We have a gas boiler for steam heating radiators. The boiler is new (installed in 2004) and has an automatic water feeder with a low water cut-off. After every heating cycle the glass water gauge indicates that there is too much water in the boiler -- there is water beyond the top of the gauge. We have tried letting out the excess water (until the gauge shows about half full). But the boiler fills up with every heating cycle.
We are not sure if the problem is with the automatic water feeder or something else.
Is there a way to control the water level in the boiler without us having to empty buckets of water all the time?
Many thanks for any help or advice!

 

I'd dare to suggest that there seems to be a problem with the condensate return...from what you are reporting, it seems slow is coming back. A partially clogged wet return perhaps?

The boiler produces its steam, which goes up to the mains/risers and radiators, but if the condensate is slow in returning, the auto. feeder does what its job is expected to be. Later, when the condensate finally starts showing up, it floods your boiler.

I've seen problems such as this one in multifamily buildings...but it'd be quite unusual in a small home. Is this a building or a residence?

 

Before going to deep into this, has this been going on since the new boiler was installed? IF it has, there is probably something at fault with the installation.

If you had this problem BEFORE the new boiler was installed, there may be something wrong with the return like pflor mentions.

Keeping it simple, do you know how the return is piped back into the boiler? Do you know what a Hartford Loop is? If you can tell us EXACTLY how the return is piped back in and whether or not there is a Hartford Loop would help alot! Maybe you can take a digital picture of the return piping and post it. I think that most techs would check this out first before digging deeper.

It sounds like the condensate (return water from the steam) is being slowed down and then getting siphoned or pushed into the boiler all at once. I personally suspect faulty return piping, or the loop was not done correctly, but it can be alot of other things.

Check it out! Post a picture.

Good luck,

Charlie

 

Thank you for all your responses, boilersrus and pflor.

To answer your questions:

Pflor, this is a single family house (not a mutli family).
We moved into this house 5 months ago -- so we don't know if there was a history of this problem. We only realized this when water started leaking from the second floor radiator (the last one). And having checked this website, we figured that there was a problem with the water level, and started monitoring it. The radiator is not leaking anymore, but the water level remains a problem.
We've also noticed that during the heating cycle, the water level fluctuates quite a bit.

Not sure about how the return is piped back (we're rather clueless about these matters)
Attached several photos of the boiler from different angles -- hopefully they'll make sense.

http://i268.photobucket.com/albums/j...m/IMG_3572.jpg
http://i268.photobucket.com/albums/j...m/IMG_3568.jpg
http://i268.photobucket.com/albums/j...m/IMG_3565.jpg
http://i268.photobucket.com/albums/j...m/IMG_3563.jpg
http://i268.photobucket.com/albums/j...m/IMG_3562.jpg

Hope this information will be useful...

Many thanks again!

Vikunum

 

I'd like to know, if possible, the M/N of this Burnham steam boiler.

I do not see a Hartford loop here.

From the picture (it's been taken a bit too far, so I cannot tell for sure), it looks like the discharge of the Relief Valve (PRV) is not piped downwards to within 6" off the floor (a safety issue and code violation)
It does not appear to be a nipple (dirt-leg) on the gas feed (only the tee and a plug)...but see the water heater next to the boiler, that one does have it, as it should be.

It appears that near-the-boiler piping recommendations from the Mfr have not quite been folowed here. More when you are able to furnish the M/N.

I'm going out with the family...will be back late at night. Hope to be of more help then.

 

Is the water level fairly steady whaen making steam. My guess is the water level is bouncing a lot. May be a skimming issue. Along with the problems Pflor stated it appears the pressure may be high. It should be set to shut off at 2psi and back on at 0.5 psi.

 

Thanks !
Can't find the Model Number in the documentation (the information is not filled in), or on the boiler. But it is the Burnham Independence series, if it's of any help. According to the instructions manual, the M/N should be available on the rating label inside the front cover -- will try to get to that, but not sure if we'll be able to.

The pressure stays at around 12 psi when the boiler is off, and goes up to about 18 psi when it's making steam. The upper limit seems to be set at 15 psi. Possibly the relief valve is not working because it's not installed properly (as pflor pointed out)?

The water level does bounce around when the boiler is making steam.

 

The Independence series from Burnham comes in 2 presentations: "Natural Draft" and "Power Vented"
http://www.burnham.com/PDF/ind-indpv.pdf

The Manual for the Nat. Draft is here:
http://www.burnham.com/PDF/8141049.pdf
and for the PV:
http://www.burnham.com/PDF/IndependencePV_I&O.pdf

Take a look at the catalog(s) and tell us which one is the baby you have at home.


12-to-18 psig??? something is not quite right here! Are we sure about this pressures? I don't think the Honeywell pressuretrol goes that high.

The PRV is o.k., it needs a nipple, a 90Ell and a pipe pointing down. The present condition does not affect its operability. This is rather a safety concern.

 

KEEP IT SIMPLE GUYS.

DOES ANYBODY SEE A HARTFORD LOOP ANYWHERE???

HELLO. HELLO. HELLO. DOES ANYBODY HEAR ME?

READ MY INITIAL POST AND YOU NEED GO NO FURTHER. THE RETURN IS PIPED DIRECTLY INTO THE BOILER! (PICS)

SOMEONE STOLE THE DAMN HARTFORD LOOP!

I THINK BOB VILLA FORGOT TO SHOW HOW TO PUT ONE IN

LOTS OF LUCK.

VIKANUM ---------------------------------------------YOU DO OWN SOME LARGE PIPE WRENCHES, RIGHT?


CHARLIE

 

vikanum----

Good thing you posted those pictures!

I almost thoght that it was a hot water boiler and they hid the circulators on us!

I predict that you will build some upper body strength in the coming new year! As in pipe work!

GOOD thing you got those two unions on the returns or you would be doing some sawzzzzzzzallllling too!

Good Luck!

Charlie

 

Thanks everyone for all the help!
This is now looking way beyond what we can deal with....
Time to call a professional to come and take a look at our mess!
Many thanks again. You guys are great!

Vikunum

 

V-

Find a good steam guy. As boilersrus and others have pointed out, the system is not piped per manufacturer instructions. Check out page 18 on http://www.burnham.com/PDF/8141049.pdf

and you'll see how it should be done. Commit those two piping options to memory. A competent installer will set it up right per those diagrams.

 

I do see a half-a**ed Hartford loop. It is NOT a proper Hartford loop because the pipe must be all the same size as the boiler outlet.