New Hydronic boiler over heating water. Need Help!!!

Herbie

ok, I'll start by describing the equipment, Is a "Penco" 140,000 BTU (gas fired) hot water boiler. That's been used to heat 4 apartments.All four, with 4 individual thermostats, zone valves and is all baseboard radiators(3/4" copper). The boiler was just instaled 8/04, the home is aprox. 35/40 yr old. The 1st complaint was that the boiler was making a, "Loud banging sound". I soon noticed the temperture on the gauge was reading 230 fht. However, the aquastat was set at 180 fht. I changed the new single aquastat relay (Honeywell) together with an insert well. The sensor bulb from the original swelled up so badly that it did not wanted to come out. The same situation is back...The only diference is that it dosen't happen all the time (the banging noise). It happened while I was present. When I got there the boiler was on. Three out of 4 zones where calling for heat, the flames where off and the temperture gauge was reading 170 fht. No signs of water were present on the floor. I waited for it to re-cycle and "POP" went the relief valve opened. I jumped up, lol, and sure enogh the tempeture was up to, an unbelievable, 240 fht. The banging noise started again. Therefore, I am back to square one. Is this another defective control? I thought having two defective controls would be highly unusual or likely. Please, If anyone has any ideas or has come accross the same or similar? I am trying and have been trying to find a solution to this "Mystery????". Herbie..

PS If anyone can respond ASAP I would sincerely appreciate it. I will be back at this job everyday if I have no suggestions at to what is going on. So, THANK YOU, I hope someone has seen this or can e-mail me ASAP. Your responce is surely going to be appreciated

Greg Swob

We will need more details and photos if possible for help in digesting the situation.

However, I ran into a Burnham two years back installed in a peculiar manner. The return water was piped and pumped into the outlet fitting and outlet water vice-versa. There was a lot more wrong than this ultimately. Part of what was happening was the high limit aquastat was sensing return water temps, allowing the unit to overheat and the Pressure Relief Valve would blow off briefly. It was originally wired and operated as a 'hot' boiler. Some other problems included a dead heading circulator trying to flow water into the face of a flow check rather than with the flow direction. Another was a failed flow check that allowed circulation regardless of which zone was calling seriously overheating one set of rooms. After considerable repiping, some rewiring and changing failed or improperly installed components, the noises and overheating stopped. Greg

Einsiedler_2

residual heat

I may be wrong, but I am assuming that; when the boiler shuts down, the pump is also shutting down.

If this is the case, the limit is not at fault. Limit shuts off boiler, killing pump (if wired to boiler w/o purge). hot boiler + no flow = residual heat buildup.

Watch the gauge & if the limit clicks @ 180F, and then the temp shoots up, correct the flow problem.

EIN

Weezbo

sounds like materials management problem..........

you need someone who manages not to frick the materials up the first time.

peter desens

Factory assistance

Please feel free to contact our Pennco factory Technical Support staff at 1-877-386-5475.

It sound like the water in the boiler is flashing to steam. It doesn't make sense however that it would do this while three of the four zones are calling, the pump presumably running and the boiler cycling off high limit. I would expect it to happen either prior to the boiler shutting down on high limit, or as the circulator kicks on (depending where it is located). Where is your pump located in relationship to the boiler and expansion tank?

Much like Greg's comments above, direction of flow is very important. What direction is the water flowing?

Pictures may be very helpful.

Peter Desens
ECR International - Pennco Boilers

Herbie

I got it... Is Fix Thanks to all you guys...

Yes, I read all messages posted by you guys, and it opened my eyes. This is what happened when the boiler was piped the 4 zone valves were reused, and who ever did the instalation piped them to the return, but the flow arow was facing out. Meaning it should have been piped to the feed. So what the shoe-maker did was he changed directions on the circulator pump, and now it was pumping out of the bottom inlet. (return top) crazy but thats what happened,especially when a shoe-maker is hired to install a gas boiler instead of a profecional. lol Anyway I did the nessesary repipe and corrected the flow on the circulator and there it is...
It worked like is suposed to now is shuting the flames @180 Fht. Nice... Thanx for all the atention I got from all you guys, that opened my eyes.
Thanks again all... Herbie...

Rich Kontny_2

Another point

There is another explaination for this problem, that is the distinct possibility that either the pump is undersized or the boiler is oversized. Either way, the system cannot dissapate the heat quickly enough.
Bob S

Big Ed

Aquastat Capulary

Make sure the aquastat capulary is fully inserted into the well. You may have to pull out more ,from the control to fully submerge into a extended well.........

Plumdog

Boilermaker and small shoes

You could hire a boilermaker to build shoes that have a relief valve in the toe so you won't get blisters if they don't fit.

Weezbo

Huuuh *~/:)

I love that! Thats Great! )) oops....we are outta the box anad here come the butter fly nets:)))