Rust, Rust and Rust

The Energysaver was one of Glowworm’s early efforts at a high efficiency boiler.  Like the ill fated Potterton Envoy and Baxi Barcelona, the Energysaver had the lifespan of a prawn sandwich.    Although manufacturers like Archie Kidd had perfected the art of condensing boilers decades earlier, the mass market British boiler industry left their designs to the last minute and used their loyal customer base as a test bed. 

Glowworm was snapped up by Vaillant (a leading German boiler manufacturer) over 5 years ago and the Energysaver model was quickly consigned to history and replaced by European designs.  Meanwhile, 5 or 6 years seems to be about the average lifespan before serious internal deterioration renders an Energysaver beyond economic repair.  A classic example of how ‘Green’ labelled products do not necessarily save the planet.

We now travel to Oxted Surrey, where we had been asked to provide a recommendation for a new boiler.

House in Oxted

Our customer had such a boiler and it was leaking.  Being in no mood to buy another boiler with a short lifespan, and due to the tight location within a kitchen unit, we suggested that a Worcester Ri series replacement would prove more reliable and long lived. 

New boiler in position

As usual, we provided a 5yr parts and labour warranty on the unit, and the primary component (heat exchanger) is covered by Bosch for 10 years.  Their only stipulation is that the boiler should be annually serviced.

Secret location in West Norwood

So here we have our customer property in West Norwood;  it’s a rented property with an old Vokera combination boiler in the basement.

Old boiler

The boiler has been suspended on two pieces of timber, which technically is not allowed, because wall hung boilers should be fitted to non combustible surfaces.

Boiler flue is compromised

The second problem was the boiler flue termination, which had various obstructions around it including a deep window sill, and a water butt.

And the third was the gas supply, which was around 8 metres long, in 15mm pipe, with a significant number of elbows – meaning that the existing boiler was under supplied.

The new boiler almost finished

We removed the boiler and fitted a new 18mm plywood support frame, and faced it with a fire resistant sheet.  The new Vaillant ecoTEC+ 831 boiler was fitted to this.

The gas supply was renewed from the meter in a larger bore tube.

Finally the flue was repositioned away from the window and the water butt, to an adjacent wall.

Old boiler flue removed, new one relocated

The old flue aperture was neatly bricked up.

A Vaillant Variable Termination Kit (VTK) was fitted to the flue, as the nearby property boundary was under 2 metres away.  This product lifts the flue outlet higher, and allows the plume (steam) to be directed away.

The system was powerflushed to remove contaminants from the radiators, Honeywell VT200 thermostatic valves were fitted where necessary, and the control system upgraded to feature the Honeywell CM907 programmable wall thermostat/timer.

This system will be covered by our Vaillant 5 year warranty scheme, until 2014.

Our customer also complained that the boiler regularly ‘locked out’ and never seemed to stop.  We found that the wiring centre had been thrown behind the hot water cylinder, there was no room thermostat, and no pump bypass fitted.  This device if missing, would cause the boiler to overheat.

We cured these faults and then the customer pointed out the drain attached to their Potterton boiler.  this is nemant to discharge into the main sewerage system, and any external pipework is meant to be insulated.

This is what we found;

No trouble taken

If you receive a boiler quote that seems cheaper than most, there is usually a reason, and this installation was a typical example of what to expect.  Faulty wiring, incorrect system design and shoddy workmanship.

The next example is from a pensioner’s house in Kingston, Surrey.  She has a warm air unit that was originally commissioned by her late husband (who had no formal gas training).

She was at pains to describe how there was nothing wrong with it;  however even a cursory glance showed us that the installation was in serious danger of setting the house alight and the flue design would be spilling products of combustion inside the house.

Unfortunately, when I appraised her (being as respectful as possible to her late husband) of these facts, she explained that she had been receiving hospital treatment for carbon monoxide in her bloodstream, but that the doctor had said it was naturally occurring and could not have been caused by her boiler…..!

I tried to explain the problem but she asked me to leave and locked the door behind me.  The only picture I could get was of her flue outlet…

 Hopefully she has now had a new unit fitted.

40 people die from carbon monoxide poisioning due to poorly installed or maintained appliances every year.  No one likes regulations, but unfortunately in our industry it is only too necessary.