Hi Matchless. Your wish is my command...
Vaillant F25
Recently I had reason to resolve this issue. I was told it was a very very common problem with Vaillant boilers.
Being a saddo, I decided to find out more because finding out 'why' they failed might lead to a solution and stop people from having to pay out more than they really need to.
So, you get an F75 error when the pressure sensor cannot detect enough pressure in the system once the pump has been initiated. It’s either the sensor not detecting or the pump not pumping. Mostly, it’s the sensor at fault. One can quite obviously hear the pump start.
I decided to dissect the replaced sensor. When I initially looked at it, it looked as if there was some kind of formed (deliberately designed) piece of 'something' in its inlet. Once I’d cut the thing open I discovered that it was, in fact, a hard lump of rusting magnetite.
The sensor when new has a 12-15mm deep, 4mm wide hole down to the spring loaded switch (the sensor). The switch consists of a rubber seal over a plastic push rod (plunger) with a magnet at its end. As the pressure increases, the pressure pushes the plunger against a spring and the magnet, once far enough, activates a magnetically operated switch. The electronics are physically separate from the operating magnet and the system seems very robust from a switch perspective.
So, in a heating system that’s not spotless, magnetite will slowly gather in the top few mm of the opening of the sensor. It will then build until it blocks it. At that point no pressure is detected and hey presto F75.
The channel down to the plunger is approx 12-15mm deep (difficult to measure now I’ve destroyed it!). However, the magnetite lump only forms in the top 3-5mm. To set it back to as new, all you have to do is insert a very thin flat bladed driver and crack away the magnetite and wash it out. Blade should never need to go deeper than 6mm or so.
The investigator in me wonders if its magnet is somehow attracting magnetite to the opening. However. I don’t have sufficiently sophisticated measuring equip to see if the magnetic field is drawing the magnetite in. I’d be very surprised however if it wasn’t a contributory factor…
Patently then, they become blocked because the system is loaded with debris. So when replacing one, ideally one should install a good quality filter and de-aerator which will, over time, catch whats already in and reduce the opportunity for magnetite to further develop.
In time, one can only hope that Vaillant will offer a sensor that does not rely upon magnetism when so many systems are so loaded with metal particles. The inventor in me is going to investigate fitting an alternative which would work out at pennies to change rather than the £20 it’s currently charged at… Watch this space.