Boiler Kettling

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New Energy Kinetics EK-1 boiler/hot water heater installed in June. Up until a week or so ago, the system was called upon to provide domestic hot water only: all of our thermostats were turned to cooling mode. System ran fine, produced prodigious amounts of hot water, and was very quiet.



Heating season begins last week. We have thermostats in 3 heating zones calling for heat off and on to take the chill out of the early Fall mornings. We are now experiencing a phenomenon called kettling: sound of boiling water emanating from the boiler itself.



This sound is only heard when the oil burner is firing: once the demand for heat is satisfied, the burner shuts down and the noise immediately stops.



A few things to note:



-Its a 4 month old system



-It worked just fine until we started opening zone valves in the heating circuits.



-Noise starts about 30 seconds or so after burner firing begins.



-Water chemistry: we are on well water, although we don’t have a water softening system: never needed it. Out water test shows slighlty/moderately hard water. We do use a 1 micron whole house water filter.



The most popular answer I’ve encountered online in regard to this issue is: its scale buildup on the boiler wall. Not sure I am convinced that this is the culprit, given the system has only been in service for 4 months, and given that this problem did not exist prior to opening the heating circuit zone valves.



FWIW: I’ve never observed/heard the air vent bleeding any air from the system. There is just a single vent just above the main boiler return connection. I suspect air in the system may be a contributing factor but my contractor has dismissed this as a possible cause.



Contractor plans on doing an acid flush of boiler, per the manufacturer’s recommendation so we will be trying that next week. Given everything I’ve stated above, I have strong doubts that this cleaning will resole the problem.



Any thought on what could be happening and possible remedies?
 
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Emitters are standard baseboard heating units: most are slant fin. Pictures:

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Fitter30

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Not familiar with Kinetics boiler or their casting that holds the relief and auto air bleed. Air bleed the cap on top should be removed. Page 11 Filling with water, purging. System is full of air. Looking at the install manual that how they pipe their boiler. System that i pipe use a micro bubbler air removel device with there are at least 6 brands. These will eliminate entrained air because in a system.
 
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I agree 100% with your assessment. Unfortunately, the contractor does not.
EK uses a Caleffi air vent that works like a standard float valve vent, but they have added hygroscopic discs (with holes in the center to allow air to pass) that supposedly swell in the presence of water and stop a water leak from occurring. Vent cap has slots in it so its works whether its loose or tight. No way to manually open the float without mangling the device (spoke to Caleffi tech support about it already).The manifold its connected to is a proprietary part that comes standard with the EK boiler and I assume acts like a Watts or Taco Air Scoop I had considered replacing the vent with a standard watts or equivalent but I figure what are the odds that this brand new vent is bad? Also, I am reluctant (at this point) to mess with system as the contractor might decide to walk away, not wanting to deal with the homeowner mucking around with the system.
 

Fitter30

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The efficiency of a micro bubbler is awesome. A bladder style ex tank is a must. The older style steel ex tank can't be used with these devises because they will remove the air charge in them.
Never have acid flushed a boiler. Only steam boilers have cleaned them to remove any oil from either the manufacturing, cutting oil from the pipe or when they are priming ( water level bounces rapidly).
I'm going to call Caleffi monday about their air devise. Everybody's air scoop is in the horizontal plane with a cast divider plate that separates air from water.
 
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The current plan is to go with the manufacturers recommendation and clean the system. Finger crossed.

Stay tuned for more exciting developments!

A sincere thanks to all the pros that have shared their knowledge to help a humble home-owner: much appreciated!
 

Fitter30

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Not familiar with Kinetics boiler or their casting that holds the relief and auto air bleed. Air bleed the cap on top should be removed. Page 11 Filling with water, purging. System is full of air. Looking at the install manual that how they pipe their boiler. System that i pipe use a micro bubbler air removel device with there are at least 6 brands. These will eliminate entrained air because in a system.
Been tied up couple days the air vent is just a standard float style doesn't have any hydroscopic disks in the vent. The black casting is hollow nothing is in it.
 
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Bgard

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Been tied up couple days the air vent is just a standard float style doesn't have any hydroscopic disks in the vent. The black casting is hollow nothing is in it.
It looks to me like the boiler is not piped correctly, looking at the I/O manual, it looks like the fitting at the top of the boiler is just for air elimination and a location for the expansion tank connection, NOT the system return line. The return line should be connected to the fitting at the bottom of the boiler, look at the the diagram on page 10 of the I/O manual that @Fitter30 posted. The supply should come from the the fitting at the side of the boiler.
 

Fitter30

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It looks to me like the boiler is not piped correctly, looking at the I/O manual, it looks like the fitting at the top of the boiler is just for air elimination and a location for the expansion tank connection, NOT the system return line. The return line should be connected to the fitting at the bottom of the boiler, look at the the diagram on page 10 of the I/O manual that @Fitter30 posted. The supply should come from the the fitting at the side of the boiler.
Look at page 9 symbol 9 thats the supply line. Page 6 first paragraph "notice" front of boiler is higher for air removel.
 

Bgard

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Look at page 9 symbol 9 thats the supply line. Page 6 first paragraph "notice" front of boiler is higher for air removel.
Yes, and it goes down to the fitting just below the burner blower motor, it does not connect to the fitting at the top of the boiler!
 

Fitter30

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Yes, and it goes down to the fitting just below the burner blower motor, it does not connect to the fitting at the top of the boiler!
Boiler looks like it's piped correctly. There a triacator gauge by the emergency switch read the lower half with switch off. Basement floor to highest fintube estimate the height? Pump model number?
 

Bgard

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Boiler looks like it's piped correctly. There a triacator gauge by the emergency switch read the lower half with switch off. Basement floor to highest fintube estimate the height? Pump model number?
Pictures of the front of the boiler would help to identify the fittings on the boiler!
 
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