Buderus GB142-60 need new condensate trap

dgkula

I woke up this morning and my GB142 wouldnt start with code 6A. I opened her up top to look at the ignitor which looks like it is degraded to the point of needing replacement. I also decided to open the bottom of the unit to check the output from the condensate trap - I have read that if this is blocked it can cause ignition issues.

Well the output from the condensate trap was plugged owing to a lack of maintenance on my part and as I was scraping off the white caked stuff I discovered that the aluminum condensate trap had corroded through and under the caked condensate I discovered a 1/4" diameter hole in the aluminum bottom of the plate near the condensate output. So even if I can get the boiler to fire I will have leaks out the bottom of the unit.

I went online to see if this part is available anywhere and it doesnt appear tobe - looks like the unit was discontinued in 2018.

Any thoughts? Would this GB142 Condensate trap part 67900521 be available anywhere or am i looking at a new boiler Thanks!

HVACNUT

Can you post some pics?

The trap is plastic but the block is aluminum so if there's a hole in the block, you've got some serious issues. 

dgkula

hole is in the block

dgkula

dgkula

I see the part available in the UK and UK ebay but cant find anything on the internet in the USA

https://www.ebay.com/itm/272417307981

GW

https://www.supplyhouse.com/Buderus-8718600689-Condensate-Trap-for-GB142-Boilers

dgkula

This is the part i need:

https://www.supplyhouse.com/Buderus-67900521-Condensate-Collector-Sealing-60-kW

dgkula

I have two of the spare condensate trap (plastic bottles) new in box. My problem is the entire aluminum condensate collector plate that captures the condensate and routes it to the trap bottle.

The good news is that the combustion chamber isnt under pressure so maybe we can solve the 6A ignition issue and the apply some sort of temporary seal (ie. duct tape) to the exterior of the aluminum plat so at least i wont have condensate leaking everywhere, I can heat my house, and can buy some time to find this part.

dgkula

Here is a picture that more clearly shows the corrosion from the exterior. This boiler was installed new in 2009 and I have cleaned it every few years since buying the house in 2011. I cant believe that this type of issue isnt covered under manufacture warranty.

dgkula

Any thoughts on what type of material might make a good short-term "patch" that I could apply over that hole once we solve the ignition problem?

dgkula

Of course the warranty only covers the heat exchanger ...

http://s3.supplyhouse.com/product_files/Buderus - GB142-60 - Warranty Info.pdf

dgkula

Just found this thread related to aluminum, mod con boilers and corrosion. Wow so maybe this type of failure isnt a surprise ...

https://forum.heatinghelp.com/discussion/125979/aluminum-hx-condensate-and-corrosion

Ironman

RTV caulk after you’ve cleaned the area around it down to bare metal with a wire brush.
 You’re expectation of warranty coverage is unrealistic; IDK of any boiler manufacturer that covers a replaceable part for 12 years.

dgkula

Tech came and got us up and running - super nice & smart guy. He replaced the ignition components and used High Temp RTV caulk as a patch. He did mention that these boilers only last for 10 years or so and he already sees signs of a heat exchanger leak which will be fatal and require replacement at some point. Pic below. I'll start another thread as I'd like to get feedback on replacement. Thx!

dgkula

Tech also said he wouldnt replace the condensate plate given the signs of HX leak, rather patch with RTV caulk as needed and get a new boiler in the short term.

ch4man

who told you that heat exchanger isn't under pressure? that blower blower a fuel/air mixture into the burner and heat exchanger with enough ummph to blow the flue gasses out the house. I would never use RTV on a as a bandiad. IMHO anyone who does is a fool.

sorry, just sounds like bad juju

kcopp

Jb Weld would work as a temp repair.

dgkula

Thanks - appreciate the feedback! Will get myself some JB Weld.