Pcb Control Board; Fan Assembly; Condensate Pump - Worcester Greenstar Highflow 440CDi ERP Installation, Commissioning And Servicing Instructions

SERVICING AND SPARES
6.9.2

PCB Control board

Access to boiler control components
▶ Remove the screws [1] to release the cover from the controller.
PCB Fuse
▶ Remove the fuse [2] and replace with a spare that is clipped on the
inside of the controller cover.
PCB
▶ Disconnect all electrical connections from the control board.
▶ Remove the screws [3] retaining the rear panel of the control and
remove the panel.
▶ After re-assembly check CO/CO
"Setting the air/gas ratio" on page 36.
1
Spare Fuse order
T1.6A L250V F2
T2.5A H250V F1
3
Fig. 59 PCB
6.9.3

Fan assembly:

Do not attempt to service the fan assembly and flap
valve if a CO/CO analyser is not available.
2
▶ Undo lower pipe union on gas pipe [5].
▶ Twist the mixer unit [4] with gas pipe [5] to separate from fan [1].
▶ Remove fan lead and earth connector.
The earth connector has a positive clip fixing.
▶ Remove fixing screws [3] attaching fan [1] to the burner cover [2].
▶ Remove fan [1].
▶ After re-assembly check that the CO/CO
the section "Setting the air/gas ratio".
38
levels as described in the section
2
2
T500mA L250V F3
6720818077-22.1Wo
levels are as described in
2
Flap Valve:
▶ Undo lower pipe union on gas pipe [5].
▶ Remove pipe [5] by pushing upwards and towards the rear of the
boiler.
▶ Twist the mixer unit [4] with gas pipe [5] to separate from the fan
[1].
▶ Remove flap valve [6] from within fan intake [1] and replace.
Ensure the flap valve is fitted correctly with rubber flap
upwards.
▶ After re-assembly check that the CO/CO
the section "Setting the air/gas ratio" on page 36.
6
4
5
6720818079-10.1Wo
Fig. 60 Fan assembly
6.9.4

Condensate pump

▶ Disconnect electrical connections in control box, see wiring
schematic in the 'Fault finding and Diagrams' section 7, page 43.
▶ Rotate the 15mm flexible tube [1] anti-clockwise and pull up to
remove from the pump.
▶ Remove black flexible pipe [2] from condensate pump. Take care as
there maybe condensate remaining in the pipe.
▶ Carefully remove the condensate pump [3] from the boiler and pour
any excess condensate into a suitable container for safe disposal.
1
Fig. 61 Condensate pump
Greenstar Highflow CDi
levels are as described in
2
2
3
1
2
3
6720818079-12.1Wo
ErP - 6720818077 (2016/04)