I have a Weil McLain Ultra 230 Series 2 boiler. 5 years ago the heat exchanger was replaced under warranty due to a hole developing at the condensate drain area. The same thing has just happened again. I have read that PH levels could be causing the problem. Weil McLain will not cover it this time as I am the second owner. Any advice?

 

PH is something you must correct in accordance with install instructions that come with the boiler (at least , the last one I did) The other thing to make sure is that you don't run the boiler under 160 to prevent condensate from forming. This is stated in most boiler instructions. Keynote here, reading the OEM instructions long before you install a boiler. Most don't. Many also require a bypass loop in the near boiler piping, again, check your OEM instructions. I had a friend with a Weil McLain boiler and he lost the boiler section with a hole in under 2 years. It was well water, and he had to get a water softener installed to help correct something, I can't recall if it was hardness.... I have well water and My Pensotti boiler is 23 years old, my neighbors is 20 years old and neither of us has had issues with them. They claim not all cast is alike...

 

I believe this is a condensing boiler. One thing get rid of the PVC vent. Chlorides eats up aluminum. The US is the last country in the free world that allows PVC.
Watch level on the boiler.