that nut out and then clean things up. Then reinstall the nut using two wrenches, one on the nut and the other on the body. Also, the aluminum pilot tube usually would be coming straight out of the bottom, not as angled as it is. Finally, the tubing looks like 1/8" tube, not 1/4" tube, but the fitting looks like it would fit 1/4". I'd want to look at that a little closer to see if the tubing really fits correctly and if it might have been changed.
This is gas and it's dangerous. I'm talking to you like I'd talk with a technician. If any of this is not in your wheelhouse, please do get help.
Yours, Larry
Re: Monoflow system does not heat well
Can you check the temps in and out of a few basebords? You will probably find the problem their. I would go down the line and check the main temp at the first tee and the first baseboard inlet and then the baseboard outlet and at the Monoflo tee. Repeat this down the line.
Re: Cracked cast iron rad
there is no way that boiler built up enough pressure to break that radiator!
I agree it looks like a previous frozen weekened and finally let go

Re: Monoflow system does not heat well
The head is relatively low in a monoflo loop but you need a fair bit of velocity for the water to take both branches of the diverter tees.
You may need more gpm than @EBEBRATT-Ed calculates to encourage enough flow in the branches. It would be a balance between the max velocity for the pipe size and what it takes to move the output of the boiler but if the boiler is enough smaller than the piping the water might just happily circulate around the run of the monoflo tees if you calculate only on what you need to move the heat.
Are there any balancing valves or bypass valves that need to be partially closed that are now wide open?
Just because you don't get air when you bleed doesn't mean there isn't air somewhere that can't get to the bleeder valves but more bleeding isn't going to fix that if it is the problem.

Re: Small DIY radiant bath heat
A second circulator and fittings for the hx add up fast. The second, small water heater if you fill it with a hose is probably the cheapest option.

Re: Pressure rising causing PRV to slowly leak
Here is a comment I made last year that explains how the wrong pressure in the expansion tank looks when you check it when it is connected to the system.
In your case the expansion tank with 40 PSI air pressure in it will not accept any expanding water from the system before the pressure gets over 40 PSI. the problem is that the relief valve will discharge any water pressure over 30 PSI. So that expansion tank is not an expansion tank at all, it may has well be a closed valve.
Re: 2 out of 3 heating zones not working
Lol, purging for 20-25 minutes? On a first floor air handler 8' from the boiler? I don't think the first floor air handler or the indirect water heater would need more than a minute or two at most. Especially if the automatic air vent on the boiler is working.
Does the zone valve open for the first floor air handler or the indirect water heater when they are calling for heating? Does the circulator operate? Those zone valves have a very high failure rate. Even though they might be opening it doesn't mean the end switches are functioning. It wouldn't surprise me to find 2 out of 3 bad on one boiler.
Re: Gortons spitting on cold start
A statement was made about a blow test " The Gorton vents pass the blow text, both right side up (they pass air) and upside down (they close)." This test to determine if the vent will close is not valid. Turning the vent upside down to see if it closes will only determine that the vents will close if the expansive element [canister or bimetallic strip] will move far enough and apply enough pressure to keep it closed when heated by steam. I have dozens of vents that close when air is blown into it when upside down but not when heated, See discussion " Vent testing and repair"
Re: Peerless ECT-03 vs WM SGO-3 vs Williamson OSB-3
Whichever… the quality and skill of the installer is at least as important as the label on the boiler.