New Boiler issues Weil Mclain EG 55

RNhome1

Hi All - I recently had new boiler installed to replace Burnam unit that developed a crack.
Ever since the new boiler has been running, it seems like something is not right. The installer claims that its operating fine and install was done correctly.

Issues:

1 - Loud banging from pipes and gurgling/hissing from radiators. More than old boiler.

2. The boiler keeps turning on and off before reaching the set temp on thermostat.

3. Now as it’s running more often due to lower temps, I noticed that the automatic feeder is adding water.

The boiler and install were both a huge amount of money so obviously very concerned. Any advice would be appreciated.

109A_5

Hello RNhome1,

Items 1 and 3:

Sounds like it is surging, throwing water up into the system. Probably needs skimming, maybe the skimming was never done or needs to be done more. It should be done with every new boiler. If they dumped any chemicals into the boiler, it may need to be flushed out also.

Skimming is a process that removes the oils that were used in the manufacturing and install process. The boiler won't work correctly with the oil sitting on top of the water inside the boiler.

Post some pictures of your boiler so we can see if there was a skimming port installed.

Also to see the skimming process search Youtube for "boiler skimming", many videos there.

Steam Heat should be silent, beyond the new boiler issues it sounds like your system has some other issues like poor pipe pitch in some places.

Item 2:

Maybe related to items 1 and 3 or how did they size the new boiler ? If they put in an oversized boiler it could be cycling on pressure. What is the pressuretrol set at ? Pictures help us help you.

RTW

Another improper boiler install……thats posted again and again all over this site. It's sad those effected didn't search HeatingHelp.com first for a qualified installer. I'm surprised homeowners don't insist on a "holdback" until system is tested?

I suggest to original poster to put in "boiler install problems" in this sites search engine and see all the posts that pop up on new boiler installation problems for more information

Regards,

RTW

RNhome1

Here are some pictures of the install.

The boiler works for about 10minutes then shuts off, it takes about an hour for all the radiators to get hot. 2 floor house with 11 radiators.

During the heating process the water in glass goes down significantly and also jumps up and down.

I’m not sure if skimming was done. I did take water out a few times and refilled boiler, water color is much clearer now compared to when it was first running.

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EBEBRATT-Ed

@RNhome1

Too bad but you got screwed. Get the boiler manual if they left it on site and look at the piping diagram. You will notice that it does not compare to what they installed. The piping needs to be done properly for the boiler to work and then the boiler needs to be skimmed until the water line is stable. No supply header, equalizer not piped right and probably undersized pipe.

No shortcuts

And we don't even know if the boiler is the right size. Did they measure the radiators?

And that is just for starters

installers who either can not read or are too lazy to read the install manual.

It will never work right the way it is.

RNhome1

^
Thanks for looking at it.

I’m having another company come next week, will I damage the boiler if I use it.

EzzyT

The boiler was installed improperly. That’s where you’ll need to start from. I wouldn’t even entertain having the contractor who installed it to correct it, they clearly have no clue what they are doing. Where are you located? We might know of the right people who can correct what you have.

RNhome1

I’m located in Long Island, Nassau County

EzzyT

Give Scully Plumbing & Heating a call, they’ll make sure it’s done right.

EBEBRATT-Ed

Maybe @JohnNY I think @EzzyT is just NJ

EzzyT

@EBEBRATT-Ed I go out to Long Island to consult but work along side Scully Plumbing & Heating when it comes down to do any work out there.

Jamie Hall

@Danny Scully will see you right.

RNhome1

Thanks I will contact them tomorrow.

is it ok to use boiler in mean time?

how significant is the work to repair this. The plumber that installed it said he hooked up the new boiler the same way that previous boiler was connected…..

KC_Jones

https://forum.heatinghelp.com/discussion/comment/1822600#Comment_1822600

That means it was wrong before and he didn’t know enough to recognize it.

It’s all wrong from what I can tell so all the piping around the boiler needs redone. Based on what I see you basically paid him to move the boiler to the basement as what he did piping wise is a do over.

How was it sized? I’d bet money it’s oversized too. It supports 521 square feet of radiation and you have 11 radiators. That would be 11 decently large radiators.

ethicalpaul

The boiler won't be physically damaged, but the water surging through your pipes is not good for the vents, nor for the distribution of steam to the radiators.

I would really try to limit using it until it is at least skimmed to get those oils out (you can see the oil floating in the gauge glass.)

The near-boiler piping is dead wrong, couldn't hardly be more wrong, and yet if the boiler were skimmed of those oils, it might behave reasonably correctly.

But if you see the water level drop dramatically (like more than 2 inches) during steaming, you know that boiler water is getting carried up to the main pipes and that is called "surging" or "carryover" and it's not good.

Instead of installing it how the old one was, the installer should have opened the installation manual which clearly shows how to install it.

RNhome1

https://forum.heatinghelp.com/discussion/comment/1822608#Comment_1822608

Thanks for your advice.

For some reason the water level dropping during steaming became worse and worse that’s what got me really concerned over the past few days. Once I turned the boiler off, the water went back to normal level, so I guess in reality it wasn’t low?

ethicalpaul

That's right, it wasn't low. Due to the oil in the water, and due to the horrifically bad piping, water is actually getting thrown up into the mains.

If you want to see what this looks like, see my video here

But again I have to say, if you can get it skimmed to remove the oil, it may do OK. On your side is a fantastically high steam supply pipe. Even correctly-piped boilers need to be skimmed, they all will surge until the oils are removed.

This is the skim port, the installer seems to have not ever removed the plug from it. They need to come back and install a nipple into this port to use it for skimming. Look it up on youtube, you will find several videos showing the process.

109A_5

Hello RNhome1,

Should look something like this with two vertical pipes (Steam to system) right next to each other going to your two separate mains. Also looks like the tapping for the skim port was never even touched.

RNhome1

https://forum.heatinghelp.com/discussion/comment/1822607#Comment_1822607

The last boiler was a Burnham I7 which was 210k BTUs and it lasted 25 years with that piping setup as far as I know. This WM unit was the closest to that in size. I think its probably oversized.

ethicalpaul

This WM unit was the closest to that in size. I think its probably oversized.

Always round down 😓

You will be able to tell if it's oversized once it's no longer surging, if it can get to that state with this piping (I personally think it can)

RNhome1

https://forum.heatinghelp.com/discussion/comment/1822628#Comment_1822628

What do you recommend to minimize the surging - skimming boiler?

Would it help to lower pressure or is the setting that is there correct.

109A_5

The boiler replacement time is an opportunity to improve the system, if needed. Just replacing with the same thing is a loss of opportunity or may cost more to utilize the opportunity with re-work. If a radiator EDR survey was done it may have been realized that you only needed a smaller boiler and that may have saved you some money also.

ethicalpaul

https://forum.heatinghelp.com/discussion/comment/1822643#Comment_1822643

I think I said the word "skimming" about 100 times in this thread 😅

Yes it needs to be skimmed, as do all new boiler installations.

The pressure control is set reasonably well. It should be at the bottom, but not lower.

STEAM DOCTOR

Piping is very very wrong. If you are comfortable doing this, dump a bunch of eight-way into the boiler. Fire it up. Once it starts to steam, you can shut the boiler. Wait 10 minutes or something like that, and fire boiler back up until it starts to steam. Repeat for a while. 30 to 60 minutes. Once you are done, drain-fill, drain-fill... Once water starts to come out clean and clear, fill to normal water level. Fire boiler back up and let it Steam for minimum of 20 minutes. This of course is not a replacement for proper skimming and proper repiping. But might help a good bit. From personal experience.