The more I read on this forum the more confused I get.
I can not solve this problem of course, but to clear up a few things in my mind, I have to ask,,,
Did you have these issues with your old owb ?
If not, it's the new set-up, if so, it's the house.
I read this over a couple of times and there is no indicated diff. temperatures in the lines posted.
I also noted your w/a exchanger is on the return side of the furnace fan. cold air intake.
Did you have it there with the old boiler?
Probably doesn't matter, I don't know.?
I;m not trying to upstage anyone, but my burn times on Woodmaster4400 with a wheel barrow of maple /ash are upwards of 16 hours.@ -10f./-15f.
I'm heating a 1600 bungalow with 70 ft loop of 1 pex.
If the experts can;t pin it, I doubt this will help any.
Cheers
KK