I have a Voyager - Heat Transfer Products (HTP) SSV-130-45 - natural gas boiler from the year 2000. It is used for building heat and pre-heating domestic hot water. It has been working well, but...
A leak at the exhaust manifold has appeared - one where the 3 inch exhaust tube is attached to the exhaust elbow from the boiler and another at the input to that elbow. The downstream leak was a fractured plastic weld which vented exhaust gas and condensate water. That was patched with a sticky weather seal roofing sheeting bound in place with black plastic electrical tape. Problem solved.
The upstream leak at the boiler exhaust is more of a problem, condensate water is dripping out. Attempts at the same type of seal have not worked.
Two photos of the problem areas are attached.
1) Has anyone encountered this in the past and arrived at a relatively easy fix?
2) Repair parts are NOT available from HTP. What makeshift repair has anyone used.
3) If anyone has dug into this can you tell me if the leaking at the boiler exhaust is due to damage to the metal exhaust flu where it joins the plastic elbow?
4) How is the plastic elbow attached - it looks like some kind of black plastic glue.
5) Photos of later versions of the Voyager show a modified exhaust piping. Is there any details about that?
Yes the unit is 20 years old, but it is still running well - except for that annoying leak. All help appreciated.