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rust flakes in boiler water

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Posted by Dave on June 05, 2008 at 20:33:51:

I had been having the lockouts with multiple flow switches, and you recommended one from Ameritrol,a nd so far it works great. Thanks very much.

After I replaced the flow switch, we started having a slow drip from our drain vlave in the circuit. I will give you a recap of our story....

We have a seven year old copper tube boiler that has a cast iron header on the heat excahnger. We had been having alot of noise with the boiler, so 2 1/2 years ago, we completely had the whole boiler loop repiped in 2" copper and added an Ergomax reverse indirect tank as a buffer tank.

There are 2 manifolds that come off the boiler/ergomax loop....a supply manifold with several 007 taco pumps and a return manifold.

These manifolds were carry-overs from the original setup and are composed of black iron pipe. Everything else (piping to hydroair units, etc) is copper piping.

The primary boiler loop had been black pipe also, but when we repiped 2 1/2 years ago, we replaced everything in that loop with 2" copper (except for the iron pipe that is threaded into the heat exchanger for the boiler.

The pump in this loop is a Taco 0010.

The drain valve in the primary boiler loop had been dripping for a while, so I decided to replace it. When I unscrewed it, I got about 2-3 tablespoons of rust flecks, etc. In fact, the back side of the drain valve (that faces the boiler water) was practically clogged with pieces of rust. Some of the flecks were the size of your pinky fingernail. However, the water that came out the circuit after the pieces of rust came out was clear.

Does this show some kind of problem that we are having with that much rust after a couple of years or is that a normal occurrence? We don't seem to be having to add any fresh water, which I know is a cause of rusting. Also, we have some glycol in the system...probably 25-30%.

Thanks. Dave

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