his suggestion was to go off my line temps and the temp gauge on the front of the boiler (which are always within a degree of each other most times) and turn the aquastat up until i have 180 degree readings on the line temp gauges and the front boiler temp gauge. which makes sense. He said it is more prone to do this in warmer weather. So, I tweaked with it last night and right now my settings are at 190 with a 5 degree diff....this is giving me an actual of 167 on and 180 off. so far, so good. I also told him i ordered a Ranco to try out and he said that wouldnt be a bad idea.
He mentioned that he hasnt heard of this every happening with any of the residential models, but they did have one commercial model that was tripping the high limit shut off because of the same thing: high ambient temperatures.