Worcester Bosch main heat exchanger/heat cell replacement
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- Опубліковано 9 лют 2021
- DISCLAIMER:
This video is only intended for use by qualified Gas Safe Registered engineers. You must not attempt any work on your boiler if you are not qualified. You must always carry out 26.9 checks upon completion of works on a boiler.
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In this video I show my method of replacing a main heat exchanger or heat cell on a Worcester Bosch.
A job which requires patience and a methodical approach but will give you the satisfaction of a job done properly.
You may have different methods to do this, but I hope this video helps others out and happy to discuss alternative ways to do this.
Just wanted to say thank you for this video 🙏🙏, did my first Worcester 30i system hex replacement and your video defo helped me. The one I did is the newer version but still massive help watching this before hand a couple of times. I have put it on UA-cam if you got 5 to give it a watch
Nice one mate glad it helped!
Brilliant mate. Love the vids
Excellent video really helped me to get this job done and i am a gas engineer, thanks.
Hey I thank you for uploading the video.
Normally you don't need to struggle
You don't need to bend the casing
and you do not need WD-40
You need to remove the condensate and loosen the flow clamp nut.
Use two big flat scree driver or flat metal peace.
Push and hold the cell against the bracket and lift it with flat screwdriver and then the other screw driver and up.
When people struggle to take out the cell, it is not the return pipe, it's the bracket pressed, clamped into the mounting and the weight.
It is very easy once you do it couple of time.
Good video
Thanks for the tips 👍🏽
👍
Keep it up good videos at least someone making good efforts to teach someone or showing someone, where most of us don’t have time for all this when we are at site.
Good job Chirag ❤. Quite a ballache that main heat exchanger.
First time can be daunting, but done a few and not so bad once you get the hang of it
Brilliant will help as I'm replacing on soon.
Good video, just a few tips, the bracket on the top of the heat cell to the back panel is just a retaining guide, and does not cause any resistance, it's the bottom O ring that causes the initial resistance, try a longer thicker screwdriver, you will find the leverage a lot better, also if the boiler is 8yrs +, it might be a good idea to replace the exhaust pipe seals (bottom and middle), as theses can perish over time, and alter the POC once the case is on, and once the fan is out, as with the seals, check the bearing plate, and finally, if it is the old sump with the corkscrew flue stat, replace the sump assy, good job tho. (don't move the black locking clamp on the return pipe).
Nice one mate thanks for the additional tips 👊🏽👍🏽
your channel is amazing
Thank you 👊🏾
That's fantastic video, but can you do a video on finding the fault on the boiler too, so you can see the full lifecycle
suscribed, as im doing this today
Hope it went well mate!
how did it go
Tbf I usually disconnect the top clip as this allows more movement and I use both hands to lift the heat cell out.
I've tried levering out but the frame chassis is thin and usually bends when using a screwdriver
Same here, I tried levering out and the chassis was starting to bend and I was wanting to save the heat cell. I’ve seen a WB video saying don’t disconnect the clip, but it really wasn’t working for me. Soon as I released the clip… the job was a lot easier
did the 'O' ring on the return pipe get changed? (I use polypipe lube, the WB guy in the Allan Hart vid used molykote)
Yup changed them all
Got a bang now and then on mine only on heating side burner has been clean ed out and heat plate clean ed out no air locks do you think it my be this on way out what go,s on them thanks
Yeah it needs throwing on the grass crap boilers
Weldone
Nice job. Does the new heat ex. come with baffles inside?
Thanks, no you have to order the baffles separately 👍🏾
Has anyone ever seen corrosion around the top edge seam on the main heat cell/ exchanger, crusty deposits coming out and sometimes on the bottom edge, if so what causes it and does it mean it needs replacement? I can’t find anything online about this and I’ve seen it a few times now? Can’t be the burner seal as that sits in further🤔
Yes mate this is a sign that the main heat exchanger has split from the seams. Only thing to do is to replace the main hex
Can I ask a question, please and get some advice. I have a new (3 month old) Worcester Bosch Greenstar boiler. The boiler has been off all day, yet suddenly there was a discharge of water from the boiler through the condensate pipe (I estimate about 100 ml). The boiler HAS DEFINITELY BEEN OFF for I would say 20 hours. The sound, appearance and volume of the discharging water was exactly as it is when the boiler is on and condensing, but as I say, the boiler has been off for many many hours. I can't work out why this is happening - the only thing I can glean from a search to the question "why is my condensate water pipe discharging water when the boiler has been off all day" is that water is leaking into the condensate collecting tank and as soon as it reaches a certain volume it is discharging. I also am seeing words like "cracked heat exchanger" The outside temperature is 12 degrees centigrade as has been like this all day. Surely my boiler / heat exchanger can't be faulty and leaking water after just 3 months? Please help, I am extremely anxious. Thank you.
If your boiler has been off and you still have condensate discharging then it could be 1 of 2 things. Either a split main heat exchanger (you would notice the pressure dropping on the boiler as well) or if it's been raining outside then it's possible it could be coming in through the terminal and then discharging through the condensate
@@cputilitysolutions Thanks you for the reply.
1)Split main heat exchanger (you would notice the pressure dropping on the boiler as well) - I have feeder tank in the loft (attic) , so there is no way of measuring the pressure; the water from the tank would just slowly fill the system, I think? The boiler is just 3 months old - could the main heat exchanger split so quickly? Also it was just on flush of about 100 ml over about 5 hours, because as soon as I noticed the discharge at 6 p.m. I kept watch; it didn't happen again.
Three hours later, I went into the roof space where the feeder tanks is. Despite my cleaning it out completely 3 months ago, it was quite dirty, full of lumps of slime and gunge and the water was orange coloured and there was quite a bit of "sediment" in it as well. HOw could this have happened? Also if the main heat exchanger was split and this dirty water from the tank was topping up the system was replacing the existing water and also leaking out at the heat exchanger, wouldn't I expect to see this rusty orange colour in the "condensate". The colour was clear when it flushed through.
2) How much water could leak out of a cracked heat exchanger into the condensate pipe?
3)The terminal is on the roof - it wasn't raining much around the time of the condensate discharge, and the wind wasn't blowing. Could rain water actually get in to the vent and up through to where the condensate collects before it has discharged?
4) I am hoping there isn't a fault already. Could it be that when the heating is not on and condensate had collected while the boiler was still on hours ago but hadn't discharged at the point of switching off the system that somehow some condensate could be left over and the boiler is programmed to discharge it? I am maybe clutching at straws.
5)Without pressure readings to rely on, which would show pressure falling, how would I bel able to tell if there was a split heat exchanger? Would the be other signs? Thanks for your assistance - much appreciated.
Is there a way of replacing heat exchanger without touching the flow and return valves on combis, I know some do it but how?
I'd only do that if the boiler was the highest point on the system. Last thing you want is all of upstairs to empty out on you whilst you're in the middle of it!
@@cputilitysolutions yeah true don't understand why some engineers wouldn't risk not touching isolators as creates more work but like you said may flood the house.
How much does a main heat exchanger cost
If boiler is over 10 years old which I’m sure these models are best off swapping the boiler
Usually around 400-500 but this was an insurance job so if parts are available they'll want it done!
Why did it need replacing looks ok in the video
Another reason to hate Worcesters. Lost confidence in fitting WB boilers. The housing association I used to work for fit nothing but. I felt the struggle when you were trying to wedge that cell out 😳.
Haha yeah it was a bit of a struggle as this was my first time. But I've managed to do them in an hour since then!
Put a screw driver between the case and the pipe under the boiler then I use two big screwdrivers under the sump and Rick it out works for me the bigger the screwdrivers the better
What combi would you recommend fitting if it was in your own home?
@@richardjones3112 All depends on your size of home and anount of hot water required i.e bathrooms. The amount of hot water out on a combi relies in the supplied inlet cold water pressure. I generally supply & fit Main/Baxi & Viessmann combi boilers. Tanked system boilers Ideal & Vaillant.
Clean system & servicing either way will help increase the longevity of the boiler
Your Gas Safe installer may recommend what s/he is familiar with.
What are your 26/9 checks ?
The same as everyone else's - Flue/Air intake/Gas rate and/or burner pressure/Safety devices 👍🏾
@@cputilitysolutions got one of these to do next week, some useful tips here especially don’t undo the return connection on the bottom of the heat cell. Invaluable
@@smartboilercompany1983 👍🏾
Nice video but you don't say what was wrong with the heat exchanger. My 12Ri is 18 years old no problem (touch wood). Boiler has had new main circuit board & fan assy. (complete with it's own circuit board) though.
Dude how much will your charge me for putting a refurbished one into a green star junior combi 24.please can you give me your number .
God i hate working on Worcester boilers. Designed by a cretin. Even the new ones are horrible
Why don’t you just forward the Alan heart video basically a copy and are bending all the frame you using the wrong tool
No shit...