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Re: EDR Calculation Help - In Need of a New Boiler
The number on the boiler has a 30% pickup factor subtracted from for the rest of the system losses it so the output is actually 30% more than what the ratings plate says. The load from the piping is likely far less than 30% so a somewhat smaller ratings plate number will likely work fine.

Re: Circulation issue- lp boiler
Maybe I'm ,missing something, but I don't see any way to purge the zones individually without running water through the separator — and the boiler. Which won't help at all.
Re: Circulation issue- lp boiler
It needs purge valves on the returns above the ball valves on the system side of the separator. With the purge station on the boiler side, it's just purging through the boiler.

Re: Piping for New Steam Boiler
No harm with the 4-inch header, except to your pocketbook. Probably overkill, especially if the header's dropped, which would also be overkill if you have room for a nice high header. You have to analyze the benefit in light of local conditions.
Re: Oil Burner Vacuum Question
If your not getting any air to the burner and it fires ok then I think you are ok.
You might want to put a valve between the vac gauge and the oil line to "save the gauge" The pulsations may hurt the gauge over time. If that happens the gauge may lie to you
Re: Oil Burner Vacuum Question
anything over 7” hg. vacuum we recommend a two stage pump
You are just fine at 5 to 6” vac
Re: Smoke smell in house with oil boiler
You mention that you burn wood, at least sometimes. The smell from a wood fire, or one which has almost gone out, is distinctive. So, for that matter, is the smell of diesel exhaust from an oil burning boiler.
So…
Which is it that you are smelling? The two are really very different, although it is common enough to refer to both as "smoke". More to the point, the source of the two and the causes are completely different. So we really need to know.
Re: Room seems to be stuck in a narrow range of 66 and short cycle.
why do you want it to run longer and less frequently?
Personally I would find a 3 degree overshoot or like a 6 degree swing unappealing.
When I timed that a few times, it was exactly 4 mins every time.
This makes sense because each time it is heating water from x degrees to y degrees in a very controlled environment.
Re: Room seems to be stuck in a narrow range of 66 and short cycle.
@CoachBoilermaker you could adjust the anticipator to run a longer cycle.

Re: Room seems to be stuck in a narrow range of 66 and short cycle.
How frequently does that cycle repeat? If it's only two or three times an hour, it's a bit too often — but the real bottom line is this: the job of the thermostat is to hold the space at or very close to what it's set at.
It's doing that.
I wouldn't complain.