Steam Boiler, Excessive water useage

**knarfoires** · 12-22-2012, 03:18 PM

Removed a older Weil McLain 578 steam boiler and installed a brand new (within the past two weeks) Weil McLain 580 steam boiler... Ran HERCULES Scout in the boiler for 2 weeks and now its been drained out, skimmed and refilled with domestic water only (no water additives)... New automatic water feeder and new low water cut-off.... Based on the digital read out of the automatic water feeder, EVERY DAY the system uses 20 gallons of water. No Hardford loop but a automatic condensate pump. The steam traps in the boiler room seem to be working properly.

This boiler is a two zone steam boiler. The first zone is controlled by 3'' piping, a Belimo Valve and 24 volt actuator heating a 750 sq.ft. steam radiator cottage on the right side of the dwelling. The second zone is larger, using 4" piping, 4'' Belimo valve and 24 volt actuator that handles seven attached single story steam heated garages in the center, and a second 750 square foot cottage is on the left of the dwelling. The new boiler was pressure tested for 24 hours at 50 lbs. of pressure, showing no leaks. There is no visible signs of water on the boiler floor or under the boiler. There is no smell of steam leaking in the boiler room. There is no underground Piping....

Am I looking for a problem that may not exist at all or am I not seeing the problem in front of my eyes... Is there a way to diagnose this problem.... ALL HELP WILL BE GREATLY APPRECIATED.....Thanks for your time.....Frank S

**beenthere** · 12-22-2012, 08:13 PM

Did you check in the cottages and the garages for a leak.

**snupytcb** · 12-22-2012, 08:25 PM

any hot water loops?

**dandyme** · 12-22-2012, 08:42 PM

what pressure you running on that boiler?

you've got a leak-you need to find, if there isn't a leak; this thing will stop heating soon.

**knarfoires** · 12-23-2012, 07:30 PM

Did you check in the cottages and the garages for a leak.

NO visible water leaking..... 24 hours after my last post.... Just spoke to the tenant in the left cottage... due to the holiday weekend she checked the auto water feeder and we used another 20 gallons of water today( 12-23-2012)....Thanks again for your help in this matter

**knarfoires** · 12-23-2012, 07:33 PM

Cut in is 1 with a differential of 1..... cut out is set at 3 with a differential of 1.....

ALSO NO visible water leaking..... 24 hours after my last post.... Just spoke to the tenant in the left cottage... due to the holiday weekend she checked the auto water feeder and we used another 20 gallons of water today( 12-23-2012)....Thanks again for your help in this matter

**knarfoires** · 12-23-2012, 07:35 PM

No domestic h.w. loops....No side arms..... Separate 75 gallon, oil fired h.w. heater

ALSO NO visible water leaking..... 24 hours after my last post.... Just spoke to the tenant in the left cottage... due to the holiday weekend she checked the auto water feeder and we used another 20 gallons of water today( 12-23-2012)....Thanks again for your help in this matter..... enjoy the holiday

**snupytcb** · 12-23-2012, 07:46 PM

at 20 gallons per day, you have to have a leak. i can not think of any other reason you would go through that amount of water. could you shut it off for a day and check the water usage? are both zones rads? was the complete system with valves open tested or just the boiler?

**dandyme** · 12-23-2012, 08:50 PM

it's a steamer, you may not see water unless it's on the return side.

you have a leak, find it!

**hvacvegas** · 12-23-2012, 11:51 PM

your meter is wrong, thats assuming no leak.

You got some big zones there. Whats the chances every single air vent leaks?

**knarfoires** · 12-24-2012, 09:31 AM

Both zones are Cast iron radiation.... Leak tested boiler only..... excessive water consumption was never noted to us prior to installing the new boiler... are you from pulaski rd in ny.... Bethpage ny here