Worcester Bosch Fan problems

Рет қаралды 87,856

Rob Reynolds

7 жыл бұрын

Worcester Bosch Greenstar boiler fan problems.

Пікірлер: 89

@s.e.motorsport8150 6 жыл бұрын

Absolutely brilliant pal. I'm no boiler tech. I actually build race cars. But this boiler fault been bugging me for a while and it end up such a simple problem! Pulled fan controller off and it's burnt. 👍🏽 will try get local shop to find me one tomorrow.

@cheekycockneychappie9384 10 ай бұрын

My boiler stopped working on startup after a two week holiday and being a sparky had a nose around and I found the fan pcb blown but was hesitant to just swap it out with a new one not knowing the probable cause until I saw this video..all up and running now cheers🍻🍻

@robdotreynolds 10 ай бұрын

, good job Sir, remember some people try while others just cry.....

@diy-fi6jq 8 ай бұрын

Any ideas on checking the pcb is it purple live brown neutral and should give @ 40 ohms?

@GarrettDevitt 5 жыл бұрын

Thanks Rob, useful stuff there. Keep up the good work.

@nashd001 6 жыл бұрын

Thank you Rob this is just the issue with mine. Power is present, fan is mechanically fine. Great video. It was working fine until I switched it on at the fused spur instead of at the boiler in the correct sequence. The spike damaged the pcb. It is apparently a known issue which I believe Worcester Bosch have addressed on the later models and have modified pcb. Once I've replaced pcb I'll update which component(s) has failed, not that it is worth repairing.

@robdotreynolds 6 жыл бұрын

nashd001 Thanks for the kind words.. I have many boilers with multiple issues and had over almost 30 years working in the electronics industry and thermal controls systems. Was only last year I decided to share some experiences. And hopefully this will save people some money and essentially keeping safe.

@stevereynolds7375 4 жыл бұрын

Hi Rob thanks for the top tip regarding the speed controller saved me ages fixing a Worcester this morning 👍quantity video from someone with a quantity surname 😁👍👌😉

@cheekycockneychappie9384 10 ай бұрын

Have this exact problem..turned boiler off to go on holiday..came back turned boiler on..didnt fire up an upon investigateing found the fan pcb had blown chips..so will swap it out with a replacement🤞🤞

@mh334 4 жыл бұрын

Great video Rob, one update NO BENDING OF BLADES NEEDED, the fan blade can simply be carefully pride off by using a long blade place between fan blade and housing and twist the blade until you feel the fan blade come loose, there are 2 small connectors in the back and with the fan off the board pops right out

@ZDima749 Жыл бұрын

Thank you so much! That's just what the doctor ordered. I've spent an hour trying to find out how to remove fan blades without breaking.

@PF-gi9vv 4 жыл бұрын

If you know a little electronics then you can fix these boards easy. Check the 10 ohm 5w resistor hasn't failed and swap out the 4 MOSFETs that control the motor. The MOSFET are IRF830. Before you do this though, it may be a good idea to check the coils on the motor hasn't burnt out. You can check the resistance of the twin coils are the same as the other twin coils opposite, when you pull off the drive board. Good luck.

@robdotreynolds 4 жыл бұрын

Good advice

@bradleykindell 3 жыл бұрын

FYI, you're looking for 50-60 ohms resistance across the coils that the pcb connects to through the 2 pins on the back.

@diy-fi6jq 9 ай бұрын

@@bradleykindell getting 59 ohms at the connection pins but .2 at the back other coil pins.. Is that normal?

@diy-fi6jq 8 ай бұрын

Any ideas on checking the pcb is it purple live brown neutral and should give @ 40 ohms?

@motosystemltd 7 ай бұрын

Before I found this video That's happened to may PCB, 257 - 10R safety resistor blown ,indicating most likely mosfets blow, however I measured source to drain and later to gates, didn't look shorted (unless I charged the gate) and then closed and may looks shorted, don't know the correct values .. Just briefly looked at them with multimeter .. I will get some datasheet for trans and repeat diagnosis.. Thanks for clue, but I know it something really bad when fused resistor gone .. I can't get this resistor quickly, as is cold and can't wait, I see many different rounded brown colour in Google photos (upgraded?) But can't read the numbers from it, mosfets may not be problem to get . Thank you for clue's. Also on the coils 60ohms...

@alistercarmichael4990 2 жыл бұрын

Good work. I have just traced the PCB for a CDI 40 as the fan board exploded on pre gas powerup. This was a power on check to run the pump up and check for leaks. The fan board (and motor) was the one with the small turret on top and equal pitch screws. Not the same as the one here. The monolithic IC had exploded after a number of seconds. The line and neutral from the control are the wrong way round so the fuse on the fan does nothing. The 3 control wires are incorrect. It's simply the wrong fan despite the part being original (?). The 4 fet board has the correct wiring for power and control. The fans are NOT interchangeable. All the best.

@cfgman1 4 ай бұрын

Excellent video Rob every day is a achool day

@0xxDenilsonx 5 жыл бұрын

Thanks for the excellent video. You've saved me £650!

@emy7990 4 жыл бұрын

Worcester 24i here, I had the light tripped out while the boiler was on, when I put it back the boiler would not work at all, just the blue light flashing (in fact the boiler worked with the blue light flashing for a few good months). Plumber changed the PCB board, very difficult to find the right one, (I bought it from eBay), no hope, was doing the same. We checked connector, the one that connects to the fan, it has power but the fan no response at all, it looks like new, the fan blade spins nicely.....it looks like the PCB of the fan is gone.

@mgabrielle2343 3 жыл бұрын

Usually a safety power resistor like 2.2Ohms to 10 ohms in value burns out which you might find has turned dark, different fans may have different values, this resistor burns when one or two of the the 4 power FET transistors go internally shorted out, if you replace all 4 Mosfets, then 8 out of 10 times it will work again, only in some rare cases further damage can be caused to other parts of the circuit board, I get a few gas safe engineers bring me fans for repairs.

@diy-fi6jq 8 ай бұрын

Any ideas on checking the pcb is it purple live brown neutral and should give @ 40 ohms?

@motosystemltd 7 ай бұрын

That's happened to may PCB, 257 - 10R safety resistor blown , indicating most likely mosfets blow, however I measured source to drain and later to gates, didn't look shorted (unless I charged the gate) and then closed and may looks shorted, don't know the correct values .. Just briefly looked at them with multimeter .. I will get some datasheet for trans and repeat diagnosis.. Thanks for clue, but I know it something really bad when fused resistor gone ..

@karimahmed7805 6 жыл бұрын

I have bought new bearings for my fan. Does anyone know of a video showing how to dismantle this model of fan to replace them?

@yampymusic 3 жыл бұрын

Flashing blue light and no green light, fan not spinning. Saw this video, bought a second hand fan unit off Ebay for £25 (circuit board on its own would have been £38), swapped out the circuit board. Five minutes to fit and my completely dead boiler is back working again! Many thanks, let me know if you have PayPal so that I can send you a fiver :-)

@robdotreynolds 3 жыл бұрын

I love a happy Viewer.... Robdotreynolds@hotmail.com

@diy-fi6jq 9 ай бұрын

Any ideas on checking the pcb is it purple live brown neutral and should give @ 40 ohms?

@krcright9746 2 жыл бұрын

Hi Rob, We have a Worcester 28i green-star combi boiler that have developed a problem. before we left home for our family holiday for 3 weeks, we turned the boiler off at the Switched fused spur which is situated just outside the boiler. upon arriving home. we switched the boiler back on at the switched fused spur. almost instant after switching it on. the boiler lost all power. I checked the 3A fuse in the switched spur and the fuse had blown. replaced the 3A fuse but it keeps blowing the fuse instantly upon switching the boiler on ? Hope you can shed some light on this issue,

@CiroLentano 2 жыл бұрын

Hi Rob, great video. May I ask you, had same issue. Boiler off, turned on apparently OK, call for hot water, works fine for a couple of minutes than blackout. No power. I checked the main PCB, 2A fuse blown. Replaced, and since then whatever I call there's no activity. I switched the fan PCB with a new one but still nothing happens. Shall I go for the entire fun body part? It does spin manually, I know there's electricity going through but no fan moving and so it doesn't initiate.

@squirrelsquirrel298 6 жыл бұрын

Anyone know a supplier for this PCB? mine usual are all out of stock . Cheers. MicK

@rayusman2941 3 жыл бұрын

Hi Where can i get this pcb from for the fan? I can't seem to find anywhere. Thanks

@richienorthcott Жыл бұрын

Thanks for this video. I have an issue where the fan controller is blowing the main fuse on the board. I worked our how to remove the pcb like you show. The motor windings are iro 60 ohms resistance so I believe okay. New pcb? Oh - someone has answered this below. 60 ohms is good.

@davidblurton7158 Жыл бұрын

above the fan should be a black clip on tray this catches the water if the elbow above leaks costs a tenner the elbow and sealsx2 are a tenner city plumbing bit arkward to remove as they weld themselves on with crud but some gentle bashing and levering it will come off ive always had to remove the whole unit back to the top of the burner,,, so the board change is quicker and much less cost,, apparently a diode blows and it is replaceable,, Worcester upgraded their later boards info is out there on forums so replace the board with this new diode

@robdotreynolds 6 жыл бұрын

Hi Will look tomorrow, to remind myself.

@davidnoble1058 6 жыл бұрын

I have a BW Highflow 400 RSF. There is a low resonance noise coming from the boiler, rather like a helicopter sounds in the distance. I suspect the fan is the problem. Anyone else come across this noise/problem? Thanks.

@m5xme 6 жыл бұрын

Hi rob. How do you get the back screw for the fan on a greenstar 24i system. Tried an allen key but not enough room. Also tried a angled bit but was catching the pipe on the right. Any tips ?

@robdotreynolds 6 жыл бұрын

m5xme Look at this on eBay Look at this on eBay www.ebay.co.uk/itm/231766471750

@kevinjones4023 6 жыл бұрын

normally toy get a new red gasket seal with the fan anyway, so you could just swing the whole arm out if you want to. ALWAYS REPLACE SEAL ONCE REMOVED.

@jacquesbrown3214 6 жыл бұрын

Great video! But where do you get your fan speed controllers from? Never heard of them before or seen them online / in the usual shops?? Many thanks

@cgavin1 5 жыл бұрын

Ebay. And they are the same price more or less as an entire new fan unit. Sadly.

@MikeRap246 Жыл бұрын

Hi Rob what could be the issue if the fan is starting momentarily but then stopping? Tries this a few times and then the blue LED flashes.

@robdotreynolds Жыл бұрын

Is this not the service mode blue light ?..double check or Flue blockages. Condensate pipe blockages. A faulty ignition electrode. A faulty flame sensor. Gas leaks. Low gas pressure. Low boiler pressure

@C013ain 5 жыл бұрын

heY! First of thank you for the video really helpfull. I really hope u still read the comments and can answer my question. So we bought a new house and when I turned the boiler on, the ignition light didnt came on. So searched on the internet found out the control unit on the fan was burnt out. I have ordered replacement part, changed it, heated the house up, hot water, lovely. SO the heataing was on for like an hour and than went back down to check on the boiler and it was off. No electricity. Checked the RCD and it was tripped. Burnt smell. fan control unit burnt again.. what could be the cause of it? Is it an over current in the electric circuit or just unlucky with 2 fan units?!?! I doubt it but who knows. Thank you for the help.

@thebigbaddy 7 ай бұрын

Did you find the fault?

@davidcairns238 6 жыл бұрын

Gooday Rob. My speed controller card on my 18i Greenstar has shorted out like the one you show. Do you know where these speed controller cards can be bought. Looked online but appears I have to buy a complete fan assembly. Many thanks.

@robdotreynolds 6 жыл бұрын

David Cairns Look at this on eBay www.ebay.co.uk/itm/231766471750

@davidcairns238 6 жыл бұрын

Many thanks Rob.

@kurtjakes 5 жыл бұрын

Apparently static electricity stays in the boiler when it's turned off at the mains and when turned back on that goes up the live along with the 240v and blows the board. Common fault with Worcester boiler I think as I've come across this loads. Always warn the customer on jobs where they want a boiler moved they might need a new fan and/or pcb in some cases.

@robdotreynolds 5 жыл бұрын

Good info Mr Fat :), always good to get helpful comments rather than from the trolls, can't actually help or give good constructive criticism only sat on their sofas looking for small errors.... and criticising..... I've been in the industry almost 35 years and criticism has never fixed the Machine, only advice from forums and knowledge transfer. I Guess That's Why They put the videos of cats and kittens on KZfaq for the trolls to keep them occupied in between looking for minor details in others videos.

@kurtjakes 5 жыл бұрын

@@robdotreynolds 16 years in he trade. Now working with my mate who's also good with boilers so I've learned a fair bit within the past 4 years. Boiler fault finding is a whole new ballgame and most of the public think plumbers/ heating engineers will know all about it because they fitted the thing. GREAT satisfaction fixing boilers I find but my favourite is heatpack as that's how I started my apprenticeships and I must of done over a thousand now lol. Are you a boiler specialist or all rounder still?

@C013ain 5 жыл бұрын

Hi there! I have just red your comment and I think this is what happening to my boiler. Had a fan speed control unit burnt out. Replaced it, was working for an hour, the rcd tripped, turned it back on and and the speed control unit burnt again.... I dont really knwo what to do... should i connect a gas engineer or electrician...

@kurtjakes 5 жыл бұрын

@@C013ain gas engineer 👍

@Simon67316 9 ай бұрын

Did you find the problem in the end?@@C013ain

@paulthepill 5 жыл бұрын

I'm quite happy to replace the PCB but how do I remove the boiler casing...grr...

@robdotreynolds 5 жыл бұрын

Two screws at the top.... try that

@paulwelburnphotography 2 жыл бұрын

Thanks for the video Rob. My Greenstar 28i Junior has a rapid flashing blue light with the Reset button flashing. The boiler works for a while but locks out after 10 mins or so, if running a bath for example. After resetting the boiler can work again for a while. Could this be down to the fan?

@robdotreynolds 2 жыл бұрын

Hi. It could be many things.... no gas or incorrect gas pressure gas valve faulty combustion CO2 levels out of range blocked flue (try this first) blocked condensate pipe or frozen condensate pipe ignition electrodes or harness faulty pcb faulty. Try the flue.....I've had a bird nesting in one........

@paulwelburnphotography 2 жыл бұрын

@@robdotreynolds thanks mate. Have covered most of the above so will have a good check through over the next few days

@yensabi 4 жыл бұрын

All modern Worcester boilers are notorious for having fan problems , these days if I have to service one I don't switch the power off because usually if you do the fan will die and you are then liable to get it working again......they are utter garbage.......👍

@robdotreynolds 4 жыл бұрын

I've had similar problems,

@jonlen100 2 жыл бұрын

Water getting into the top of my boiler blowing up two fans so far. Any ideas?

@robdotreynolds 2 жыл бұрын

Have you got a very small pin hole and a fine water mist spraying into the fan ?

@carlwatson8748 6 жыл бұрын

Hi Rob, got a boiler issue, until I saw your video I thought it was the main PCB so I swapped that but still no go, the small fan spins for about a second then shuts off, do you recommend a whole fan exchange or fan PCB? Cheers, Carl

@robdotreynolds 6 жыл бұрын

Carl Watson . How does the fan bearing feel ?, because I have had two recently where the bearing was perfect it was only the speed controller.

@carlwatson8748 6 жыл бұрын

Rob Reynolds The bearings seem fine tbh, Basically I’ve got a donor boiler off a friend, so have been changing over any electrical parts I can, the old PCB that I took out was a bit black in areas on the board, the fan didn’t spin at all, I popped in the donor PCB & it spins for a second then stops, I’ve since read that if the 2.5 amp fuse goes on the main PCB it’s more than likely the wirings in the motor have burnt out causing it to fail, would you agree? If so the next step would be to try the donor fan itself, in your experience what’s the sequence to getting the fan out whilst it’s hung? The donor boiler I’ve got is obviously not to attached to any mains so I just swung it out on the arm that attaches to the combustion chamber like it says in the manual, learning you have to unscrew the fan from the mixing chamber at the back to release it, after all this it’ll be getting serviced & checked out, cheers

@alanpickering4497 5 жыл бұрын

Hi mine is blowing the 2a fuse as a flash appeared from fan area when I replaced it.is it worth the risk buying the PCB or can I remove pcb and est the fan motor separately? thank alanp

@robdotreynolds 5 жыл бұрын

Not an easy one ..... but......can you spin the fan..?..... if you can and coil looks good.....not burnt ....then....maybe you can go for a PCB..

@gasdude66 6 жыл бұрын

Where’s the bit about checking and resetting the flue gas ratios -where’s your flue gas analyser -checking flap valve- great video-if you don’t mind mickey mouse playing with your safety

@robdotreynolds 6 жыл бұрын

gasdude66 Sorry again.... it's regarding the PCB only, it's more of a foot note video on PCB's Thanks for the positive feedback... Will also add the celebration notes next time... I was hoping all watching were aware of this.

@colinfleming2244 3 жыл бұрын

You should realise some people on this ain't gas engineers we know the checks to do they don't hope you never hav someone come on and say did what you said and blew my house up

@chandanvelani1273 6 жыл бұрын

Surely it should be a 3amp fuse not a 5amp???

@chandanvelani1273 6 жыл бұрын

Rob Reynolds 3:17 on the video

@robdotreynolds 6 жыл бұрын

Hi..its just a 5amp isolation point with a 3 amp fuse. Only an isolation point as the main protection will be at the consumer unit on a fast breaker. But thanks for pointing out my slip in words. Regards Rob.

@bobwoods1963 6 жыл бұрын

The main fuse on the PCs is a 20mm ceramic T2.5A (anti surge). This usually blows when the PCs goes faulty.