Ravenheat CSI 85T internal Condenser leak

[antzheat]

Having investigated this boiler (Ravenheat CSI 85T) I have come to the conclusion that there is an internal leak in the condenser. The pressure drops on the boiler over a period of 24 hours (boiler isolated from system) and there seems to be more water than expected from the condensate drain in normal CH use. However, it seems that the pressure drop is greater when the boiler is in use (CH hot), which I can't test in isolation, but might stand to reason. There are no internal leaks including from air vent (I know - surprising for a Ravenheat!).

Has anyone any experience replacing the condenser, willing to give hints and tips before I undertake this? Particularly, what they used to seal between the condenser and the combustion cavity - it looks a mess.

The Condenser unit appears to be constructed in two parts with the top bolted on. There must be a gasket between the top and bottom, is this user serviceable, or likely to be the source of the leak?

My understanding is that the unit is Aluminium and subject to corrosion and likely to have been perforated. Anyone else found this?

Thanks for your help!

 

[Billy Bob Bob]

if the recouperator has burst you will need a new boiler,they are big bucks and then you have to remove the fan that corrodes onto it

 

[antzheat]

The connection to fan assembly doesn't seem too bad and I was expecting to have to remove the fan. The connection to the burner cavity on the other hand doesn't look so good, so not sure on the seal here.

What I'd like to know is if anyone has removed one of these and look at it. Is there a serviceable gasket between the top and bottom parts of the condenser where it is bolted together and is this where the leak normally is? Or is it normally corrosion inside?

The condenser itself isn't to expensive (considering) and the boiler is only 7 years old, but like most Ravenheats, most of it has been replaced and by all accounts it has been behaving for the last couple of years.

Any input welcomed