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When using a 3-port valve, the control system may be known as a Sundial Y Plan system or a Honeywell Y Plan system. That noise and that bump are diagnostic. They tell us that the valve has moved into the mid-position where both Heating and Hot Water ports are open. If you can make a Honeywell 3-port mid-position valve move into all three of those positions, the valve and controls appear to be wired correctly and the valve appears to be working normally. As we’ve said above, Honeywell make a large range of motorised valves. The Normal state of a valve is the de-energised state. This is the state when no electrical power is being used by the valve motor. If it’s the other way round, and the 2-port valve controlling the hot water circuit is failing, it may be less obvious. The heating circuit valve may be open for long periods telling the boiler to fire. If the hot water valve is partially open, you may not run out of hot water.
The blue wire is the Neutral, N. The green/yellow wire is the Earth wire, E. The white wire is connected to the wire from the room thermostat which calls for heating (radiators or underfloor). The grey wire is used to drive the valve to the Water Off position, in which only the heating port A is open; it closes port B. The orange wire provides a Switched Live (Switched Line) feed to run the boiler and pump. If the powerhead was removed from the valve to make it easier to change the motor, it must now be re-attached to the valve. The power head cover can then be refitted and secured with the single screw. Make sure it sits squarely on the powerhead, with no wires pushing out from the sides. When a V4073A mid-position valve is set up in a Y-Plan configuration and Hot Water is called for, power to the boiler is provided directly from the cylinder thermostat. The valve is not energised. There are lots of poor quality synchronous motors out there. If the motor cap says “Synchronous” rather than “SYNCHRON ®” it may cost less than half but you’ll probably be changing it again before long! V4043H1106 is a 2 port, 28mm compression, 6-wire, normally-closed zone valve with an auxiliary end switch
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The Honeywell V4073A 3-port valve has five wires. These are blue, green/yellow, white, grey and orange. Note that the grey and orange wires are used differently from the grey and orange wires of the 2-port valve! However, if you need to replace the motor it may be easier to remove the powerhead so you can work on it in the open. Remember, on early Honeywell motorised valves (pre-1985) you can’t remove the powerhead without draining down first! V4044C motorised valves are 3 port diverter valves. They send flow to either the hot water port or the heating port but not both, except briefly during switchover. They are 3 wire valves.
If, for example, the heating valve is failing in this way, you will get heat round the radiators while the cylinder hot water is being heated too. When the cylinder is up to temperature, the hot water motorised valve closes and no longer tells the boiler to fire, so the heating now stops too. When all electrical power to the heating controls is switched off, the spring pulls the ball across to close port A, leaving port B open. This is the relaxed state or de-energised state of the valve. It is also sometimes called the Normal state. If Hot Water is then satisfied (either by the programmer or cylinder stat), the grey wire is energised. As there is still a demand for Heating, the valve will motor to the Heating Only position (port A open; port B closed) and switch a 230V supply onto the orange wire, to power the boiler.Occasionally we come across a Honeywell motorised valve where the powerhead jams but the spindle (actuator shaft) is still free. Where this happens it is usually with the valve jammed open. If all the power to the central heating system is turned off, and the manual lever is still loose across the whole slot, the mechanism may be jammed. When a demand comes from the programmer (via the thermostat), the motor is energised and drives the valve open to allow water to pass. When the valve is fully open, a microswitch is operated in the powerhead, connecting the grey wire to the orange wire. This is called closing the switch. It sounds a bit counter-intuitive, but when a switch is closed it is completing the circuit and allowing current to pass; when the switch is opened it is opening a break in the circuit and stops current from passing. The Honeywell valves have a D-shaped top to the spindle but you can also use a spanner on this. If you do this, you must use very little force as it is very easy to shear a spindle or damage the valve internally. If the powerhead (actuator) can be safely removed from the valve body (see warning above about pre-1985 Honeywell valves) you can try to turn the spindle. You may need a tool unless you have strong fingers. You must also isolate the electrical supply before removing a Honeywell motorised valve powerhead.
The commonest fault with Honeywell motorised valves is motor failure. Honeywell valve motor fault? Testing a Synchron valve motor Slide the blunt end of the motor sideways until the flange comes out from the tab holding it down. This can be a bit of a fiddle. The motor then comes free of the valve, held only by the two wires which connect it electrically. These two wires may be blue (in a Honeywell original Synchron motor) or orange (most replacement Synchron motors). With modern boilers, the boiler sends a Live feed to the circulating pump which then pumps heated boiler water through the valve. It will go to the radiators or to the cylinder coil, depending on which valve was opened. With older boilers, the Live from the auxiliary circuit end switch goes directly to the pump at the same time as it goes to the boiler Switched Live. The Honeywell V4043H1106 28mm 2-port zone valve has 6 wires. Five of these wires are the same as 22mm 2-port valve.Green/yellow is Earth, blue is Neutral, brown is Live (or Line) to the motor, grey and orange are connected to the end switch and form part of a separate circuit.
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A normally-closed valve is closed when no power is being applied to it and needs electrical power to drive it open. System boilers may also have a diverter valve or zone valve built into them and might not have any external zone valves. V4043C1156 is a 2 port, ½” BSP Female threaded, 3-wire, normally-closed zone valve but has no end switch Both of these genuine SYNCHRON motors work in Honeywell motorised valves. The motors SYNCHRON make specifically for Honeywell come with two blue wires The Honeywell mid-position motorised valve has three ports in a T configuration. Water enters via port AB. Water leaves by either port A or port B or by both at the same time. Port A is normally connected to the radiator circuit and Port B to the cylinder coil (to heat hot water). The circulating pump is usually connected to feed water from the boiler into port AB.
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