Cracked Weil Mclain boiler

[Woody007]

I have a Weil Mclain Gold boiler that was installed in 1995. It recently developed a crack in the boiler block.

After talking to a couple of Gentlemen that have been in the HVAC biz for a combined 50+ years I learned that this is not an uncommon occurrence in WM's boilers from that time period. They attributed it to "faulty casting".

Can other HVAC professionals on this forum confirm this?

Thank you.

[beenthere]

1. Faulty casting.
2. Improperly installed.
3. Improperly maintained.

It was one of those 3 reasons.
WM stands by their product, they'll send you a new block or section, you pay frieght and install.

[Woody007]

Well, it was installed by a professional, I have it serviced every year and as needed by a professional.

Should I expect WM to cover the cost of it other than installation?

Thank you.

[tinknocker service tech]

WC has always steped up to the plate and havent had any problems with thier warrenti as long as service has been kept up

[Woody007]

WC has always steped up to the plate and havent had any problems with thier warrenti as long as service has been kept up

I hope that's the case here. I'm just concerned being "the little guy" in this. I've been told I need to pay all up front and then WM will reimburse me after inspecting the block. I'm feeling a bit uneasy about that. Why would they give me any benefit if they don't have to?

Thank you

[tinknocker service tech]

call WC and have them come and look at your problem and take it from there

then you will have you answer up front

[HeyBob]

What they do is have you buy the block, pay for installation and the contractor returns the block to his supplier. WM will inspect the block and make a determination.

Now in these parts we have really bad water and a lot of people have system leaks which means a lot of makeup water, that brings all the iron and calcium into the boiler, it settles on the bottom of the block, you get a hot spot and then a crack.

That is what we usually see, I have only ever had one section ever covered under warranty.

Almost all of the boiler blocks I have opened had 2" of crap in the bottom.

[Woody007]

"I have only ever had one section ever covered under warranty."

That's not good news Bob.:eek:

I'd think 12 years is still too short a life for this. Or is it?

Thank you.

[HeyBob]

"I have only ever had one section ever covered under warranty."

That's not good news Bob.:eek:

I'd think 12 years is still too short a life for this. Or is it?

Thank you.


You have to remember something though, we have horrible water around here. Also if you have had a lot of make up water from unrepaired leaks, be prepared to be buying that block.

[BaldLoonie]

We had a poor sap that had a leak in the slab on a pipe leading to baseboard. We told him to get it fixed, he didn't. Ruined the boiler, sections were completely stopped up with crud. We didn't even ask W-M for warranty. Got it rebuilt but knucklehead didn't fix the leak. Happened again. Sections ruined, pump ruined. Then he finally got the message and had the leak fixed. No further trouble.

Your dealer should be able to tell with a quick look what's going on.

[RichardsHeating]

I have replaced several of the early gold series boilers,,,,,they all were cracked near the upper door hinge under te coil. WM as far as I know has bought the block but will not cover labor feeder, releife valve, etc

[Woody007]

I have replaced several of the early gold series boilers,,,,,they all were cracked near the upper door hinge under te coil. WM as far as I know has bought the block but will not cover labor feeder, releife valve, etc

That's where mine is leaking from! The water is coming out from around the top hinge. So the leak is someplace above that.

As for everything else around the unit it's neat and clean. It sits on the concrete slab in my basement and I have no water problems whatsoever.

Thank you.

[RichardsHeating]

I knew you were going to say that. It is a defect and they should replace the block.

[Roscoe]

Man I typed a long reply only to have the pop up say I wasn't logged in.:confused:

We had installed a W.Mclain H.E about 10 years ago and it leaked in less than a year. We picked up another boiler from the supplier and put it in, returned the old one. I wasn't going for a section or block. I got a letter from WM about 3 weeks later disallowing the credit. It said there was lime in the old boiler and we should install a water meter to prove out that there is a leak.


I freaked then called the supplier and said no way was I gonna pay for that boiler. Now I'm laughing cause this is an older house with all the piping exposed no way there is a leak. The supplier stepped up and handled it.

Anyway this also happened to my brother with an P68 oil boiler he put in a attorney,they didn't get away with that needless to say.

Good luck

[Woody007]

I just spoke with the WM rep who will be inspecting my boiler block. I explained that I expected a full reimbursement. According to him that's what I can expect given the situation and history of this model.
I contacted my supplier to inform them of this as well.
I just need to pay for everything up front and then I'll be reimbursed after.
Hopefully it all plays out this way.
I have to say that all the people I spoke with from WM were helpful so far and seem willing to stand behind their product.
I'll post a followup when it's complete.

Thank you to everybody for the input.:)

[Roscoe]

They learned a lesson, Wm had some problems and stupidly attempted to disallow warranties.

I know a lot of contractors who stopped selling them.

I'm sure they will handle it let, us know how you make out.

[Woody007]

The work was done way back in March.

I Finally received my "FULL" refund from WM this past Wednesday.

They didn't just have blocks so I received a completely new boiler.

Thanks to all who helped inform me.

There's nothing like a little knowledge from people "in the know" to help in matters like this.

Thanks again:)

[tinknocker service tech]

glad everything worked out for you
enjoy the new system

thanks for letting us know the final outcome. Must times we never find out how things work out

[Boiler Owner]

I found this thread and web site because I have a similar problem. I had a Weil McLain boiler installed in 1997. In 2001 the core cracked. It was replaced by the installer. I only paid for the labor and the parts for a new ignitor which was also damaged by the leaking core. Now in February 2008, the core has cracked again. My preliminary contact with the installer seems to indicate that Weil McLain will not pay for the core again. Weil McLain believes there is something wrong with the installation.

My house is a 1920's colonial in the midwest. All heat is through cast iron radiators and baseboard (fin-tube) radiators. I only have two zones, one for the first floor and one for the second. I have no in floor heat, no signs of leaks.

So what is the issue with the Weil McLain boiler cores? Is there a manufacturing defect? I do not know whether I should attempt a core replacement again or look for a totally new boiler. Can anyone offer advice out there?

[hvactech1jm]

Weil McLain Boilers are just as bad as Burnjunk boilersevery dam one of them crack. Bryant makes a good cast iron boiler and new yorker makes a good steel boiler.

[beenthere]

LOL.

New Yoker, is owned by burnham. I forget who makes Bryants.

Nothing wrong with Burnham or Weil McLain.

[beenthere]

My preliminary contact with the installer seems to indicate that Weil McLain will not pay for the core again. Weil McLain believes there is something wrong with the installation.

My house is a 1920's colonial in the midwest. All heat is through cast iron radiators and baseboard (fin-tube) radiators. I only have two zones, one for the first floor and one for the second. I have no in floor heat, no signs of leaks.

So what is the issue with the Weil McLain boiler cores? Can anyone offer advice out there?

Can you post pics of the install. Mostly the piping around the boiler.
Also the mod number of the boiler. The number and size of the rads.

It may very well be a piping problem.

Your system is zoned, the zoning could be causing the problem, depending on how its piped, and the control system of the boiler.

Meaning that any brand you choose could have the same problem.

For the record. Burnham did have a casting problem with the V& series, it is no longer made. But Burnham still honors the warranty on the V7 boilers.

[energywise]

Bryants are made by Dunkirk.

Mark

[beenthere]

Bryants are made by Dunkirk.

Mark
Thanks.
I just couldn't remember who it was.

[tinknocker service tech]

Like been said post some pictures

with rads and the unit isnt piped a certan way you can bring back a lot of cold water for longer then normal time and thermal shock the boiler causing failor over time.

Wielmclain has dirrections on how to pipe the unit and should have been done that way

[skippedover]

Let me get this straight. The year is 1880 and New York City buildings are getting brand new CAST IRON boilers for central heating! Fast forward 127 years and guess what? We're still installling CAST IRON boilers!! :eek: Weil McLains leak, Burnhams Leak, all cast iron boiler manfucaturers are tryingn to stay in the business by being the cheapest heat source on the market. That leads to bad CI, thin walls, cracked boilers. Face it, those cast iron boilers are 1800's technology, shrunk down and thinned out so they look more modern, all trying to keep up with 2008 technology. They're an anachronism who's time has come. Cast iron shouldn't even be considered IMO. The world has moved on. Oh yeah, the new metals cost a whole lot more and not everyone can afford them. Just like between 1880 and 1950, not everyone could afford a central heating system. Buderus, Viessmann, System 2000 are all examples of changed technology.

[hvactech1jm]

LOL.

New Yoker, is owned by burnham. I forget who makes Bryants.

Nothing wrong with Burnham or Weil McLain.

i havent had much luck with either of them. just my opinion you no there like a**holes everyone has one.

[beenthere]

Too often, the boiler maker is blamed for bad piping.

[Boiler Owner]

Thanks for the assistance. The boiler is a Weil Mclain Model #CG-5-PIDN Series 12. I have attached some pictures of the piping at the boiler. I can provide more information about all of the radiators and baseboard fin-tubing, but I don't know how best to provide this information. Would outside dimensions of cast iron radiators provide any useable information? Regarding the piping, you will notice that the original piping for the house is from the 1920's, and the copper piping at the boiler was installed with the installation. Thanks again for any guidance/help. The more I know, the better I am able to make a decision on how to proceed.

[beenthere]

My guess. :)

When just the baseboard zone is calling, the boiler gets up to limit, and sometimes while its at limit temp, the cast iron rad zone calls and floods the boiler with cold water. Shocking it with cold water. And weaking the cast. eventually, it cracks.

Is the temping valve open, closed, or throttled back.

Baseboard is measured by it liniar length.
Cast Iron rads by there heigth number of columns, and number of sections.

I think I'd slave the baseboard zone.

[tinknocker service tech]

classic case of where primary secondary would be best served and the boiler would never see thermal shock.

even with the small bypass the cold water coming back from the rads is going to get hot enough.

baseboard a few gallons of water is beeing deat with and no harm

rads you are talking gallons and gallons depending on number of rads and size

if the piping isnt done differant then you next boiler will do the same thing in a few years

[Boiler Owner]

Great information! Remember that I am just a home owner. What is the temping valve? And what does it mean to slave the baseboard zone?

Thanks again.:D

[beenthere]

That would be when you wire the baseboard zone that it can only have heat if the main zone(the cat iron rads) is calling for heat.