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Hoffman Boiler Feed, persistent trickle feed and overflow
Update 7/15/14: Found a considerable amount of muck in the line leading to the feed valve, coal like material that could be dug out. Photo posted below. Disassembled and flushed valve to no avail; it wouldn't seat properly so I replaced the whole thing.
This thread morphs into asking how I can prevent another failure.
On a Burnham V 905 series steam boiler (small commerical, 4GPH) there is a Hoffman Boiler Feed Series VBF Model 30-VBFS-B condensate tank. Feeding it from a 1/2" domestic water supply, there is a Watts 9D-M3 backflow device and then a Bell and Gosset FB-38TU pressure reducing valve.
The condensate tank slowly feeds water all the time, and as a result the boiler floods.
Here's what I've done:
1) The screen leading to the backflow device on the supply side is clean and clear.
2) The strainer on the side of the PRV was totally crudded. I removed it, flushed fresh water through the valve into a pail and installed a new strainer. I activated the valve's feed lever several times in hopes of clearing anything that might be lodged in the seat. Sidenote, the tank says not to allow more than 30 PSI feeding it, the PRV is set to factory default of 12.
The tank continues to trickle water and will overflow. What else do I need to do so the trickle will stop?