Rattling Heat Exchanger in Combi Boiler

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I have a Loblich (Austrian make you probably never heard of - and never want to) 35 kW wall mounted gas Combi boiler/hot water heater. The unit is 4 years old, and it's on its fifth (count 'em, fifth) heat exchanger.

There is a fairly loud rattle coming from the heat exchanger. According to the manufacturers, the primary and secondary are one unit; the CH pipes are thin pipes which run inside the HW pipe in the heat exchanger. The rattling happens when the flow of the CH water causes in inner pipe to knock against the outer. The heat exchangers are fine for about 6 months, then they start their death rattle. I did have a problem with lime scale but bought a water softener-treatment unit a year ago which has taken care of that, but still the rattle returns.

The unit is out of warranty now, so I have to try to convince them that this was a fault since new which was never really fixed.


Has anyone come across this rattling problem in other makes/models? Is this type of design common? Any info much appreciated.
 
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I did come across a combi which made a tapping sound from within the primary heat exchanger but only when hot.

I replaced it and can only conclude there was a screw or something which oscillated when it got hot.

Tony
 

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