The company "CLIMATIC" provides service and repair services for cast iron boilers KChM, Universal, as well as cast iron boilers from foreign manufacturers - VIESSMANN, BUDERUS, PROTHERM, DAKON, VIADRUS, MORA and others. Deep knowledge and extensive experience of our employees working with this equipment, the availability of professional tools, original consumables and spare parts allow us to be confident in the quality of work.

Replacement of sections in boilers KChM, Universal-RT

Replacement of heat exchanger sections of boilers VIESSMANN, BUDERUS, PROTHERM, DAKON, MORA, etc.

Repair of boilers Universal-6M, Universal-5M.

Cast iron boilers Universal-6M, Universal-5M are repaired in the same way as all sectional cast iron boilers. The repair of boilers of this type is complicated by the presence of heavy lining made of refractory bricks and the massiveness of the boiler sections. Our company has extensive experience in repairing boilers of this type. Replacement of sections in Universal-6M boilers will be carried out by our specialists in the shortest possible time and at a high professional level. The availability of specialized installation tools and original spare parts allows us to guarantee high quality work on the repair of Universal-6M boilers.

In what case will it be necessary to replace a section of a cast iron boiler?

Over time, the heat exchanger wears out, corrosion and scale take their toll. However, its complete replacement of the heat exchanger is impractical, since individual sections usually fail; therefore, the cast iron section of the boiler in which a crack appears must be replaced. Repairing the section does not give the desired effect - due to the constant temperature expansion of cast iron, the weld is destroyed after a short time.

In some cases, a crack can only be detected during boiler diagnostics. Therefore, for a certain time, the technique is used with a crack present, which increases destruction. At the same time, if you do not want the boiler to completely fail, then the problem must be solved immediately after detection.

Cost of replacing a section of a cast iron boiler

The price of replacing a section of a cast iron boiler depends on the model of your equipment, its power, and the complexity of the work performed. The final price can be determined only after a visual inspection of the work site by a master.

Is it possible to replace a section of a cast iron boiler yourself?

Some equipment owners try to replace a section of a cast iron boiler on their own. However, here they face a number of problems:

• How to disconnect a damaged section of a cast iron boiler from a package of sections.
• How to seal joints between installed sections.
• How not to damage adjacent sections and the package of sections as a whole.
• How to generally perform the entire complex of work without special tools.
• How to tighten the package of sections correctly, without distortions and overvoltage of the entire heat exchanger.

Self-repair of a cast iron sectional heat exchanger is quite problematic - as a rule, there is no necessary tool, no skills for such work. Despite the apparent simplicity of the process, there are often cases of damage to a new section due to improper installation, as well as damage to neighboring, previously entire sections. As a result, independent repairs result in even greater costs than hiring a specialized installation company.

Fast, high quality, reliable. With a guarantee!

We guarantee prompt and high-quality completion of the entire cycle of work on replacing sections on your boiler. Vast experience in carrying out repair work on cast iron boilers of various capacities allows us to assert that the work will be completed with high quality and on time! The installation team will independently deliver all the necessary spare parts and consumables to your site - and this will not affect the cost of the work in any way, no additional payment for delivery.
After assembling and crimping the heat exchanger, if heavy lining is not required (Universal-6M boilers and similar), the boiler will be ready for operation in normal mode. The work performed is provided with a guarantee of 6 to 12 months, depending on the boiler manufacturer.

When using household cast iron gas boilers, water leaks often appear. The reason most often lies in violation of the operating regime. What are the “risk factors” for accidental damage? What should the repair be like?

Causes of damage to a cast iron domestic boiler and replacement of defective sections

The technology for eliminating damage to the compartments of a cast iron heat exchanger is dictated by its design. Prepair problemis being decidedreplacing a boiler section . The heat exchanger is a prefabricated structure. The elements are assembled into a single unit using components (conical connecting nipples).Violation of the integrity of one of the sections leads to failure of the entire device. What are the causes of destructive deformations and leaks of the heat exchanger?

A little theory - what phenomena cause the destruction of the heat exchanger?

Heating devices made of cast iron are more durable compared to steel counterparts. Cast iron is less corrosive in an aquatic environment. That's whygas boilers This material almost does not rust. However, cast iron (unlike steel) is more sensitive to local temperature peaks. The preservation of the physical properties of the structure is negatively affected by the effect of cold water on heated metal.

The following situations arise when service rules are violated:

Clogging of the device leads to overheating of individual small areas of the cast iron surface.

Recharge for workinga gas boiler cold coolant creates a temperature contrast.

Incorrect burner settings disrupt the overall thermal conditions.

These phenomena lead to the appearance of the so-called. "heat shock" of the metal. As a result, one or more elements are deformed relative to others or simply burst.

A common failure during operation is device leakage. There may be several reasons for this: a microcrack in the body of the structure, drying out of the sealant. Then the need arisesreplacing a section of a cast iron boiler . For repairs, it is better to invite specialists from a service organization. Such companies carry out repairs regularly. They have professional tools to assemble the devices.

Stages of bringing the heat exchanger into working condition (Instructions)

The repair is carried out in stages. It begins with diagnostics of the structure body and ends with testing and commissioning. Intermediate operations:

Removal of the casing and sectional disassembly;

And the screed of all elements;

Connecting the device to the heating system;

Installation of external cladding.

For diagnostics, the device is stopped. After cooling, the casing and thermal insulation layer are dismantled. The nature of the damage and the number of compartments to be replaced are determined visually. If the leak is caused by a microcrack, and the location of the defect cannot be immediately detected, the water pressure is increased to 2 kg and left for a day.

Splitting into sections is carefully done mechanically.

In this case, they try to hit only the defective element.

Followed byreplacement of cast iron boiler sections . Elements adjacent to the damaged ones are inspected for timely detection of contamination. They are washed or replaced with new ones. Sometimes craftsmen decide to assemble the unit and then wash it with water and chemical reagents.

Assembly of cast iron sections.

Before screeding, all contact surfaces between the elements are thoroughly cleaned. The coolant passage is sealed with new nipples and lubricated with a special paste. Afterreplacing a boiler section the smoke path is also sealed. To do this, cover the joints with mastic or tighten them with cords.

The screed is performed using a special tool.

It is very important to prevent distortion and accurately connect the sections.

When replacing several elements, they are added to the assembled structure strictly one at a time.

In the next step, the device is connected to the system and is subject to pressure testing. For this operation, the maximum pressure allowed by the manufacturer is supplied to it. For each model, this parameter is indicated in the passport.

Required without obvious violation of integrity. When the coolant pressure in the device regularly drops and it has to be frequently refilled with water. The reason for this behavior of the boiler is hidden in the appearance of a microcrack in the firebox. At high temperatures, the liquid has time to evaporate and is removed with the flue gases. Unstable operation is a valid reason to contact customer service.

Our service center Servic 71 carries out replacement of sections of cast iron heat exchangers of the household series of floor-standing boilers from manufacturers: Protherm, Vaillant, Viessmann, De Dietrich, Buderus, Ferroli, Wolf and others.

Regarding the cost of services, the availability and cost of sections and related components, as well as the timing of the work, our engineers will advise you by phone:

+7 ( 906 ) 627 69 64

Name of works	price, rub.
Dismantling, tie-down of one boiler section up to 50 kW Subsequent sections (per piece)	15000 3000
Dismantling, tie-down of one boiler section from 50 to 90 kW Subsequent sections (per piece)	20000 4000
Dismantling and tightening of one section of a boiler over 90 kW Subsequent sections (per piece)	from 25000 from 5000

“Risk” factors leading to the need to replace heat exchanger sections of a cast iron boiler.

Most floor-standing domestic boilers in the middle and higher price ranges are made of cast iron. Unlike steel boilers, whose structure is welded and monolithic, cast iron boilers are a structure of individual elements - sections connected to each other by conical nipples. Cast iron boilers are less susceptible to corrosion and more durable, but are more demanding in maintaining temperature conditions. Basically, violations of the temperature regime occur due to clogging of the boiler (which leads to local overheating), replenishment of the heated boiler with cold water and incorrect burner settings (in pressurized boilers). All of the above phenomena cause the so-called “thermal shock” and lead to deformation of the sections relative to each other, and more often to the destruction of the sections.

Damage can be of varying degrees: if the burst section is completely destroyed and this is obvious, then the microcrack may remain invisible for some time. A microcrack in an atmospheric boiler can be detected by a small puddle under the boiler. A microcrack inside the furnace of a pressurized boiler may not appear visually for a long time, since the liquid may have time to evaporate and fly out into the chimney along with the flue gases. However, a regular drop in coolant pressure and its replenishment should be a reason to check the integrity of the boiler body.

Stages of repair of a cast iron boiler heat exchanger.

Repair of the heat exchanger of a cast-iron boiler occurs in several stages: diagnostics of the boiler body, delivery of cast-iron sections, dismantling of the boiler and dismantling (splitting) of the heat exchanger section by section, replacement of failed sections and tie-down of sections, connection of the boiler to the heating system, pressure testing and installation of the boiler casing.

Diagnostics boils down to the following. The boiler is stopped and cooled. The boiler casing (casing and thermal insulation) is dismantled. The boiler furnace door is opened (for pressurized boilers). If necessary, the coolant pressure rises to 2 kg. A visual inspection determines the nature of the damage and the number of sections to be replaced. Sometimes, when it is visually impossible to immediately determine the location of the leak, because... it occurs from a microcrack in the heat exchanger; the boiler is left under pressure in a cold state for a day or more. And already in this case, by looking at damp places and smudges, it will be possible to determine the location of the leak.

Dismantling (splitting) the boiler into sections is done roughly using a sledgehammer and a chisel, but in such a way as not to damage serviceable sections. That is, impacts should only occur on the sections to be replaced.

After disassembling and removing the burst sections of the heat exchanger, adjacent sections are inspected for contamination. If adjacent sections are found to be clogged (clogged) and cannot be washed, a decision is made to either replace the adjacent sections, or, after assembling and testing the boiler, wash the boiler body with chemical reagents.

The most important stage is the screed (assembly) of the cast iron sections of the heat exchanger. Before assembling the sections, all contacting surfaces of the sections are thoroughly cleaned. To seal the hydraulic path, new nipples are installed and lubricated with a special lubricant. To seal the smoke duct, the sections are covered with special mastic or cords. The heat exchanger sections are assembled with a special tool. Avoiding distortion, the screed is carried out until the sections come into complete contact. Sections are assembled strictly one at a time (if several heat exchanger elements are changed).

After screeding, the boiler is connected to the heating system and pressure testing is carried out with the maximum permitted pressure for this boiler (see boiler passport).

If the test is positive, the boiler casing is installed and the boiler is put into operation.

Details: repair of cast iron heating boilers with your own hands from a real master for the website website.

The technology for eliminating damage to the compartments of a cast iron heat exchanger is dictated by its design. The repair problem is solved replacing a boiler section. The heat exchanger is a prefabricated structure. The elements are assembled into a single unit using components (conical connecting nipples). Violation of the integrity of one of the sections leads to failure of the entire device. What are the causes of destructive deformations and leaks of the heat exchanger?

A little theory - what phenomena cause the destruction of the heat exchanger?

Heating devices made of cast iron are more durable compared to steel counterparts. Cast iron is less corrosive in an aquatic environment. That's why gas boilers This material almost does not rust. However, cast iron (unlike steel) is more sensitive to local temperature peaks. The preservation of the physical properties of the structure is negatively affected by the effect of cold water on heated metal.

The following situations arise when service rules are violated:

Clogging of the device leads to overheating of individual small areas of the cast iron surface.

Recharge for working a gas boiler cold coolant creates a temperature contrast.

Incorrect burner settings disrupt the overall thermal conditions.

These phenomena lead to the appearance of the so-called. "heat shock" of the metal. As a result, one or more elements are deformed relative to others or simply burst.

A common failure during operation is device leakage. There may be several reasons for this: a microcrack in the body of the structure, drying out of the sealant. Then the need arises replacing a section of a cast iron boiler. For repairs, it is better to invite specialists from a service organization. Such companies carry out repairs regularly. They have professional tools to assemble the devices.

The repair is carried out in stages. It begins with diagnostics of the structure body and ends with testing and commissioning. Intermediate operations:

Removal of the casing and sectional disassembly;

Replacing a boiler section and screed of all elements;

Connecting the device to the heating system;

For diagnostics, the device is stopped. After cooling, the casing and thermal insulation layer are dismantled. The nature of the damage and the number of compartments to be replaced are determined visually. If the leak is caused by a microcrack, and the location of the defect cannot be immediately detected, the water pressure is increased to 2 kg and left for a day.

Splitting into sections is carefully done mechanically.

In this case, they try to hit only the defective element.

Followed by replacement of cast iron boiler sections. Elements adjacent to the damaged ones are inspected for timely detection of contamination. They are washed or replaced with new ones. Sometimes craftsmen decide to assemble the unit and then wash it with water and chemical reagents.

Before screeding, all contact surfaces between the elements are thoroughly cleaned. The coolant passage is sealed with new nipples and lubricated with a special paste. After replacing a boiler section the smoke path is also sealed. To do this, cover the joints with mastic or tighten them with cords.

The screed is performed using a special tool.

It is very important to prevent distortion and accurately connect the sections.

When replacing several elements, they are added to the assembled structure strictly one at a time.

In the next step, the device is connected to the system and is subject to pressure testing. For this operation, the maximum pressure allowed by the manufacturer is supplied to it. For each model, this parameter is indicated in the passport.

Repair of cast iron heat exchanger required without any obvious violation of integrity. When the coolant pressure in the device regularly drops and it has to be frequently refilled with water. The reason for this behavior of the boiler is hidden in the appearance of a microcrack in the firebox. At high temperatures, the liquid has time to evaporate and is removed with the flue gases. Unstable operation is a valid reason to contact customer service.

The CLIMATIC company provides service and repair services for cast iron boilers KChM, Universal, as well as cast iron boilers from foreign manufacturers - VIESSMANN, BUDERUS, PROTHERM, DAKON, VIADRUS, MORA and others. Deep knowledge and extensive experience of our employees working with this equipment, the availability of professional tools, original consumables and spare parts allow us to be confident in the quality of work.

Replacement of sections in boilers KChM, Universal-RT

Replacement of heat exchanger sections of boilers VIESSMANN, BUDERUS, PROTHERM, DAKON, MORA, etc.

Repair of boilers Universal-6M, Universal-5M.

In what case will it be necessary to replace a section of a cast iron boiler?

Over time, the heat exchanger wears out, corrosion and scale take their toll. However, its complete replacement of the heat exchanger is impractical, since individual sections usually fail; therefore, the cast iron section of the boiler in which a crack appears must be replaced. Repairing the section does not give the desired effect - due to the constant temperature expansion of cast iron, the weld is destroyed after a short time.

In some cases, a crack can only be detected during boiler diagnostics. Therefore, for a certain time, the technique is used with a crack present, which increases destruction. At the same time, if you do not want the boiler to completely fail, then the problem must be solved immediately after detection.

Cost of replacing a section of a cast iron boiler

The price of replacing a section of a cast iron boiler depends on the model of your equipment, its power, and the complexity of the work performed. The final price can be determined only after a visual inspection of the work site by a master.

Is it possible to replace a section of a cast iron boiler yourself?

Some equipment owners try to replace a section of a cast iron boiler on their own. However, here they face a number of problems:

• How to disconnect a damaged section of a cast iron boiler from a package of sections.
• How to seal joints between installed sections.
• How not to damage adjacent sections and the package of sections as a whole.
• How to generally perform the entire complex of work without special tools.
• How to tighten the package of sections correctly, without distortions and overvoltage of the entire heat exchanger.

Self-repair of a cast iron sectional heat exchanger is quite problematic - as a rule, there is no necessary tool, no skills for such work. Despite the apparent simplicity of the process, there are often cases of damage to a new section due to improper installation, as well as damage to neighboring, previously entire sections. As a result, independent repairs result in even greater costs than hiring a specialized installation company.

Fast, high quality, reliable. With a guarantee!

We guarantee prompt and high-quality completion of the entire cycle of work on replacing sections on your boiler. Vast experience in carrying out repair work on cast iron boilers of various capacities allows us to assert that the work will be completed with high quality and on time! The installation team will independently deliver all the necessary spare parts and consumables to your site - and this will not affect the cost of the work in any way, no additional payment for delivery.
After assembling and crimping the heat exchanger, if heavy lining is not required (Universal-6M boilers and similar), the boiler will be ready for operation in normal mode. The work performed is provided with a guarantee of 6 to 12 months, depending on the boiler manufacturer.

Homemade heating boiler

In addition to purchasing heating boilers presented on the market by well-known and not so global or domestic manufacturers, there is always the opportunity to make a heating boiler with your own hands. And at the same time save on a whole list of options that your heating system can easily do without. All you need for this is knowledge of the structure and operating principle of the type of boiler you have chosen, materials, tools and equipment, as well as practical skills in working with them.

If desired, you can build almost any type of heating boiler. The main thing is to make the right choice, and for this you need to know the main advantages and disadvantages of the most popular types of heating equipment. AND So, heating boilers are:

It is not recommended to manufacture boilers of this type on your own: gas equipment has technical requirements that you are unlikely to be able to satisfy in a makeshift environment.

Household electric boiler

The fairly high popularity of this category of heating boilers is explained by the simplicity of the design and relatively low safety requirements during installation and operation.

A huge disadvantage of electric boilers is high electricity prices. As a result, such equipment is used to provide periodic heating, for example, of a cottage or garage.

1. Liquid fuel

Homemade liquid fuel boiler

The design of such a boiler is not very complicated. However, the cost and subtleties of setting the nozzles that supply fuel to the combustion chamber will make anyone think at least twice before starting to create a heating unit that runs on fuel oil or diesel.

1. Solid fuel

Do-it-yourself long-burning boiler

Representatives of this type are optimally suited for heating both private homes and various commercial or industrial facilities. High efficiency and versatility in use provide solid fuel boilers with the highest demand on the market.

According to the principle of operation, solid fuel boilers are divided into wood, pyrolysis, long-burning and pellet. The most popular option for self-production are long-burning boilers, while pyrolysis and pellet boilers are used much less frequently due to the high cost of individual components.

The design of the heating boiler is influenced by several conditions:

• cost and availability of materials;
• Type of fuel;
• coolant circulation method.

Heat-resistant stainless steel demonstrates the greatest durability. However, it is this that has the highest price on the market, and its processing is a rather complex task that cannot be handled without special equipment. The same applies to cast iron, which, however, costs much less than stainless steel. Traditionally, for the manufacture of heating boilers, sheet steel with a thickness of 4 mm is used - this option is relatively easy to process and, most importantly, is quite reliable and durable.

To ensure natural circulation of the coolant, it is necessary to use heating circuits and connecting fittings of large diameter, and place the storage tank at a height. If this is not possible, you will have to use a circulation pump - it will reduce the diameter of the pipes. However, the heating boiler pumping system is energy-dependent, which must be taken into account when choosing the design and functionality of the unit.

The pipes with which your boiler will be equipped must have a diameter of at least 32 mm - a thick-walled steel pipe is suitable for their manufacture. The heating circuit should be made of galvanized steel, not forgetting to seal the threaded connections.

Homemade wood-burning boiler

The cheapest option for making your own is a wood-burning boiler. Structurally, such a unit consists of two containers placed one inside the other. The inner one serves as a firebox, the outer one as a heating tank. The design of a wood-burning boiler is really simple, and it can work not only with wood, but also with other types of solid fuel.

The wood boiler design includes:

• steel firebox (with door);
• ash pan (with door);
• firebox grates;
• soot collector;
• chimney;
• gate valve;
• inlet and outlet pipes;
• legs;
• cast iron lid.

Construction of a solid fuel boiler

The big disadvantage of a wood-burning boiler is its low efficiency, that is, a huge consumption of firewood or a constant lack of heat in the house.

Pyrolysis boilers are more expensive to manufacture: they have two combustion chambers - for fuel and for pyrolysis gas, and some of their components themselves are very expensive. Nevertheless, such equipment is in great demand due to its cost-effectiveness - it fully pays for itself within just 3-4 seasons.

The classic scheme of a pyrolysis boiler includes:

• combustion chamber with nozzle;
• gasification chamber;
• air supply system;
• chimney system;
• loading chamber;
• water heat exchanger;
• coolant circulation system;
• temperature and pressure sensors;
• control valve.

Operating principle of a pyrolysis boiler

Pellet boilers were invented at the end of the 20th century. They operate on pressed sawdust, and their main operating principle is to transfer heat from the gas released during combustion of the latter, which heats the coolant in the heat exchanger.

DIY pellet heating boiler

The design of the pellet boiler includes:

• frame;
• combustion chamber with air window and cleaning door;
• heat exchanger with water circuit;
• smoke extractor;
• thermal insulation gasket;
• automatic control and management.

In pellet boilers, it is best to use cast iron heat exchangers: they have a higher heat transfer rate and are not subject to corrosion.

The main element of an electric heating unit is a thermoelectric heater (TEH) - it is necessary to convert electricity into heat. The body of the electric boiler can be made of any material, and the components necessary for its operation - regulators, sensors, etc. - can be purchased at any specialized store.

Electric heating boiler design

Structurally, the electric boiler consists of:

• heating element;
• expansion tank;
• circulation pump;
• safety valve;
• filtration unit.

Operating principle of an electric heating boiler

The coolant in the system can circulate either naturally, for which it is necessary to provide a height difference between the radiators and the boiler tank, or forcedly using a pump. The simplest option for an electric boiler is to install a heating element directly into the heating system. If this design is not suitable, you can design an electric boiler with a removable pipe - this will make it possible to quickly get to the heating element if repair or replacement is necessary.

The optimal solution for heating, say, a small cottage is a small, separately located electric boiler. The pipe of such a boiler will have a diameter of about 220 mm, and the body length will be no more than half a meter, which allows it to be installed almost anywhere, of course, taking into account safety rules.

The body of the electric boiler must be sealed. It is equipped with a hole for the heated coolant to enter the heating system, as well as a pipe for the return supply of cooled water.

In addition to solid fuel and electric boilers, a number of alternative heating units are suitable for self-production:

1. Induction boilers

They are transformers consisting of a primary and secondary winding. In such a boiler, the electricity on the external winding is converted into an eddy current, and the created magnetic field is transferred to the internal winding, which transfers energy to the coolant.

1. Condensing boilers

They retain the thermal energy of condensate, therefore they are considered more efficient than gas and even solid fuel ones. Steam condensation occurs in a heat exchanger with a special design - it is this that provides such boilers with a 15-20% efficiency advantage over traditional gas equipment.

1. Liquid fuel boilers

Such units evaporate waste and then burn its vapors. The energy thus obtained is transferred to a heat exchanger, which heats the heating agent of the heating system. Equipment of this type has two significant disadvantages - low efficiency and a large amount of emissions into the atmosphere.

1. Combination boilers

This equipment is universal in use, but to manufacture it yourself will require remarkable skill and excellent knowledge of the operating principles of various types of heating equipment. The individual components of such units can be quite expensive, but in general, combined boilers can pay for themselves in no more than 5-6 seasons.

When manufacturing a boiler of any type, you must be guided by the requirements of safety regulations and standards in force for the category of heating equipment you have chosen.

A gas boiler complex mechanism. It can be divided into 3 main parts: electronics, gas pipes and burners, heat exchange unit (pump, tank, fan). You can only repair the last part yourself.

Attempts to restore the first two parts, without the proper skills, will lead to final breakdown boiler, gas leak and other negative consequences.

Gas boilers rarely break. This happens as a consequence normal wear and tear equipment, or due to factory defect. Other cases of breakdowns are necessarily associated with the following factors.

The boiler may break due to water. At risk, first of all, are dual-circuit devices used not only for heating, but also for hot water supply.

The fact is that rust from the pipeline, other fractions clog the thin tubes of the heat exchanger over the course of a year.

Helps you avoid troubles related to water quality coarse filter. It is installed during installation to the supply pipe liquids. For greater security, you can add to the system fine filter, or install a full cleaning system.

Household appliances are resistant to voltage surges and shutdowns electricity. But a gas boiler is more delicate equipment. A power surge will cause the boiler to shut down or damage the electronics. A malfunction of the device or a power outage will lead to freezing of the heating pipes.

To avoid sad consequences, install at least one of the additional devices.

• Stabilizer- a device that will solve the problem of power surges. Its size is small and can be installed both in an apartment and in a private house.

Photo 1. Electronic voltage stabilizer Resanta Lux for a heating boiler. The device is mounted on the wall.

• Uninterruptable power source. Will equalize the input voltage. Allows the boiler to operate for some time in the absence of electricity. Suitable for use in both apartments and houses.
• Gasoline generator. It does not affect the stability of the network in any way, but can save you during a long-term power outage. Used only in the private sector.

Attention! When purchasing a generator, check whether it is really single-phase.

Installation of complex equipment unprofessional will entail serious consequences. In frequent cases, the following problems occur:

• During installation neglected grounding. This leads to the accumulation of static on the device body. When an electric arc occurs, the boiler automation often fails.
• After installation did not bleed air from the system. The resulting plug will lead to rupture of the coolant pipes and breakdown of the pump.
• Violations in harness gas boiler systems with a cast iron heat exchanger will cause a split in an important part of the apparatus.

If the installation of a gas boiler is carried out correctly, operational problems arise only due to weather conditions. In cold winter, the desire to stay warm pushes people to use the boiler at maximum speed. The equipment can withstand such conditions, but the gas system cannot. A decrease in fuel pressure leads to interruptions in the operation of the device. The automation starts to turn off the boiler. The problem is that this can't be called a breakdown and it will not be possible to eliminate it.

Any malfunction of a gas boiler must be dealt with by a specialist. However, it is not always possible to use the services of a specialist, and breakdowns are trivial. Let's look at problems that can be solved independently.

Usually the smell of gas appears when it leaks from the threaded connection of the supply hose. If there is a smell in the room where the boiler is installed, you need to open the window and turn off the boiler. Then follow the instructions:

1. Prepare the necessary things: soap solution, FUM tape, open-end or adjustable wrench.
2. Apply solution for all threaded connections. If bubbles begin to inflate, the leak has been identified.
3. Close the gas valve.
4. Key expand the connection. Reel for external thread FUM tape and put everything back together.
5. Reapply the solution and restore gas supply.
6. If the leak is fixed and the smell of gas is gone, remove residues solution.

Attention! When the leak location cannot be found, turn off the gas, call a specialist.

If during boiler operation The sound made by the turbine has disappeared or decreased- indicates a malfunction of the blower fan. For repairs you will need: screwdriver, new bearing, cloth, grease.

1. Necessary switch off boiler and turn off the gas.
2. Remove the turbine.
3. With a rag clear from turbine blades dust and soot.
4. Inspect the electrical coil fan for blackening. If everything is ok, move on or replace the fan.
5. Disassemble the fan housing. Mounted inside on the turbine shaft bearing, his needs to be replaced. Some fans have sleeve instead of a bearing. In this case, her needs to be lubricated.

The turbine may also not work due to reduced network voltage or control board malfunction. The first can be eliminated with the help of a stabilizer, but the second can only be eliminated by calling a specialist.

Chimney problems arise only at boilers floor type. This is due to its size and vertical position. Mounted units do not require chimney cleaning.

Chimney consisting from metal parts, clean with a wire brush. It needs to be disassembled and the accumulated soot mechanically removed. Whole The chimney is cleaned with special vacuum cleaners or chemicals. But for this you need to call a professional.

Photo 2. Three ways to arrange a chimney for a floor-standing gas boiler. The first option is the most difficult to clean.

Boiler overheating is associated with heat exchanger contamination. To clean the device you will need: a special hydrochloric acid solution, adjustable wrench, FUM tape, metal brush. Then follow the instructions:

1. Turn off the boiler turn off the gas and water.
2. Remove the heat exchanger using an adjustable wrench.
3. Clear it with a brush.
4. Through the pipe pour in to the heat exchanger acid solution. If foam appears, it means there is a lot of scale inside.
5. Pour out solution and repeat procedure.
6. Rinse.
7. Install back, preliminary wrapping all threaded connections with FUM tape.

Problems usually arise with combustion electrode. If the burner flame goes out after a few seconds, and the boiler gives an error, then the problem is in the combustion sensor. Turn off the boiler and turn off the gas.

To repair the electrode you will need sandpaper, with which the sensor probes are cleaned without removing it. If the damage remains, the sensor is replaced.

Exist two problems, which lead to spontaneous shutdown of the boiler. The combustion sensor is broken or the chimney is clogged. Repair of both faults is described above in the article.

Watch a video that talks about malfunctions that occur during boiler operation.

Most boiler breakdowns can be fixed on their own, but This does not mean that you should neglect the help of a specialist. Gas equipment is potentially life-threatening.

And also don’t forget about maintenance. Cleaning the heat exchanger and chimney will protect against possible damage.

There are actually not so many reasons why the boiler leaked. First, corrosion may be the culprit. What is corrosion - is the destruction of the metal structure under the influence of the external environment. Internal corrosion of a gas boiler is caused by the influence of oxygen in the water, external corrosion is caused by combustion products.

The next cause of leakage may be the poor quality of the metal from which the heat exchanger is made and the quality of the seams of its connections.

High pressure in the system or water hammer also cause leaks in boilers. Burnout of the heat exchanger walls also causes a leak.

In some cases, when water is dripping from your boiler and you think your boiler is leaking, it may actually be condensation from the chimney that is flowing down the chimney pipe and onto the burner. If this situation occurs frequently, a moisture collection cup should be installed in the chimney. When it drips near the circulation pump, the bolt located in its center may have become loose. Tighten the bolt.

Below we will consider each case separately in more detail and describe what to do if this happens.

Heat exchangers installed in heat generators can be made of copper, steel and cast iron. Each of them has its own pros and cons. Copper heat exchangers are corrosion resistant and durable if the boiler is used correctly. Steel heat exchangers are the most common, due to their low cost, resistant to thermal stress due to their ductility, but are more often subject to corrosion.

Heat exchanger corrosion

Cast iron is resistant to corrosion and has a long service life, although they are susceptible to temperature changes and water hammer. Most manufacturers do not use anti-corrosion coatings. But in the latest models of Ferroli gas double-circuit boilers, steel heat exchangers are covered with an anti-corrosion aluminum coating with environmentally friendly internal insulation.

On Baxi units, copper heat exchangers are coated with a special anti-corrosion compound. Protherm, Buderus and Beretta have a cast iron heat exchanger, which is coated with a special anti-corrosion compound. In addition, such a heat exchanger consists of separate sections that can be replaced if they are damaged without completely replacing the heat exchanger.

Wall-mounted boilers Rinnai, Celtic, Bosch are equipped with copper heat exchangers, Vaillant and Navien are made of stainless steel, it is believed that they are less susceptible to corrosion.

Frequent feeding of the boiler has a great influence on the formation of corrosion. Ideally, so-called “dead water”, without oxygen, should circulate in the heat generator. It is oxygen that promotes the formation of corrosion.

If you often have to recharge the heat generator, you should eliminate the reasons for the pressure drop in the unit. Oxygen corrosion forms an ulcer on the inside of the heat exchanger, which is very dangerous. Growing inward, it forms through rust and destroys the heat exchanger.

The strength of the boiler depends on the quality of the welded joints. If a weld seam has cavities or irregularities, sooner or later this seam may leak. The void located inside the seam is considered especially dangerous. Ideally, the seams should be X-rayed, but not all manufacturers do this.

Although heating boilers are pressure vessels and must be subject to increased manufacturing requirements, defects sometimes occur. And, as a rule, it drips from the heating boiler after the warranty expires. It is not always possible to weld the boiler inside and stop the leak.

It depends on how the heat exchanger is designed. In models where a bithermal heat exchanger is installed (the secondary and primary are in the same housing, heat exchange occurs thanks to the two-in-one design), this is problematic. But, even if you did this, as practice shows, this will not help you for long.

Excessive pressure in the system can also cause a boiler leak. There can be many reasons for high blood pressure. The main reason may be a malfunction of the expansion tank, air locks in the system, a clogged strainer, a malfunction of the safety valve, or the make-up tap.

A malfunction of the safety valve is indicated by constantly leaking liquid from the tube. High pressure can not only cause a crack in the boiler, but also cause an explosion. Monitor the serviceability of the pressure gauge and relief valve; sometimes the valve jams due to the formation of a layer of salts on it. Wash it in citric acid.

Heating boiler safety valve

It is necessary to regularly check the correct pressure on the valve and in the expansion tank. When installing an expansion tank, it is necessary to calculate the volume of coolant. How to calculate - there is a calculation formula, and the average value is -1.5 Atm or 0.2 Atm lower than in the system. For prevention, do not forget to wash the filters at the inlet and outlet of the heating circuit; after recharging the system, it is necessary to ventilate the batteries.

The cause of the leak may be burnout of the combustion chamber wall. Steel and cast iron burn out when carbon evaporates from their composition, so the metal in the combustion chamber becomes thicker. As a rule, burnout occurs when the height of the combustion chamber is incorrectly set, the burner power is set incorrectly, the burner is not adjusted to minimum and maximum power, or the flame is too high.

Burnout occurs when the boiler is constantly operating at maximum power; this occurs in the case of insufficient insulation of the home or when the heat generator is selected without taking into account the heated area.

When purchasing a boiler, read reviews on the Internet and give preference to reputable manufacturers. It is better to buy a heat generator with a little more power, with reliable flame modulation and entrust the settings to specialists.

How to repair a leak - the leak repair algorithm is the same for both solid fuel boilers, such as Don, KChM, and gas boilers, for example, AOGV, Alixia 24, Ariston, Deu, Arderia, Electrolux.

1. Turn off the device.
2. Drain the water.
3. Wait until the boiler cools down completely.
4. We will describe how to remove the heat exchanger below.
5. Solder and eliminate the fistula.

What does a heat exchanger look like - it is a metal or cast iron body, heated by a burner flame and transferring thermal energy to the liquid that is inside it.

To disassemble it and solder it yourself, you need to remove the front panel, protective casing and combustion chamber protection using a long screwdriver. Then disconnect the sensor wires and the pipelines suitable for the heat exchanger, try not to damage the pipes and pipes, hold them with a wrench.

In order to connect everything correctly later, you should first take a photograph of the inside of the heat generator. Then disconnect the fan and smoke detector. When removing the heat exchanger, do not use force or make sudden movements; do everything with extreme caution.

If you find a gap between the circuits in the tube, it is impossible to repair such a hole; you will have to change the heat exchanger. The heat exchanger cannot be welded; soldering with a gas torch should be used.

Soldering the heat exchanger

In order to do soldering yourself, you must first clean the place where the fistula has formed. This can be done using fine sandpaper. Soldering is carried out using an oxygen gas mixture with solder containing the same chemical elements from which the heat exchanger is made.

Tin cannot be used in this case, since such repairs will again lead to the formation of a fistula after some time. After soldering, a protective coating, for example, a layer of aluminum, should be applied to the problem area.

When purchasing a heat generator, carefully examine the quality of the soldering of the connecting seams, both on the water and on the primary heat exchanger; there should be no sagging or unevenness.

Set up the burner according to the instructions in the instructions. To avoid the appearance of fistulas, it is necessary to take timely measures in the presence of high pressure and airiness in the system. Avoid frequent refilling of the system with water; find out the cause of the pressure drop in this case and eliminate it.

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