Lochinvar Boiler Leaking Gas

Alan (California Radiant) Forbes

I received an impassioned text today from a SF customer where we installed a KHB boiler 6 years ago. He said that there was a strong gas smell coming from the boiler whenever it goes into high fire. They’ve shut the boiler down until I get there in the morning.
It’s a radiator system with the boiler vented through the roof; makeup air a separate pipe from a sidewall to the outside. There’s also an indirect water heater.
Perhaps one of the PP vent connections separated even though we used lock rings. Any thoughts before I go out there?

mattmia2

if you have an air leak anywhere between the gas valve and the combustion chamber you have a gas leak. possibly a spray bottle with sop but there is the how do you get the gaskets without getting the electrical stuff

Alan (California Radiant) Forbes

I went to the jobsite this morning and sprayed leak locator solution at all of the connections after the gas valve as the smell is only there when the boiler is running. Couldn't find a leak. I then sprayed the lid of the HX at the sight glass and blower and it started bubbling, but I don't know if it's from the solution boiling or if there is an actual leak.

I've ordered new gaskets for all the lid penetrations. Unfortunately, no one stocks Lochinvar parts out West here and they have to be ordered from the factory. Does anyone know of a stocking distributor?

hot_rod

https://forum.heatinghelp.com/discussion/comment/1846493#Comment_1846493

Intermountain Sales in Salt Lake is my lochinvar rep. They keep an inventory, try them at

801 936 0228

Tech line 801 936 0334

Custsvc@intsales.com

Western Nevada Sales has a good hydronics department, I don’t know if they do Lochinvar. Reno headquarter, branch in Truckee if you want to make a ski trip and parts run☃️⛷️

mattmia2

can't you run the fan without firing it in test mode?

Alan (California Radiant) Forbes

Lochinvar says replacement heat exchanger gaskets are 2-4 weeks out, not including shipping. Bah!

mattmia2

Permatex? Looks like the nuts must have been loose?

Alan (California Radiant) Forbes

Yes, the nuts were loose, but I think the real culprit is the refractory. There’s nothing to secure it to the cover plate and when I pulled out the burner, the refractory had slid over the burner. I think this caused overheating which caused the gasket to fail.

tim smith

Alan, did you get the part yet, Im sure my rep has one in stock here in Washington. I would question that the refractory was down over the burner due to the rim thats appx 1" or so down from top of heat exchanger retains the refractory from going down further. How long has it been since it was serviced? If you want PM me to talk about it and leave ph #. See attached photo

khb heat x.pdf

Tim

EBEBRATT-Ed

What I hate about Mod Cons gaskets 2 weeks out + shipping time. I would call lochinvar and **** them out they would know who has gaskets in stock.

mattmia2

or get a sheet of the same material and cut it out

Larry Weingarten

Hi, No doubt McMaster has the right sheet goods, and they ship fast.
Yours, Larry

ScottSecor

We too deal with very similar issues. Frustrating to say the least that parts are so difficult to get for a six year old boiler. In my area this boiler is considered high end, I sometimes wonder.

Alan (California Radiant) Forbes

@tim smith Yes, Tim. You are absolutely right about the refractory being sandwiched in place and I realized it as soon as I re-installed it just a couple of hours ago. This was the first time the boiler has been serviced since we installed it about 6 years ago.

Part #100287111 for the HX gasket. I purchased the boiler at Pace Supply, but they don't stock many parts. I eventually ordered my parts list (igniters, flame probes, gaskets, etc.) from Ferguson who said some of the gaskets are "made-to-order" from Lochinvar.

I also called the Lochinvar rep. - California Hydronics - and they were out of stock and couldn't tell me anything about availability that I didn't already know.

Parts availability is a top priority for me as service and repair is my main gig and Lochinvar used to be my #1 replacement boiler.

Thanks, @Larry Weingarten. I'll order some sheet goods from McMaster, but I wonder if Lochinvar or my liability insurance would cover me if something went wrong.

Larry Weingarten

Hi @Alan (California Radiant) Forbes Is there any way of getting the specs on the present gasket rubber? Hardness, temperature range, etc? McMaster is good with their descriptions, so if you matched the existing specs, I'm not seeing how a lawyer could cause trouble. I suppose you could get a written agreement from the owner letting them make the choice between waiting for heat, or proceeding with letting you cut a gasket… I'll take my attorney hat off now. 🤠

Yours, Larry

hot_rod

I spoke with Intermountain Sales in SLC, they have the gasket kits on the shelf. I sent the part number and pic you indicated, but have the model and serial number also to confirm, if you contact them.

Alan (California Radiant) Forbes

https://forum.heatinghelp.com/discussion/comment/1848860#Comment_1848860

Thank you, hot rod. Tim Smith up in Seattle was also able to bird dog the part for me and it arrived today from Suntoya. I also needed the refractory and they had both. We just got back from The City now and the boiler has new life.

pedmec

FIA, Inc in Woburn Massachusetts is our Lochinvar rep in the Boston area and stocks a lot of Lochinvar parts. if all else fails you can try them. 617-938-8900