Worcester Greenstar Si Boiler Burner Gasket Failure

Hello Folks,

I have bought a Worcester Greenstar Si boiler five years ago. From last few days, some burnt gasses are leaking constantly from the boiler’s heat exchanger & recirculating all around the boiler. Does someone know what the matter is & how to fix it?

Thanks

Jenny

Hi Jenny,

Before addressing your problem, I would like to share that Worcester Greenstar boilers are based on ‘Zero governors’ or ‘premix burner’ design. In premix burner design gas and air gets blend for setting a ratio & then essentially blown into a burner for ignition. The major part this design is burner gasket as it creates the strong seal between the venturi and burner, which gives the gas and air to your burner. In your case, the gasket meant to fail all around the ionization probe and spark electrodes & eventually results in leaked burnt gases. In spite of being dangerous, it causes condensation to stay on the inner side of the covering, which can cause corrosion. As you said, that your boiler is five years old then, it probably makes some sense to have an eye on it & replace it.