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Heating Boiler Expansion Tank Size Guide
How to choose the right expansion tank size
- POST a QUESTION or COMMENT about heating system expansion tank size or capacity
Hot water heating system expansion tank / compression tank size guide:
This article provides basic sizing charts for hydronic (hot water) heating boiler expansion tanks or compression tanks.
We include links to additional expansion tank sizing guides from equipment manufacturers such as Amtrol / Extrol and PEX as well as links to online calculators that can give an expansion tank sizes based on known water volume of the heating system.
This article series explains how to identify, inspect, install, repair, or service heating boiler expansion tanks: here we explain the function of expansion tanks on hot water (hydronic) heating systems.
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Expansion Tank Sizing Procedures
The photo at page top shows a modern Extrol(R) bladder-type heating system expansion tank.
[Click to enlarge any image]
Shown here is a gray cylindrical ceiling-mounted traditional bladderless expansion tank for a hot water heating boiler using cast iron baseboard heat in most of the building with a radiant floor slab in one small room.
Question: expansion tank sizing for large older home, cast iron radiators
2016/11/20 Steve said:
Expansion tank sizing: In a very large old home, there is a huge boiler(size of a small car) and an old style expansion tank in the rafters. The tank recently started leaking, so I'd like to replace it with the newer bladder type.
Understand that for hot water heating boiler expansion tank sizing calculations, you need to take the system volume, temperature differential, etc. into account.
But with a house so large with dozens of radiators & seemingly miles of piping, I can't begin to imagine how you could calculate the total volume. Isn't there a way to make this determination using the size of the old expansion tank? Its 12" x 60", so about 30 gallons. Thanks for the help.
This question was posted originally
at EXPANSION TANK LEAK REPAIR FAQs
[Click to enlarge any image] Shown here, an Amtrol Extrol expansion tank on a hydronic heating boiler.
Reply:
Steve
I agree this is an onerous task - expansion tank sizing. Typically the big manufacturers offer a calculator that begins by requiring you to enter exactly what you don't know: the total water volume of the system.
The technical factors in boiler expansion tank size include total volume, operating temperature, and starting operating pressure.
I think that most heating service techs eyeball the system and pick what they guess is a safe (big) expansion tank from the range of standard sizes they've seen in residential properties.
There are actually just a few typical expansion tank model sizes (and thus model numbers) and some heating companies map those against boiler net BTUH output and the type of heating system: finned copper baseboard, convectors/unit heaters, or radiators, or cast iron baseboard
You'll also choose between (using Amtrol / Extrol as an example) an expansion tank that includes a fill valve (Amtrol Fill-Trol) and one that does not (Amtrol-Extrol) the latter means you're using an external or separate boiler fill valve.
Typical Expansion Tank Sizes for a Cast Iron Radiator type typical residential heating system
- For a 100 MBTUH boiler you'd use either an Amtrol Extrol #60 or an Amtrol Fill-Trol #111
- For 125-150 MBTUH you'd use an Amtrol Extrol #90
- For a 175-200 MBTUH boiler you'd use an Amtrol Extrol #SX30V
- For a 250-300 MBTUH boiler you'd use an Amtrol Extrol #SX40V
- For a 350-400 MBTUH boiler you'd use an Amtrol Extrol #SX60V
In other words, unless you're an HVAC design engineer you would probably eschew measuring the number of linear feet of pipe, and its diameter and counting the number of radiators and adding the volume of these to that of the boiler. Instead you'd choose a reasonable model from the rather short list of what's actually sold.
Below are tables sizing expansion tanks for typical hot water (hydronic) heating boiler systems.
To use these boiler expansion tank sizing charts you need to know just the type of heating system radiation used: finned copper baseboard, convectors/unit heaters, cast iron radiators, or cast iron heating baseboards and the heat output of the heating boiler in 1000s of BTUs / Hour or Output BTUh.
Photo: an Amtrol Fill-Trol expansion tank that incorporates a brass fill-valve - just visible under the air-scoop/air purger and found on the top of this expansion tank.
More about Fill-Trol tanks from Amtrol is at AMTROL's EXTROL®, the FILL-TROL®
Expansion Tanks for Finned Copper Baseboard Heating Systems
Table of Hydronic Heating Boiler Expansion Tank Size vs. Finned Copper Baseboard Heat Radiation Method & Boiler Output in 1000's of BTUS/Hour |
|||||
| Baseboard, Finned Copper Tubing Heat | Typical Hydronic Heating Boiler Output in 1000s of BTUS / Hour (data tag) | ||||
| BTUH Output | 25-50 K BTUh | 75-150 K BTUh | 175-250 K BTUh | 300 K BTUH | 350-400 K BTUH |
| Expansion Tank Model | Amtrol Extrol a #15 or Amtrol Fill-Trol b #109 |
Amtrol Extrol #30 or Amtrol Fill-Trol #110 |
Amtrol Extrol #60 or Amtrol Fill-Trol #111 |
Amtrol Extrol #90 |
Amtrol Fill-Trol #SX-30V |
| Expansion Tank Volume | 2.0 gallons | 4.4 gallons | 7.6 gallons | 14 gallons | 14 Gallons |
Notes to the table above
This data is for hydronic heating boilers - that is, building heating systems. It is not intended to size thermal expansion tanks for domestic hot water heaters. See the references below.
Adapted from PexUniverse and Amtrol data sources cited below at EXPANSION TANK SIZING CALCULATORS
- Note a: The Amtrol Ex-Trol models provide am expansion tank that does not include an automatic fill valve. An external control valve will be needed to fill and maintain water in the heating boiler.
- Note b: The Amtrol Fill-Trol expansion tank models provide an expansion tank that includes an automatic fill valve incorporated with the tank
See details at AMTROL's EXTROL®, the FILL-TROL® - "K" BTUh = Thousands of BTUS per Hour of Output Heat from the Boiler
- The BTU output per hour or BTUH used is the net hydronic boiler output BTUs, typically found on the boiler's data tag.
- For mixed systems combining radiators and baseboard, use the larger expansion tank size.
Watch out: these are "ballpark" data points. Check with the installation and maintenance manual for your heating system, with its manufacturer, and with your local heating equipment service company or supplier for their opinon on accurate boiler xpansion tank sizing.
Expansion Tanks for Cast Iron Baseboard Heating Systems
Table of Hydronic Heating Boiler Expansion Tank Size vs. Cast Iron Baseboard Heat Radiation Method & Boiler Output in 1000's of BTUS/Hour |
|||||||
| Cast Iron Baseboard Heat | Typical Hydronic Heating Boiler Output in 1000s of BTUS / Hour (data tag) | ||||||
| BTUH Output | 15 K BTUh | 30 K BTUh | 75-100 K BTUh | 125-150 K BTUH | 175-200 K BTUH | 250-300 K BTUH | 350-400 K BTUH |
| Expansion Tank Model | Amtrol Extrol a #15 or Amtrol Fill-Trol b #109 |
Amtrol Extrol #30 or Amtrol Fill-Trol #110 |
Amtrol Extrol #60 or Amtrol Fill-Trol #111 |
Amtrol Extrol #90 |
Amtrol Fill-Trol #SX-30V | Amtrol Fill-Trol #SX-40V | Amtrol Fill-Trol #SX-60V |
| Expansion Tank Volume | 2.0 gallons | 4.4 gallons | 7.6 gallons | 14 gallons | 14 Gallons | 20 Gallons | 32 Gallons |
Notes to the table above
This data is for hydronic heating boilers - that is, building heating systems. It is not intended to size thermal expansion tanks for domestic hot water heaters. See the references below.
Adapted from PexUniverse and Amtrol data sources cited below at EXPANSION TANK SIZING CALCULATORS
- Note a: The Amtrol Ex-Trol models provide am expansion tank that does not include an automatic fill valve. An external control valve will be needed to fill and maintain water in the heating boiler.
- Note b: The Amtrol Fill-Trol expansion tank models provide an expansion tank that includes an automatic fill valve incorporated with the tank
See details at AMTROL's EXTROL®, the FILL-TROL®
i class="LI_Spaced">"K" BTUh = Thousands of BTUS per Hour of Output Heat from the Boiler
- The BTU output per hour or BTUH used is the net hydronic boiler output BTUs, typically found on the boiler's data tag.
- For mixed systems combining radiators and baseboard, use the larger expansion tank size.
Watch out: these are "ballpark" data points. Check with the installation and maintenance manual for your heating system, with its manufacturer, and with your local heating equipment service company or supplier for their opinon on accurate boiler xpansion tank sizing.
Expansion Tanks for Cast Iron Radiator Heating Systems
Table of Hydronic Heating Boiler Expansion Tank Size vs. Cast Iron Radiator Heat Radiation Method & Boiler Output in 1000's of BTUS/Hour |
||||||
| Cast Iron Radiator Heat | Typical Hydronic Heating Boiler Output in 1000s of BTUS / Hour (data tag) | |||||
| BTUH Output | 25 K BTUh | 50-75 K BTUh | 100-125 K BTUh | 150 K BTUH | 175-300 K BTUH | 350-400 K BTUH |
| Expansion Tank Model | Amtrol Extrol a #15 or Amtrol Fill-Trol b #109 |
Amtrol Extrol #30 or Amtrol Fill-Trol #110 |
Amtrol Extrol #60 or Amtrol Fill-Trol #111 |
Amtrol Extrol #90 |
Amtrol Fill-Trol #SX-30V | Amtrol Fill-Trol #SX-40V |
| Expansion Tank Volume | 2.0 gallons | 4.4 gallons | 7.6 gallons | 14 gallons | 14 Gallons | 20 Gallons |
Notes to the table above
This data is for hydronic heating boilers - that is, building heating systems. It is not intended to size thermal expansion tanks for domestic hot water heaters. See the references below.
Adapted from PexUniverse and Amtrol data sources cited below
at EXPANSION TANK SIZING CALCULATORS
- Note a: The Amtrol Ex-Trol models provide am expansion tank that does not include an automatic fill valve. An external control valve will be needed to fill and maintain water in the heating boiler.
- Note b: The Amtrol Fill-Trol expansion tank models provide an expansion tank that includes an automatic fill valve incorporated with the tank
See details at AMTROL's EXTROL®, the FILL-TROL® - "K" BTUh = Thousands of BTUS per Hour of Output Heat from the Boiler
- The BTU output per hour or BTUH used is the net hydronic boiler output BTUs, typically found on the boiler's data tag.
- For mixed systems combining radiators and baseboard, use the larger expansion tank size.
Watch out: these are "ballpark" data points. Check with the installation and maintenance manual for your heating system, with its manufacturer, and with your local heating equipment service company or supplier for their opinon on accurate boiler xpansion tank sizing.
Expansion Tanks for Convector-Type (Unit Heater) Heating Systems
Table of Hydronic Heating Boiler Expansion Tank Size vs. Convectors / Unit Heaters Heat Radiation Method & Boiler Output in 1000's of BTUS/Hour |
||||||
| Convectors / Unit Heaters | Typical Hydronic Heating Boiler Output in 1000s of BTUS / Hour (data tag) | |||||
| BTUH Output | 25-50 K BTUh | 75-100 K BTUh | 125-200 K BTUh | 250 K BTUH | 300-350 K BTUH | 400 K BTUH |
| Expansion Tank Model | Amtrol Extrol a #15 or Amtrol Fill-Trol b #109 |
Amtrol Extrol #30 or Amtrol Fill-Trol #110 |
Amtrol Extrol #60 or Amtrol Fill-Trol #111 |
Amtrol Extrol #90 |
Amtrol Fill-Trol #SX-30V | Amtrol Fill-Trol #SX-40V |
| Expansion Tank Volume | 2.0 gallons | 4.4 gallons | 7.6 gallons | 14 gallons | 14 Gallons | 20 Gallons |
Notes to the table above
This data is for hydronic heating boilers - that is, building heating systems. It is not intended to size thermal expansion tanks for domestic hot water heaters. See the references below.
Adapted from PexUniverse and Amtrol data sources cited below at EXPANSION TANK SIZING CALCULATORS
- Note a: The Amtrol Ex-Trol models provide am expansion tank that does not include an automatic fill valve. An external control valve will be needed to fill and maintain water in the heating boiler.
- Note b: The Amtrol Fill-Trol expansion tank models provide an expansion tank that includes an automatic fill valve incorporated with the tank
See details at AMTROL's EXTROL®, the FILL-TROL® - "K" BTUh = Thousands of BTUS per Hour of Output Heat from the Boiler
- The BTU output per hour or BTUH used is the net hydronic boiler output BTUs, typically found on the boiler's data tag.
- For mixed systems combining radiators and baseboard, use the larger expansion tank size.
Watch out: these are "ballpark" data points. Check with the installation and maintenance manual for your heating system, with its manufacturer, and with your local heating equipment service company or supplier for their opinon on accurate boiler xpansion tank sizing.
Hydronic Heating Boiler (Hot water heating boiler) Expansion Tank Sizing References
- Amtrol Corporation, Hydronic Expansion Tank Sizing [Online Calculator], AMTROL Inc.
Corporate Office
1400 Division Road
West Warwick, R.I. 02893
Phone: (401) 884-6300
Fax: (401) 884-4773
For general inquiries: info@amtrol.com
For warranty inquiries: warranty@amtrol.com
- retrieved 2016/11/20, original source: http://www.amtrol.com/support/extrol_com_sizing.html
Requirements: you'll need to know total heating system volume, minimum and maximum operating temperature, and minimum/maximum operating pressure. - Amtrol Corporation, Thermnal Expansion Tank Sizing [Online Calculator], Op. Cit., Original source: http://www.amtrol.com/support/therm_res_sizing.html
- Amtrol Corporation, Well Tank [Pressure tank] Tank Sizing [Online Calculator], Op. Cit., Original source: http://www.amtrol.com/support/well_sizing.html
- HOT WATER EXPANSION TANKS at InspectApedia.com - requirements for thermal expansion absorbing tanks or relief valve systems on hot water heating systems
- HOT WATER PRESSURE EXPANSION RATE - what is the expansion rate and volume of water when it's heated?
- PexUniverse, "How to size and select a proper Expansion Tank", PexUniverse, PexUniverse.com 5407 Foster Ave Brooklyn, NY 11234, USA, vendor of PEX supplies, heating and plumbing supplies, pumps, valves, fittings & components for HVAC and IAQ equipment, Email: sales@pexuniverse.com, Tel: 800-818-3201 Website: PexUniverse.com - retrieved 2016/11/20, original source: http://www.pexuniverse.com/how-size-and-select-proper-expansion-tank
...
Reader Comments, Questions & Answers About The Article Above
Below you will find questions and answers previously posted on this page at its page bottom reader comment box.
Reader Q&A - also see RECOMMENDED ARTICLES & FAQs
On 2021-02-12 - by (mod) -
Gary
Please take a look at the expansion tank sizing tables given above on this page - as that gives the most-accurate answer to your question.
Please don't hesitate to ask further if any of that is unclear.
On 2021-02-12 by GARY PARIKH
i had old c.i. boiler w/375000 btu output for my bldg. fintube radiation. what size expansion tank to install
On 2020-11-01 - by (mod) -
OK.
Sounds as if the Extrol is doing its job.
On 2020-11-01 by William conklin
I ha 8 small radiator. Thete is a new peerless boiler. Installed 100.000 btu 1/2 pipe goung to extro l. 30 there us no expansion trouble. On running or off
On 2019-01-16 by Tom
I'm in trade school for HVAC and we were sizing expansion tanks and we have some expansion tanks that are undersized and some that are oversized. The question was posed: how much can you undersize and oversize the expansion tanks on a hot water boiler?
On 2018-11-05 - by (mod) -
Thank you for the nice comment, Rod. We're glad that you found it useful.
We also welcome questions and critique. Working together is good for both of us.
On 2018-11-04 by Rod
Great information I thank you for it
...
Continue reading at FIND the EXPANSION TANK or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.
Or see these
Recommended Articles
- EXPANSION TANKS, BOILERS - home
- AMTROL's EXTROL®, the FILL-TROL®
- ATTIC & ANTIQUE EXPANSION TANKS, HEATING
- BOILER DRAIN DAMAGES EXPANSION TANK
- EXPANSION TANK AIR VALVE LEAKS
- EXPANSION TANK DIAGNOSIS
- EXPANSION TANK DRAIN & AIR RE-CHARGE
- EXPANSION TANK IO MANUALS & SIZING GUIDES
- EXPANSION TANK LEAK REPAIRS
- EXPANSION TANK PRESSURE ADJUSTMENT
- EXPANSION TANK SIZING GUIDE
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- EXPANSION TANK WON'T DRAIN
- FIND the EXPANSION TANK
- HEADER TANKS
- RELIEF VALVE LEAK DUE TO EXPANSION TANK
- TANKLESS COIL INTERNAL LEAKS INTO the BOILER
- THERMAL EXPANSION of HOT WATER
- THERMAL EXPANSION TPR VALVE LEAKS
- WATER PRESSURE TOO HIGH: DANGERS
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EXPANSION TANK SIZING GUIDE at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.
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Citations & References
In addition to any citations in the article above, a full list is available on request.
- Holohan, Dan, "Why compression tanks waterlog", HeatingHelp.com (June 2014) - retrieved 19 March 2015, original source: https://heatinghelp.com/systems-help-center/why-compression-tanks-waterlog/
- Etherton, Mark (contractor), "Expansion Tanks 101: the facts and myths", Contractor Magazine, contractormag.com, (March 2000), retrieved 19 March 2015, original source: http://contractormag.com/hydronics/cm_column_75
- Extrol Corporation, "Installation & Operation Instructions, Extrol (R) Hydronic Diaphragm Expansion Tanks In-Line & SX-Series", Extrol Corporation, 1400 Division Road, West Warwick RI 02983, Tel: 401-884-6300, Website: www.amtrol.com, retrieved 3/3/2014, original source http://www.amtrol.com/media/documents/extrol/9015183_3_11_EXTROL_IO.pdf
-
Research on permeability of rubber used in internal bladder-type heating system compression tanks or expansion tanks
- Bodell, Bruce R. "Distillation of saline water using silicone rubber membrane." U.S. Patent 3,361,645, issued January 2, 1968.
- Ciesielski, Andrew. An introduction to rubber technology. iSmithers Rapra Publishing, 1999.
- Fuller, James, and David M. Stedham. "Expansion tank with a predictive sensor." U.S. Patent 8,633,825, issued January 21, 2014.
- Martinello, Ermanno, and Mark Weih. "Membrane coating for a water pressurization Bladder." U.S. Patent Application 12/498,128, filed July 6, 2009.
- Stern, S. A., F. J. Onorato, and Charles Libove. "The permeation of gases through hollow silicone rubber fibers: Effect of fiber elasticity on gas permeability." AIChE Journal 23, no. 4 (1977): 567-578.
- Terashita, Fumihiro, Shingo Takagi, Shinzo Kohjiya, and Yasutoshi Naito. "Airtight butyl rubber under high pressures in the storage tank of CAES‐G/T system power plant." Journal of applied polymer science 95, no. 1 (2005): 173-177.
- [4] B&G / ITT Reducing Valves, Instruction Manual V55999: Reducing Valves Installation, Operation, & Service Instructions, Bell & Gossett Air Separators and other heating system components, Bell & Gossett, 8200 N. Austin Ave., Morton Grove IL 60053, USA - Tel 847 966-3700 Fax 847 965-8379. Original source www.bellgossett.com/literature/files/610.pdf
- [5] Bell & Gossett Airtrol® System Installation, Operating and Service Instructions, Bell & Gossett, 8200 N. Austin Ave., Morton Grove IL 60053, USA - Tel 847 966-3700 Fax 847 965-8379. Retrieved 8/9/2012, original source B&G, [copy on file as Airtrol_Installation_Manual.pdf linked in this reference]
- Domestic and Commercial Oil Burners, Charles H. Burkhardt, McGraw Hill Book Company, New York 3rd Ed 1969.
- National Fuel Gas Code (Z223.1) $16.00 and National Fuel Gas Code Handbook (Z223.2) $47.00 American Gas Association (A.G.A.), 1515 Wilson Boulevard, Arlington, VA 22209 also available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Fundamentals of Gas Appliance Venting and Ventilation, 1985, American Gas Association Laboratories, Engineering Services Department. American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209. Catalog #XHO585. Reprinted 1989.
- The Steam Book, 1984, Training and Education Department, Fluid Handling Division, ITT [probably out of print, possibly available from several home inspection supply companies] Fuel Oil and Oil Heat Magazine, October 1990, offers an update,
- Principles of Steam Heating, $13.25 includes postage. Fuel oil & Oil Heat Magazine, 389 Passaic Ave., Fairfield, NJ 07004.
- The Lost Art of Steam Heating, Dan Holohan, 516-579-3046 FAX
- Principles of Steam Heating, Dan Holohan, technical editor of Fuel Oil and Oil Heat magazine, 389 Passaic Ave., Fairfield, NJ 07004 ($12.+1.25 postage/handling).
- "Residential Steam Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- "Residential Hydronic (circulating hot water) Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- "Warm Air Heating Systems". Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- Heating, Ventilating, and Air Conditioning Volume I, Heating Fundamentals,
- Boilers, Boiler Conversions, James E. Brumbaugh, ISBN 0-672-23389-4 (v. 1) Volume II, Oil, Gas, and Coal Burners, Controls, Ducts, Piping, Valves, James E. Brumbaugh, ISBN 0-672-23390-7 (v. 2) Volume III, Radiant Heating, Water Heaters, Ventilation, Air Conditioning, Heat Pumps, Air Cleaners, James E. Brumbaugh, ISBN 0-672-23383-5 (v. 3) or ISBN 0-672-23380-0 (set) Special Sales Director, Macmillan Publishing Co., 866 Third Ave., New York, NY 10022. Macmillan Publishing Co., NY
- Installation Guide for Residential Hydronic Heating Systems
- Installation Guide #200, The Hydronics Institute, 35 Russo Place, Berkeley Heights, NJ 07922
- The ABC's of Retention Head Oil Burners, National Association of Oil Heat Service Managers, TM 115, National Old Timers' Association of the Energy Industry, PO Box 168, Mineola, NY 11501. (Excellent tips on spotting problems on oil-fired heating equipment. Booklet.)
- Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
- In addition to citations & references found in this article, see the research citations given at the end of the related articles found at our suggested
CONTINUE READING or RECOMMENDED ARTICLES.
- Carson, Dunlop & Associates Ltd., 120 Carlton Street Suite 407, Toronto ON M5A 4K2. Tel: (416) 964-9415 1-800-268-7070 Email: info@carsondunlop.com. Alan Carson is a past president of ASHI, the American Society of Home Inspectors.
Thanks to Alan Carson and Bob Dunlop, for permission for InspectAPedia to use text excerpts from The HOME REFERENCE BOOK - the Encyclopedia of Homes and to use illustrations from The ILLUSTRATED HOME .
Carson Dunlop Associates provides extensive home inspection education and report writing material. In gratitude we provide links to tsome Carson Dunlop Associates products and services.
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