Raypak System or Internal Water Leak

Boiler leaking water from bottom of cabinet or around piping connections.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Leaking heat exchanger on Raypak boiler, Failed pressure relief valve discharging, Loose union or piping connection, Corroded gasket on header or manifold

How to Fix / Troubleshooting

Safety: Turn OFF power and, if leak is significant, shut OFF water supply to the boiler and allow it to cool. Beware of hot water and surfaces.

Steps:

  • 1. Identify leak source: Remove the front panel and use a flashlight to trace water back to its highest visible point. Check around the heat exchanger headers, relief valve, and all unions.
  • 2. Check relief valve: If water is coming from the relief valve discharge pipe, read the system pressure gauge. High pressure may indicate a failed expansion tank or fill valve. Do not cap the relief discharge.
  • 3. Tighten fittings: For minor seepage at unions or threaded fittings, gently tighten with appropriate wrenches. Do not overtighten and crack fittings.
  • 4. Replace gaskets: If a header or manifold gasket is leaking, the boiler must be isolated, drained, and the gasket replaced following Raypak procedures.

A leaking heat exchanger itself usually requires replacement of the heat exchanger or boiler. Contact a qualified technician for internal leaks.

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Repair Difficulty

Hard 4/5

Required Part

Heat Exchanger
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