Potterton Powermax HE150 A01

steve.mack · 20 Oct 2019

I've found a few threads on this but I'm at a loss now as to the next step. Do we just go with a new boiler as I've had enough of this one, it's 12 years old now but we've only lived here a year

We're using a home emergency policy so this isn't costing me money but it's irritating that they can't fix it.

First time they changed the gas valve, boiler reset and worked for 2 weeks then failed again with constant A.01 error.

Second time they changed the electrode and flame detector, this has again worked for 2 weeks and now we're on constant A.01 faults as of today....

This time it's different though, instead of lighting for 2 seconds then cutting out with no green burner light, now it's lighting for 2-3 minutes then going into A.01 mode, any ideas as the engineers we're being sent haven't a clue about the boiler and have been asking me for the manual to help them...

ianmcd · 20 Oct 2019

sounds like the condensate is backing up, here is the manual

https://www.acwilgar.co.uk/Boiler-Manual-PDF/Potterton/PowermaxHE_Installation_Service.pdf

steve.mack · 20 Oct 2019

Thanks for the link!

Sounds like a diy job, I'll report back on my findings!

steve.mack · 20 Oct 2019

Thought you'd solved it then.

Found water dripping from the condensate flex pipe, further investigation shows it's coming through the pcb board above and dripping onto the flex pipe and then onwards and soaking the floorboard underneath! Hasn't quite damaged my ceiling yet underneath. Has the engineer damaged my boiler? It's never leaked before

steve.mack · 20 Oct 2019

Ps, yes I've switched the boiler off completely now.

ianmcd · 20 Oct 2019

well you will have to find where the water is coming from , It could still be a blocked condensate further up

steve.mack · 20 Oct 2019

I was thinking this but the condensate trap pipe is lower than the PCB and then it goes 500mm to the rear of the boiler/bottom of the main heat exchanger is the outlet, so there's no feasible way the condensate could be above the PCB to leak onto it. I can't delve deeper into now without the electrical cover off etc, I've only taken the main clip on covers off so far.

steve.mack · 20 Oct 2019

Solved it.. The water is coming out the bottom of the ionisation probe that was fitted. Ideas?

Edit.... It's the bolt under the probe actually, it's seeping out from that. Also the same on the other side, forcing its way out through the lower bolts..

Could this be the blocked trap still?

ianmcd · 20 Oct 2019

yes the condensate trap is blocked and the condensate is backing up inside the heat exchanger and leaking out through the first place it can , really needs an engineer to be honest as if the condensate can leak there, when the condensate is cleared then fumes can also leak from there

steve.mack · 20 Oct 2019

Super, you've solved it I think, weird to think the heat exchanger isn't that well sealed. Makes me wonder if any of the other parts were ever needed then, the ionisation probe must have been under water or wet hence it failing until the water level dropped.

Boilers off anyway and engineer on way for the Nth time tomorrow AXA inform me, we have a 2 CO alarms in the house anyway so post repair we're safe too.

steve.mack · 24 Oct 2019

ianmcd said:
yes the condensate trap is blocked and the condensate is backing up inside the heat exchanger and leaking out through the first place it can , really needs an engineer to be honest as if the condensate can leak there, when the condensate is cleared then fumes can also leak from there

The plot thickens...
Engineer looked at it monday, said the trap isn’t blocked was able to ‘blow through it’

He ordered a new seal for the burner, just tried to fit it today, old one was rotten. Water still forcing it’s way out the screws though so he’s ordered a new burner...

thoughts?

ianmcd · 24 Oct 2019

steve.mack said:
Engineer looked at it monday, said the trap isn’t blocked was able to ‘blow through it’

The condensate has a trap in it so he wouldnt be able to blow through it, he is talking shoite.

steve.mack said:
Water still forcing it’s way out the screws though so he’s ordered a new burner.

It is a new Engineer you need not a new burner, it can only be a blocked condensate or a pinholed/leaking heat exchanger, there is no water in the burner, another wrong diagnosis Im afraid

steve.mack · 24 Oct 2019

I had that kinda feeling about the trap too!

I wasn’t there when came, my wife was, he made a smart ass comment about, your husband has told me he knows what’s wrong with it apparently

ianmcd · 24 Oct 2019

It possibly is the heat exchanger but I would be very surprised , My money is on a blocked condensate backing up, when the boiler is not working does it still leak out through the ionisation probe gasket ?

steve.mack · 24 Oct 2019

ianmcd said:
It possibly is the heat exchanger but I would be very surprised , My money is on a blocked condensate backing up, when the boiler is not working does it still leak out through the ionisation probe gasket ?

Nope, only leaks when the boiler is turned on/burner&pump running

it’s not losing pressure either

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Potterton Powermax HE150 A01

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