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Lochinvar Solution boiler issue with high temp/relief valve/tank

I have a 10 year old Lochinvar Solution boiler. I mostly use wood during the cold cold months, but in season transition I use the boiler for my hot water and heat. Sometime last year it started rumbling and making whistling noises. I started to observe and noticed it occurred when it was at high temperature 200+. So I had the local Lochinvar "experts" come out four different times and never fix the problem. They tore it down, cleaned it, called the Lochinvar experts in Indiana, but never fixed the problem.
Here is what I've found in my own diagnosis. The setpoint temp is 140, differential at 11, and high fire at 10. The aquastat on the outlet is currently set at 200. I can't get any air OR water from the expansion tank. The relief valve spits water EVERY time it heats up. I'm currently only heating water.
I just fired it up to start working on it again and with the setpoint at 140 it will continue to heat until it gets to approximately 215 and then shut down. Still no water or air from tank at any time during heat up. Relief valve trickles water the whole time from approximately 150 +.
Any ideas would be appreciated. I know it's getting too hot. But I also think the expansion tank has issues.
Here is what I've found in my own diagnosis. The setpoint temp is 140, differential at 11, and high fire at 10. The aquastat on the outlet is currently set at 200. I can't get any air OR water from the expansion tank. The relief valve spits water EVERY time it heats up. I'm currently only heating water.
I just fired it up to start working on it again and with the setpoint at 140 it will continue to heat until it gets to approximately 215 and then shut down. Still no water or air from tank at any time during heat up. Relief valve trickles water the whole time from approximately 150 +.
Any ideas would be appreciated. I know it's getting too hot. But I also think the expansion tank has issues.
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Comments
Check the pump size and operation, you may need to remove it to see if it spins when powered.
Assure it has good air elimination, it could be air locked.
What is the pressure on the boiler?
How did they clean the boiler? Was a descaler chemical circulated thru the boiler?
Relief valve seep could indicate a waterlogged tank, does it feel heavy when you try to wiggle it, or feel full when you rap your knuckles against it?
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
The pressure on the boiler was about 20PSI.
For cleaning They didn't do any descaler chemical in the boiler. They took it apart and cleaned used brushes to clean the inside of the unit. There was some minor build up on the "fins" and they claimed this could cause issues. No change.
The tank feels light and airy. When wiggled it feels empty - like the bladder is stuck shut.
I do have hard water and I'm wondering if this is clogging stuff up? Maybe tank is jammed up and maybe needs some of the desclaler you are talking about? I'm wiling to replace tank just because but I know that's probably not the key issue. And the high temp has me concerned but I'm not sure that's not normal.
If the pressure goes from 20 to 30 the tank may be undersized, improperly pressurized, or failed. Is this a new problem or has the relief always trickled when it fires?
Often when temperature rises quickly or overshoots in that boiler there is a flow problem. And the noise it makes also would point to flow issues, caused by partially blocked heat exchange tubes.
Any leaks in the system causing fresh water to enter? That will scale them up quickly.
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
This is a new problem. I've only owned house for 4 years but didn't have any trouble until last year. Relief valve only started trickling recently - the noises started well before that.
No leaks that I know of.
Check tank pre-charge
When running check in and out temperature, that along with kettling sound could indicate time to delime.
The manual may explain the procedure to descale the boiler. You can download one if you do not have the original.
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
D
I haven't removed the tank to look yet but here is what the system looks like near the boiler.
There is another circulator in the system? I think the pump in the pic is dedicated to the boiler flow, not intended to be the system pump?
Is the manual nearby, see if the piping matches the requirements shown in the manual.
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
Read below: system flow cannot be lower that required boiler flow.
Also a pump, providing adequate flow, must run whenever the boiler is firing.
If a thermostat turns off the pumps while the boiler is still firing, not so good.
With that many pumps you should not need a boiler
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
The expansion and and or relief valve need to be looked at.
The boiler control seems to have some issues. 140 is probably too low for a non condensing boiler. 200 is way too high, especially when set to 140.
Those copper tube boilers have very low mass and very low surface area to BTU ratios. They do not do well in low flow situations. That snap, crackle and pop is likely little micro flashes of water, boiling, expanding and collapsing in the boiler exchanger. Does the problem get better if you turn on all the zones? I would recommend repiping boiler per manufactures instructions.
Albert Einstein
trainer for Caleffi NA
The magic is in hydronics, and hydronics is in me
Albert Einstein