Boiler Hydronic System. 2nd Floor cold run.

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Hohenheim

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Hi, I am new to this forum and I am your typical homeowner DIY guy. I am not a professional by any means as far as boilers go and will try to paint my picture as best I can. I just got my house in 2019 and started using the oil-based boiler system last winter over my ductless units, which are not rated for the temperatures we get here in NEPA. There has always been an issue with air in my lines and the plumbing here is scary awful.

The system was installed in 1965. 128,000 BTU furnace that does both my hydronic baseboards and my kitchen/bath hot water lines.
The expansion tank is in good condition, no water is in it. (Yes I need the system inspected but it really does heat well for first floor baseboards, basement baseboards, sink water and shower water)
I added a picture to this thread, if any more information is needed please ask and I will make a video or take more pictures.

2 story 2 bedroom house 1 bath with attic(crawlspace attic) and basement.

My problem is the second floor is cold to the touch, eventually gets slightly warm near the location where the water first comes up to the second floor but that is it.

After following all runs for my baseboards, I only found ONE bleeder valve which is located at the end of 1 run found at the returning line in the basement.
I always heard the waterfall effect from the second floor return going down to the basement. I Installed a 3/4" bleeder valve on the second floor where the water rises and runs along the baseboards in both bedrooms. Bled the lines of air and now that waterfall sound is finally gone and air is purged from the second floor. BUT the water is still cold.

I have 2 return lines, they both have a water spigot but NO shut off valve, the valve doesn't come in until they both connect in a Y and then there is a large shut off valve, followed by the circulating pump, followed by another shut off valve.

Just before the first shut off, a 1/2" pipe is also joined and goes into the wall(it is a return from a first floor run that has no shut off, no bleeders, no spigot) I don't believe traditional purging will work because I've hooked up a hose to these spigots, closed the valve to the circulator pump with the furnace off and let the water run, seeing bubbles rise to the top of my bucket outside and that air always came right back even after running it how over an hour one time.

The runs go like this.. a large 1"(might be 1 1/4 but I'll stick with 1") pipe comes out from the boiler and splits 3 ways going down to 3/4" at different points in the run while down in the basement.

"Zone 0" The first break goes from 1" to a 1/2" (4 inch long pipe) back to 3/4" and goes up to the 1st floor, does a small 32" baseboard. Continues along the living room through another longer baseboard(about 10ft) comes down and converts again to 1/2" copper and meets just after the Y where both zone returns meet before the shutoffs and circulator pump. There is no return spigot for this smaller run Zone 0

"Zone 1" the second break goes from 1" to 3/4" into a baseboard along my basement, back up to the ceiling, runs along the ceiling and up into the 1st floor, continues on the other side of the living room and does another baseboard roughly 10ft, comes back down where there actually happens to be a bleeder valve(too corroded to open back up, afraid I'll break it) and returns to boiler

"Zone 2" Problem child the third break goes from 1" to 3/4" and runs along the basement into the very back room where I have majority of my septic system plumbed and it has fins it heats to keep them from freezing up in that room, goes up into the 1st floor bathroom through 2 4-1/2ft baseboards and up into the second floor guest bedroom closet, this is where I installed a new bleeder valve to purge the air that worked out well, from there it runs along the 3 full sides of the house, through both bedrooms then back down through the 1st floor and into the basement, this portion is where I would hear that waterfall sound from water running that I have now eliminated, and return to the boiler. The bathroom doesn't get warm, typically the coldest room in the house, bedrooms get warm from heat rising before bathroom does.

Sorry if I used wrong terms for anything, really just want to find a way to fix my issue with my Zone 2, which is also the longest run I have in the house, it is more than double the other runs.
 

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If the problem zone is one the second floor what is the pressure in the boiler you should see a gauge it should be reading somewhere
In the low mid 20s there should be red mark at 30 psi the relief valve will drip, it's over pressurized does the thermostat make the circulator pump come on????
 
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If the problem zone is one the second floor what is the pressure in the boiler you should see a gauge it should be reading somewhere
In the low mid 20s there should be red mark at 30 psi the relief valve will drip, it's over pressurized
Yeah so you are correct there. The setting is actually on 10psi but it was at about 18 psi last i looked before i left my house. The relief valve does have a drip as well. It wasnt dripping until today when i bled the system but i noticed that after posting this as well. My hi is 180 low is 140 and psi set at 10.
 
Gotta run the 2 zones that are working properly and see what the working pressure is,were you say the system is 1965 there could be some old parts ,the(fill valve) oyes on the cold water feed to the boiler could be bad, bit run things 1st and see were the pressure gauge goes to then youay have to adjust from there
 
20211117_234206.jpgsorry i thought the one setting was pressure, idk what diff means but it is at 10. My pressure guage looks to be about 15 right now. Heat isn't running at the moment bc the 1 and only thermostat located in my living room is at temperature. Relief valve dripped a lot last year and I know it needs to be replaced, just an expensive part so i put that off.

The fill valve works well, if i lift the tab it fills faster as well. I've used that for refilling the tank quicker as i tried purging with a hose.

Do you think a second pump upstairs would help? I wonder if my current pump isnt satisfactory for 3 separate runs.
Thanks by the way. I appreciate all the advice
 
Has the 2nd fl ever heated properly, turn that zone on and see were the gauge ends up, need more than 15 to get to 2nd fl, if you don't change that relief valve it may open up and not **** off sometime when you adjust the thermostat does the circulator pump come on?????
 
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There are no valves to shut off other zones, i can't isolate zones as per my first post. This is my 3rd winter, 2nd using the boiler, and no the bathroom, and upstairs run were always cold. 2nd floor only got warm bc the heat would rise and I keep my bedroom door shut now to keep the cat out.
 
Yes the pump works, i can distinguish it running when the boiler turned off.
The pipes are hot to the touch upstairs now, but the living room warms up to temp so quick i think that the upstairs doesnt get a chance to heat up.

Boiler in basement is pretty much directly below the room that has the single thermostat that controls it. There are no manual calls installed in this system either by zone.

I wonder if the best solution is to install shut off valves on each zone, and partially close the first floor and basement runs to allow the second floor to heat up more evenly then?
 
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Just turn down the thermostats on the 2 working zones and turn up the thermostat in the zone in question listen for the thermostat to click on, then check the circulator pump to see if it's running that way the working zones won't call for heat, only the one in question
 
Just turn down the thermostats on the 2 working zones and turn up the thermostat in the zone in question listen for the thermostat to click on, then check the circulator pump to see if it's running that way the working zones won't call for heat, only the one in question

That's not possible. They aren't truly separated. it's all plumbed like 1 zone with no shutoff and only ONE thermostat for the entire system

Let me rephrase that. There is nothing installed in-line with the hydronic system that actually detects temperature and calls for the pump to activate.
Only the physical wall unit thermostat in the living room detects room temperature and sends a signal to the unit to engage
 
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Has it always been this way???????done see any flow checks but that eye fitting has flat head screw driver slots wondering if you slightly close the garage one in question if it will slow enough to heat when you say base board are you touching the cover or the fin tubing under the cover
 
Sounds like if it never really warmed up on the second fl, I think the floors below are heatin g up and the thermostat is getting satisfied, I think you need a local company out to work out the kinks, I think of youoved the thermostat it would over heat the lower floors did you try that screw driver stop, I think that would slow the water down, possibly heating it better
 
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