Worcester GREENSTAR HIGHFLOW 440CDi Instruction Manual page 44

NOTE: A SERVICE TO THE FAN ASSEMBLY AND FLAP VALVE MUST NOT BE ATTEMPTED
IF A CO/CO ANALYSER IS NOT AVAILABLE.
2
F
D
E
L
42
REPLACEMENT PARTS
A B C
H
M
N
K
REPLACEMENT PARTS
Fan Assembly:
Undo lower pipe union on gas pipe (E).
Remove fan lead and earth connector.
The earth connector has a positive clip fixing.
Remove fixing screws attaching fan (A)
to the burner cover (B).
Remove fan (A) with gas pipe (E) and
mixer unit (D).
Twist mixer unit (D) with gas pipe (E) to
separate from fan (A).
After re-assembly check CO/CO
as described in the section "Setting the
air/gas ratio".
Flap Valve:
Undo lower pipe union on gas pipe (E).
Remove pipe (E) by pushing upwards
and to the rear.
Twist mixer unit (D) with gas pipe (E) to
separate from fan (A).
Remove flap valve (F) from within fan
intake (A) and replace.
After re-assembly check CO/CO
as described in the section "Setting the
air/gas ratio".
J
NOTE: Ensure the flap valve is fitted correctly
with rubber flap upwards.
Condensate pump:
G
Disconnect electrical connections in
control box, see wiring schematic in the
'Fault finding & Diagrams' section.
Remove 15mm flexible tube (H) from pump
by rotating anti-clockwise and pulling up.
Remove black flexible pipe (J) from
condensate tank. Take care as there may
be condensate remaining in the pipe.
Carefully remove the condensate pump
(G) from the boiler and pour any excess
condensate into a suitable container for
safe disposal.
Diverter valve motor
Ensure that the appliance is in service
mode (there is no need to drain the
appliance).
Disconnect the electrical connector (K)
from the diverter valve motor (L).
Pull the motor (L) towards you, the
assembly will slide free from the valve.
To refit, follow the reverse of above.
NOTE: In case of problems when refitting the
motor: connect the electrical connector to
the motor and switch the appliance on. When
the motor goes into the middle position the
motor can be fitted without difficulty.
Diverter valve
Ensure that the appliance has been fully
drained.
Disconnect the electrical connector (K)
from the diverter valve motor (L).
Undo the two screws holding the valve
actuator body to the plastic housing (N).
Remove the motor and valve actuator
body from the diverter valve.
Withdraw the valve actuator from the
diverter valve.
To refit assemble in reverse, ensuring
that the valve actuator is properly seated
on the two lugs of the actuator body.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219c (03.2010)
levels
2
levels
2