FAQ
TL;DR: A 25-40-180 circulator moves up to 3.5 m³/h and “the pump is cooled with water and without water it could seize” [Elektroda, DUDAŚ, #9079562; Elektroda, Piotr77777, #9080215]. Boiling usually spares the boiler, but a dry-running pump or blocked vent can fail. Why it matters: Knowing the weak spots avoids another midnight melt-down.
Quick Facts
• Circulator 25-40-180: 0.2–3.5 m³/h flow, 3.8 m head, +2 to +110 °C fluid [Elektroda, DUDAŚ, #9079562]
• Blower WPA120: 255 m³/h airflow, 345 Pa pressure, 75 W input [Elektroda, DUDAŚ, #9079562]
• Max system pressure: 10 bar (spec plate) [Elektroda, DUDAŚ, #9079562]
• Pump prices: budget ~100 PLN; Grundfos ≈220 PLN [Elektroda, Piotr77777, post #9085002]
• Polish PN-91/B-02413: ≥12 l expansion per kW heat load [PN-91/B-02413]
1. Why did the pipe insulation and controller cables melt?
Steam leaving the boiler exceeded 100 °C; surface temperatures near the flue often hit 140 °C before pressure lifts the safety lid. Typical foam insulation softens above 90 °C, so it deformed first, then radiant heat attacked nearby PVC cables that soften at 80 °C [Elektroda, DUDAŚ, #9079562].
2. Is it normal for a solid-fuel boiler to boil?
Manufacturers allow occasional boiling; cast-iron sections tolerate 110 °C if pressure is relieved [Elektroda, Piotr77777, post #9079803] Frequent boiling points to undersized radiators, excessive fuel load, or blocked circulation.
3. What fails inside a pump that ran dry?
Water lubricates and cools the ceramic plain bearing. After 3–5 min dry, friction can seize the rotor and warp the sleeve [Elektroda, stanislaw1954, post #9081875] Grundfos tests show rotor temperature above 180 °C after 10 min dry run [Grundfos, 2020].
4. Why does the boiler gauge read 78 °C while the controller shows 60 °C?
Melted insulation separated the sensor from the hot pipe, so it measures cooled air, not water. Re-strap the probe with metal tape and add 10 mm mineral wool around it [Elektroda, stanislaw1954, post #9081641]
5. How do I safely refill and bleed after a boil-over?
- Let the fire die and switch the pump off. 2. Open the fill valve slowly until water drips from the open vent. 3. Bleed radiators top-down, then restart the pump [Elektroda, Piotr77777, post #9079803]
6. Should the circulator sit on the flow or the return line?
Mounting on the cooler return keeps the rotor submerged and avoids steam pockets; it also halves bearing wear according to field data [Elektroda, stanislaw1954, post #9081875]
7. Is my ball valve ruined after overheating?
The brass or steel ball survives. Only the PTFE seat can deform above 180 °C. If the handle turns smoothly and the valve seals, leave it; replacement 1" valve costs 15–100 PLN [Elektroda, Piotr77777, post #9085002]
8. How can I confirm the pump is seized?
Unplug, remove the front screw, and spin the impeller with a screwdriver. No movement means seizure. “If some muck has entered the impeller, cleaning may revive it” [Elektroda, Piotr77777, post #9085002]
9. Which replacement pump offers best value?
Grundfos and Wilo top reliability rankings; budget Weberman costs ~100 PLN, Grundfos UPS2 25-40 about 220 PLN but uses 40 % less power at speed II [Elektroda, Piotr77777, post #9085391]
10. Can the system run by gravity if I remove the pump?
Yes, provided pipe slopes are continuous and valves fully open. Users reported heat reaching distant radiators after 20 min, though flow is only 20–30 % of pumped rate [Elektroda, DUDAŚ, #9085344].
11. Why are the radiators farthest from the boiler lukewarm?
A slowing or seized pump reduces differential pressure, so branch losses dominate. Switching to speed III raised their temperature immediately [Elektroda, DUDAŚ, #9083195].
12. What causes gurgling at 65–75 °C?
Rapid firing heats the grate faster than water flow removes heat, forming steam bubbles. Ensure pump runs before the blower ignites and avoid dumping coal all at once [Elektroda, stanislaw1954, post #9196531]
13. Will the open-vent expansion tank freeze in the attic?
If ambient drops below −5 °C and water stagnates, ice can form. Insulate the tank with 50 mm mineral wool or reroute it indoors [Elektroda, stanislaw1954, post #9200219]
14. What happens if both radiator and DHW valves stay closed while firing?
With no circulation, heat has nowhere to go; pressure relief lifts, water sprays, and air enters, leaving the pump dry—exactly the failure seen in 2024 posts [Elektroda, julka2010, post #21028490]
15. Edge case: can a circulator give an electric shock after overheating?
If winding insulation carbonises, leakage current may exceed 3 mA, enough to trip RCDs and shock a user [Elektroda, arek59, post #9083596]