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I have re-piped the boiler in the mechanical room. All the piping in the rest of the house was left alone.
I had the boiler piped to the header and back to the boiler with inch and a quarter threaded pipe and pressure tested it and did not see any bubbles, I did lose about 1 psi per hour. I used dawn dish soap 50/50 water and soap on every threaded joint. There is a hydraulic separater in the system if that makes any difference. Anybody have any suggestions?