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radiohe4d
Info:
Worcester Greenstar Heatslave
Drayton MA1 Mid Position Valve Actuator
Summary:
Had to replace the valve actuator as the old one was sticking. Wired up the new one with the same pinout as the original. Tested but got the following failed outcome;
Off = DHW
Water On = DHW
Heating On = CH + DHW (makes clicking sound)
Both On = CH
Boiler Hell:
We only moved in a few months ago and haven't needed the heating much, but we did notice it was coming on at random or when water was run. Worked out that the valve was sticking, removed it and only got around to replacing it today.
The boiler had a full service at the start of this year (2020) and had the PRV, Pump and fuel lines replaced.
So I after the actuator failed to move to the expected positions I thought must have always been wired wrong (as i matched the previous wiring). So I hunted out the Greenstar and Drayton manuals and tried to figure out what wires did what. A multimeter, a lot of cursing and 6 hours later, I managed to map what the boiler outputs and matched it to what the actuator does.
I've now got the DHW and CH working separately. But for the life of me I can't figure out how to get them to run both at the same time (actuator at mid position, yenno, the whole damn point of the £70 hole in my pocket!).
I've got pictures if it'll help but I'll not spam until theyre needed.
Boiler => Actuator Wiring:
Blue => Blue
Green => Green
Grey => Orange
Orange => Grey
Brown => White
Boiler Output Voltage For States:
These don't make much sense to me. Both On shouldn't be the same as Water only?
Off
Grey = 0v
Orange = 0v
Brown = 0v
Water
Grey = 240v
Orange = 240v
Brown = 30v
Heating
Grey = 0v
Orange = 240v
Brown = 240v
Both
Grey = 240v
Orange = 240v
Brown = 30v
Actuator Position Settings:
I manually tested the actuator with switches connected to a wall socket to determine how to set each position. 240v was applied to white, grey or both white & grey wires. The Orange wire outputs various voltages based on position.
DHW (default position)
Grey
Orange = 0v
Mid
White
Orange = 60v
CH
Grey + White
Orange = 240v
Conclusion:
I'm pretty experienced with electronics but have little to no experience with boilers and heating systems.
I am however confident that the diverter valve is functioning correctly, the actuator isn't faulty as from my successful manual position testing and that I hate boilers 1000 times more than I did yesterday.
I'll admit that I'm pretty lucky to have everything else working, so I am counting my blessings there but I can't walk away when it's so close to working 100% correctly.
Apologies for the long post but hopefully I've talked enough that someone out there will somehow know exactly what I'm talking about.
Cheers,
Brian.
Worcester Greenstar Heatslave
Drayton MA1 Mid Position Valve Actuator
Summary:
Had to replace the valve actuator as the old one was sticking. Wired up the new one with the same pinout as the original. Tested but got the following failed outcome;
Off = DHW
Water On = DHW
Heating On = CH + DHW (makes clicking sound)
Both On = CH
Boiler Hell:
We only moved in a few months ago and haven't needed the heating much, but we did notice it was coming on at random or when water was run. Worked out that the valve was sticking, removed it and only got around to replacing it today.
The boiler had a full service at the start of this year (2020) and had the PRV, Pump and fuel lines replaced.
So I after the actuator failed to move to the expected positions I thought must have always been wired wrong (as i matched the previous wiring). So I hunted out the Greenstar and Drayton manuals and tried to figure out what wires did what. A multimeter, a lot of cursing and 6 hours later, I managed to map what the boiler outputs and matched it to what the actuator does.
I've now got the DHW and CH working separately. But for the life of me I can't figure out how to get them to run both at the same time (actuator at mid position, yenno, the whole damn point of the £70 hole in my pocket!).
I've got pictures if it'll help but I'll not spam until theyre needed.
Boiler => Actuator Wiring:
Blue => Blue
Green => Green
Grey => Orange
Orange => Grey
Brown => White
Boiler Output Voltage For States:
These don't make much sense to me. Both On shouldn't be the same as Water only?
Off
Grey = 0v
Orange = 0v
Brown = 0v
Water
Grey = 240v
Orange = 240v
Brown = 30v
Heating
Grey = 0v
Orange = 240v
Brown = 240v
Both
Grey = 240v
Orange = 240v
Brown = 30v
Actuator Position Settings:
I manually tested the actuator with switches connected to a wall socket to determine how to set each position. 240v was applied to white, grey or both white & grey wires. The Orange wire outputs various voltages based on position.
DHW (default position)
Grey
Orange = 0v
Mid
White
Orange = 60v
CH
Grey + White
Orange = 240v
Conclusion:
I'm pretty experienced with electronics but have little to no experience with boilers and heating systems.
I am however confident that the diverter valve is functioning correctly, the actuator isn't faulty as from my successful manual position testing and that I hate boilers 1000 times more than I did yesterday.
I'll admit that I'm pretty lucky to have everything else working, so I am counting my blessings there but I can't walk away when it's so close to working 100% correctly.
Apologies for the long post but hopefully I've talked enough that someone out there will somehow know exactly what I'm talking about.
Cheers,
Brian.
