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Plucky

I had a call out to a problem with 2 glow worm energysave boilers which are running in tandem. They have been converted over to LPG. Sypmtoms were that the boilers were cutting out and causing overheat stat to trip (manual reset on these boilers)

First thing I done was stick my analyser in and found one boiler circa 500ppm co and the other over 700ppm. Stripped and cleaned as they didnt look like they had ever been cleaned (although someone has been servicing yearly, yeah right!) Both boilers burning under 60ppm with decent ratios)

However customer still reports same fault. The only way they can keep the boilers running at the moment is to turn these boilers to theyre summer setting and turn the stat right down low. These boilers have a high(winter) setting and a low(summer setting) when on low they kick out approx 12kw and on high I think around 24kw.

A previous plumber has changed the pump which hasnt made a difference.

I am thinking of checking the quality of the water in the system and am thinking maybe heat exchangers are sludged up? I find it hard to believe a mechanical fault with 2 seperate boilers occuring at the same time. Its as if the flow rate through the boilers isnt enough.

I know 40kw is miles too much to heat a cylinder of water twice a day but they still shouldnt overheat. The stats should just cut the boilers out and they would cycle alot not trip overheat stat surtely?

System has an auto bypass and even when fully open the same fault.

Any ideas???
 
Sounds like a sludged system or a faulty boiler stat not turning off before the overheat kicks in.
 
is the problem been there ever since ? what is the new pump like ?can u not turn one off in the summer ?
 
Could turn one off in the summer yes but the problem is still going to be there and customers are eager to get issue resolved before winter. New pump is a decent grudfos 25/55 180 so a light commercial circulator.

MGFS - 2 boiler thermostats failing at the same time? - highly unlikely


I have found that the minimum flow rate through these boilers is 22.5 l/m How would I go about measuring this?
 
Plucky, where's the Bi-pass, and is it automatic? Just a thought. If the flow through both boilers is compromised with reduced demand then maybe they're getting to hot to quickly? An auto bi-pass may resolve the issue. Honestly don't know, you'd have to put stats on F&R to check diff when running!
 
Diamond - thanks for your response. Auto bipass is on correct position, its a 28mm jobby and problem occurs even when fully open. Its wierd, im going back there thursday I am hoping to drain the boilers and find aload of crap come out, at least I will know for sure what it is!
 
Krikey been a long time since I've seen one of these ... just checked out the mi's ...

good amout of heatsink around the boiler stats doesn't harm it! Check out on one only and see if it makes any differnce! Again just a thought as we had loads fitted here in NCl council .. absolute pain for o'heating!
 
Have tried one boiler only, same fault. Only way to get em to work is to drop em to the summer setting and stats right down low.
 
Just a thought,but if you can shut off boiler 'A' and leave boiler 'B' working,if boiler 'A' overheats,then it must be 'B's boiler stat.If not,try shutting down 'B' and leave 'A' working.If both boilers overheat,then boiler 'B' stat is at fault,as circulation could take heat from 'A' to 'B' or vice versa.If water is getting to 95 in one,and circulating to the other,it will take out both.Lots of time involved though!
 
Have you tried replacing the stat on one? may be woirth a try if to do nothing but eliminate temp control and point more towards circulation through the heatexchangers!
 
Just a thought,but if you can shut off boiler 'A' and leave boiler 'B' working,if boiler 'A' overheats,then it must be 'B's boiler stat.If not,try shutting down 'B' and leave 'A' working.If both boilers overheat,then boiler 'B' stat is at fault,as circulation could take heat from 'A' to 'B' or vice versa.If water is getting to 95 in one,and circulating to the other,it will take out both.Lots of time involved though!

good idea! time as you say but on hw only isn't that long eh?
 

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