Todd,

I've got an issue with my Brewtus II (purchased 12/26/07 from WLL)
that is stumping me.

I've got a slow drip out of the E61 group.  I've got an intermittent
gurgling sound in the bowls of the machine.  I get an occasional over
pressure of the steam boiler, which causes the pressure relief valve
to open.  And, lastly, if I've left the machine on all day, when I
come home from work and pull a shot, I hear one of the boilers
refilling (not sure which one) before the shot will start. I also note
what appears to be more water than normal in the drain pan.

Today I pulled the cover off, started up the Brewtus from "cold
irons", and watched what happened.

1. The steam boiler heated up normally.  Once up to pressure, the heat
cycled on at about 1.2 bar and off at about 1.4 bar.  I noted that the
dripping from the E61 group started once the boiler hit about 1.1
bar.  The dripping was continuous after that.  The dripping was from
the bottom valve of the E61 group with the handle in the full-down
position.  If I put the handle in the mid position, the dripping will
come from the portafilter.

2. The water boiler heated up normally after the steam boiler came up
to pressure.  The water boiler reached 95 and then the water and steam
boilers cycled on and off normally to maintain temperature/pressure.

3. The gurgling sound appeared to emanate from the steam boiler.
While listening to the noise I noted bubbles going through the plastic
tube between the heat exchanger outlet on the steam boiler and the
inlet on the water boiler.  If I disconnect the pump control switch
(so that the pump will not come on with the handle in the full-up
position), the gurgling sound increases appreciably, as does the flow
out of the portafilter.  Eventually the flow will go to nothing but
steam.  The plastic tube between the steam and water boilers will have
nothing but steam in it.  If I re-engage the pump, water will again
flow through the plastic tube, but it will take 10-15 seconds to get
water flow at the portafilter.

4.  I get random occurances of over-pressure on the steam boiler,
resulting in the pressure relief valve opening at around 2 bar.  There
is no apparent pattern to when this will happen.

5.  My habit patter when I pull a shot is to first pre-heat my cup
with water from the steam boiler and then pull the shot.  When I come
home from work (Brewtus has been left on all day) and open the valve
for hot water to pre-heat my cup, I'll get immediate flow of hot water
from the wand, but then I'll hear one of the boilers refilling for
about 20 seconds.  I'll also note that the drip tray seems to have
more water than expected from my normal routine of shot pulling.

I had thought that perhaps there was a crack or a pin-hole in the heat
exchanger which was allowing boiler pressure and steam to migrate into
the water boiler and group head.  However, if I put a blank in the
portafilter and run the pump, I do not see a concurrent increase in
pressure in the steam boiler, which should occur if there were a crack
or hole in the heat exchanger.

I'm stumped.  Hope you can help.  I figure the p-stat at a minimum
needs to be replaced, but the dripping and gurgling and water
consumption has got me scratching my head.

Sincerely,
Mike



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