Common Boiler Issues (And How to Spot Them Before They Cost You)

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When a boiler fails, it usually doesn’t happen all at once — there are signs. Whether you’re heating a home in Okotoks, a shop in the Foothills, or managing multiple zones in a commercial building, catching these issues early can save you from a costly breakdown or mid-winter emergency.

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Here are the most common boiler problems we see in the field — and how you can spot them.

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1. Short Cycling

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The problem:
The boiler turns on and off too frequently, never completing a full heating cycle.

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How to spot it:

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• Boiler fires up, runs briefly, shuts down, and repeats
• Home feels inconsistently warm
• Increased gas bills
• System noises like clicks or relays constantly engaging

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What it means:
This often points to improper flow, poor system design, or faulty sensors. It kills efficiency and wears out components faster.

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Pro tip:
Check for dirty strainers, bad expansion tanks, oversized boilers, or lack of a proper primary/secondary loop.

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2. Loss of Pressure

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The problem:
The system drops below operating pressure (typically 12–15 psi cold), causing it to shut down or lose heating performance.

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How to spot it:

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• Pressure gauge below 10 psi
• Air in the pipes
• Cold zones or baseboards
• Boiler lockout warning

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What it means:
Could be a leaking relief valve, failed expansion tank, or hidden system leak.

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Pro tip:
Top-ups are a short-term fix. If you're refilling the boiler more than once a season, something’s wrong.

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3. Boiler Lockouts & Error Codes

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The problem:
Modern high-efficiency boilers shut themselves down when something’s wrong — which is good… but also frustrating if you don’t know why.

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How to spot it:

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• Blinking lights or error codes on the display
• Boiler not firing
• No heat or hot water

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What it means:
Could be venting issues, dirty flame sensors, water quality problems, or low condensate drainage.

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Pro tip:
Snap a photo of the code and call your tech. Don’t keep resetting it blindly — you’ll just mask the real problem.

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4. Noisy Pipes, Banging, or Gurgling Sounds

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The problem:
Air, debris, or expansion noise in the system.

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How to spot it:

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• Gurgling in baseboards
• Clicking or “kettling” sounds from the boiler
• Sudden bangs when zones start or stop

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What it means:
Air trapped in the system, poor venting, hard water scaling, or failed circulator bearings.

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Pro tip:
Don’t ignore the noise. It’s a sign your system isn’t circulating properly — and can lead to real damage if untreated.

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5. Yellow Flames or Soot

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The problem:
Dirty or improper combustion.

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How to spot it:

• Flame is yellow or orange instead of blue
• Soot buildup near the vent
• Boiler smells odd or sets off your CO detector

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What it means:
Blocked burners, bad gas pressure, or venting issues. This can be extremely dangerous — shut it down and call immediately.

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Pro tip:
Install a low-level CO detector near your boiler. It’s cheap insurance for peace of mind.

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When to Call in the Pros

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If you’re seeing any of the signs above, don’t wait. Boilers are closed systems with gas, pressure, and potential for water damage. Most problems are small at first — until they’re not.

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At Project Heating and Plumbing, we’ve seen it all. We specialize in diagnostics, clean repairs, and upgrades that make your system run better than ever.

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📍 Serving Okotoks, the Foothills, Calgary & surrounding areas
📞 403-601-5387
💻 projectheating.ca

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Project Heating and Plumbing — The local experts for everything boiler-related.

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