Thermona Internal Water Leak

Boiler leaking water from underneath the casing or from pipe 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 Thermona plate heat exchanger gaskets, Corroded primary heat exchanger, Dripping automatic air vent, Loose compression fittings on flow/return or DHW connections

How to Fix / Troubleshooting

Safety: Isolate electrical power immediately if water is leaking inside the boiler. Risk of electric shock and component damage.

  • Turn off water supply: Close the cold water inlet and, if possible, isolate the heating flow and return valves under the boiler.
  • Identify leak source (visual): Remove the front cover and carefully inspect for signs of water trails, staining, or active drips. Pay attention to the Thermona plate heat exchanger, pump unions, and automatic air vent.
  • Tighten fittings: Gently tighten any accessible compression nuts that are visibly leaking. Do not overtighten plastic components.
  • Dry and monitor: Dry the area and restore water briefly to confirm if the leak persists and from where.
  • Component replacement (engineer level): Replace leaking components such as the plate heat exchanger, automatic air vent, or corroded pipe sections. Refill, vent, and test the system for further leaks.
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Repair Difficulty

Hard 4/5

Required Part

Plate Heat Exchanger
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