Saunier Duval Condensate leakage / flue condensation issue

Water heater leaks from the flue or top of the unit, especially on condensing models

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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

Blocked or incorrectly fitted condensate trap, Cracked condensate collector, Incorrect flue slope causing condensate to run back, Damaged flue seals

How to Fix / Troubleshooting

Safety first: Turn off power. Condensate is mildly acidic; wear gloves and eye protection.

Steps:

  • Inspect condensate trap: Remove, clean, and refit the Saunier Duval condensate trap, ensuring all seals are correctly positioned.
  • Check flue slope: Verify that the flue is installed with the correct gradient so condensate drains towards the heater or drain as specified.
  • Examine flue joints: Check all flue seals and joints for signs of water staining or leakage. Replace damaged seals.
  • Condensate collector: If the plastic collector at the base of the heat exchanger is cracked, it must be replaced.

Warning: Flue system integrity is critical for safety. If in doubt, have the flue inspected by a qualified technician.

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Repair Difficulty

Medium 3/5

Required Part

Condensate Trap
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