Worcester GREENSTAR Highflow 440 Instruction Manual
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Worcester GREENSTAR Highflow 440 Instruction Manual

Floor standing rsf gas-fired combination boiler
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GREENSTAR HIGHFLOW 440
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING

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  • Page 1 GREENSTAR HIGHFLOW 440 INSTRUCTION MANUAL INSTALLATION COMMISSIONING & SERVICING...
  • Page 2 PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. ANY DOUBT PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED BENCHMARK LOG BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813 (EIRE ONLY) WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR SERVICING.
  • Page 3 SAFETY & REGULATIONS APPLIANCE INFORMATION PRE-INSTALLATION INSTALLATION COMMISSIONING SERVICING & SPARES CONVERSION KITS FAULT FINDING & DIAGRAMS...
  • Page 4 DON'T SMOKE OR STRIKE MATCHES. DON'T TURN ELECTRICAL SWITCHES ON OR OFF. DO PUT OUT NAKED FLAMES. DO OPEN DOORS AND WINDOWS. DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED. DO TURN OFF THE CONTROL VALVE AT THE METER. DO CALL YOUR GAS COMPANY. IMPORTANT - The service engineer must complete the Service Record in the Benchmark Log Book after each service.
  • Page 6 DESCRIPTION UNITS Natural Gas L.P.G Central Heating Domestic Hot Water Gas flow rate Gas supply pressure Flue Condensate Electrical Expansion Vessel General Data...
  • Page 8 IMPORTANT: All the following pre-installation sections must be read and requirements IMPORTANT: met before starting boiler or flue installation. Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty.
  • Page 9 IMPORTANT: Non-return, back flow prevention devices (including those associated with water meters) fitted to the mains water supply can cause a pressure build up which could damage the boiler and other household appliances.
  • Page 11 • Do not use galvanised pipes or radiators. TYPICAL SEALED SYSTEM:...
  • Page 13 • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route and not exceed 3 metres outside the building. • (into a serviceable internal trap (min. 75mm) such as a sink/washing machine) •...
  • Page 14 install service Space required for unvented areas with a removable door or panel. This space can be reduced to 50mm for one side only as long as both the side clearances add up to the total of both the side measurements shown or more.
  • Page 15 must not IMPORTANT: any switch or appliance control using mains electricity must not be able to be touched by a person using the bath or shower. Electrical switches, fused spur and socket outlets must not be situated in the bathroom.
  • Page 17 Minimum dimensions of flue terminal positions for balanced room sealed flues with fanned draught: DRWG. TERMINAL POSITION (KW INPUT EXPRESSED IN NET) DISTANCE REF: See 'Contact Information' on the inside front cover for flue guard information. In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
  • Page 18 IMPORTANT: All horizontal sections must rise away from the boiler by 52mm per metre (3°) to allow the condensate to drain back to the boiler.
  • Page 19 If a sharp implement is used, care must be taken not to pierce the carton or cause injury. At all times the correct method for handling heavy objects should be strictly observed.
  • Page 20 Measurements shown include the minimum service clearances. * IMPORTANT: for horizontal flues, increase this height by 52mm for every 1000mm of horizontal length that the flue opening is away from the boiler NOTE: all horizontal flue sections must rise away from the boiler by 52mm per meter to ensure that condensate flows back into the boiler for safe discharge via the condensate waste pipe.
  • Page 22 (60/100mm diameter) For vertical flues and 80/125mmØ horizontal flues, please refer to separate Flue Kit instructions. Note: to ease the assembly of flue components, apply silicone lubricant to the flue sealing surfaces. Note: a minimum 300mm of straight flue length is required to accommodate the uncut elbow extension.
  • Page 23 Note: for easier access to the inner case, the expansion vessel can be unhooked (by removing the retaining screw on the hinge) lowered and moved to the side. Take care not to overstretch the flexible pipe connections. The boiler is supplied ready to fit a rear flue outlet. To flue vertically or from the side of the boiler, follow the procedure below:...
  • Page 24 The condensate pump (G) fills up and periodically discharges through the flexible condensate pipe (H) 200mm to 1500mm from floor level. After this point the condensate continues down the 21.5mm plastic pipe to the outlet using gravity. (See Pre-Installation section for condensate pipework running from the adaptor (K) to the discharge outlet).
  • Page 26 The drain pipe (B) should be at least 15mm diameter and run down away from any electrics or other hazard. IMPORTANT: The pressure relief valve is a safety device for the boiler and if activated may discharge boiling water or steam through the relief valve drain pipe.
  • Page 27 = EARTH = LIVE = NEUTRAL = SWITCHED LIVE IMPORTANT: OBSERVE ELECTRONIC STATIC DISCHARGE PRECAUTIONS. DO NOT TOUCH THE PCB CIRCUITS...
  • Page 29 Note: The CH circulating heating pump is preset to number '3' and should not be altered. The diagram opposite shows the pump output. IMPORTANT: If the boiler is not to be commissioned immediately then: after successfully completing all of the checks and any rectification work, close the water valves, shut off the gas supply and electrically isolate the boiler.
  • Page 30 If an extra expansion vessel is fitted to the central heating return, adjust this to the same pressure as the appliance internal expansion tank, refer to separate instructions with the extra expansion vessel.
  • Page 31 IMPORTANT: Never run the appliance when the appliance/system is unpressurised or empty. The power on indicator (B) illuminates green and the burner on indicator (D) illuminates red. Note: the boiler runs for 15 minutes at minimum heating output to fill the condensate trap, the display (C) alternates between '-ll-' and the central heating flow temperature or 't' &...
  • Page 32 IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. The inhibitor or combined inhibitor/anti-freeze must not cause damage to the materials within the boiler (mild steel, stainless steel, copper and brass) and any other materials/components within the system.
  • Page 34 IMPORTANT: Any service work must be IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR GAS carried out by competent registered SOUNDNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS engineers, such as British Gas or Corgi DESCRIBED IN COMMISSIONING. ANY O-RING OR GASKET THAT APPEARS DAMAGED registered personnel.
  • Page 35 Note: for easier access to the inner case, the expansion vessel can be unhooked (by removing the retaining screw on the hinge) lowered and moved to the side. Take care not to overstretch the flexible pipe connections.
  • Page 36 There is a special accessory kit available (No. 840) specifically designed for cleaning the heat exchanger. If required order 7 719 001 996. The heat exchanger should only be cleaned if the pressure is -2.2mbar or less. To Remove Condensate trap:...
  • Page 37 Do not use a wire brush.
  • Page 38 IMPORTANT: Any service work must be carried out by competent registered engineers, such as British Gas or Corgi IMPORTANT: Refit or replace any components removed from the appliance in the reverse registered personnel. order using new gaskets/'O' rings/sealant/heat transfer paste where necessary. Any 'O' ring or gasket that appears damaged must be replaced.
  • Page 39 The earth connector has a positive clip fixing. NOTE: Ensure the flap valve is fitted correctly with rubber flap upwards. Alternatively: After refitting: See 'Filling the System' and 'Water Treatment' under the Commissioning section.
  • Page 40 Central heating flow temperature sensor (A): Safety temperature limiter (B): Tank sensors (C): Tank overheat thermostat (D): Flow sensor/flow regulator assembly (E): Flue Temperature limiter (H): Domestic hot water temperature sensor (J):...
  • Page 41 The pipe (A) may be removed between the flow sensor outlet and the plate heat exchanger to improve access to the rear connections. See 'Setting the gas/air ratio'.
  • Page 43 IMPORTANT: The appliance is set at the factory and adjustment to the CO2 settings (gas/air ratio) is only required where the appliance has been stripped down and assembled or if the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type.
  • Page 44 10.8 10.5 If the CO level is over 200ppm, the gas volumetric flow rate is too high. Reduce the gas flow rate on the adjustable gas flow restrictor until the CO level is below 100ppm. The display and the button (B) will flash. If the CO level is over 200ppm, the gas volumetric flow rate is too high.
  • Page 45 1 Burner: 2 Fan assembly: 3 Circulating Pump: 4 3-Way diverter valve: 5 Diverter valve motor: 6 Flow sensor: 7 Flow regulator: 8 Temperature sensor: 9 Temperature limit (Flue or heat exchanger): 10 Thermistor sensor (Tank): 11 Overheat thermostat (Tank): 12 DHW thermister: 13 Heat exchanger: 14 Gas valve:...
  • Page 46 Servicing & Spares...
  • Page 47 Terminal block, 230VAC mains supply. Hot water NTCsensor, Under floor module, Pin 3 = black, Pin 4 = red. Roomstat link. Pin 17 = yellow, Pin 18 = yellow. Fan & condensate pump 230 VAC. Earth connection. Condensate end switch, Solenoid valve 1, Fuse, slow 2.5A.
  • Page 48 MAIN SWITCH NOTE: The sequence ensures that the condensate siphon is not empty after long OFF periods. GREEN LIGHT CENTRAL HEATING DEMAND LOCKOUT 5th Attempt? Boiler unused for long period?
  • Page 49 NOTE: This diagram is a simplification of the function of the boiler (for example; the hot water demand is a complex decision based on flow rates and existing temperatures etc.). MAIN SWITCH GREEN LIGHT Check tank temperature. Is it still near set point? GAS VALVE OFF.
  • Page 50 NOTE ; This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent. The electronic control system for this boiler incorporates a two-digit display. This is used to show normal operating information (as described in other sections), but during a fault, also provides fault-code information to help provide fault...
  • Page 52 INSTRUCTION MANUAL INSTALLATION COMMISSIONING & SERVICING Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd.
  • Page 53 Greenstar Highflow 440 FLOOR STANDING RSF GAS-FIRED COMBINATION BOILER FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER THIS APPLIANCE IS FOR USE WITH NATURAL GAS OR LPG (Cat II 2H3P TYPE C13 & C33) NATURAL GAS: 47 311 82...
  • Page 54 LPG - Liquid Petroleum Gas CH - Central Heating DHW - Domestic Hot Water SEDBUK - Seasonal Efficiency of Domestic Boilers in the United Kingdom USER INSTRUCTIONS & WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04) CUSTOMER CARE GUIDE...

  • Page 55: Table Of Contents

    Summer mode, hot water only Frost protection Fault condition ENERGY SAVING TIPS ON ENERGY SAVING MAINTENANCE MAINTAINING YOUR APPLIANCE FAULT FINDING FAULT OR BREAKDOWN GUARANTEE YOUR GUARANTEE GUARANTEE REGISTRATION WORCESTER BOSCH GREENSTAR HIGHFLOW 440 CONTENTS 6 720 611 731a (08.04)

  • Page 56: Excellence Comes As Standard

    EXCELLENCE COMES AS STANDARD Thank you for purchasing a Greenstar Highflow 440 gas-fired condensing boiler manufactured by Worcester Bosch. The company prides itself on manufacturing boilers to the strictest quality control standards throughout every stage of production. Worcester Bosch has led the field...

  • Page 57: Safety Precautions

    Benchmark Log Book after each service The appliance contains no asbestos and no substances used in the construction process to contravene the COSHH Regulations (Control of Substances to Hazardous Health Regulations 1988) WORCESTER BOSCH GREENSTAR HIGHFLOW 440 SAFETY PRECAUTIONS 6 720 611 731a (08.04)

  • Page 58: General Notes

    This is quite normal. For further information contact Worcester Heat Systems Ltd. Technical Department. GENERAL NOTES WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04)
  • Page 59 Do not operate the appliance if the flue terminal fitted on the outside wall or roof is obstructed or damaged. WORCESTER BOSCH GREENSTAR HIGHFLOW 440 GENERAL NOTES 6 720 611 731a (08.04)

  • Page 60: Boiler Location And Clearances

    Minimum free air required for both vents: For air directly from outside: 148cm per vent. For air from internal space/room: 296cm per vent. WORCESTER BOSCH GREENSTAR HIGHFLOW 440 BOILER LOCATION AND CLEARANCES 6 720 611 731a (08.04)

  • Page 61: Controls

    12. FILLING LOOP CONNECTION 2 . P U L I F T REMOVE THE BOILER CASING FRONT PANEL TO GAIN ACCESS TO THE SYSTEM PRESSURE GAUGE & FILLING LOOP CONNECTION WORCESTER BOSCH GREENSTAR HIGHFLOW 440 CONTROLS 6 720 611 731a (08.04)

  • Page 62: Operating The Appliance

    Set room thermostat to the desired room temperature. Set temperature driven control unit, if fitted. Refer to the instructions with the control. Set the thermostatic radiator valves to the desired settings. OPERATING THE APPLIANCE WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04)

  • Page 63: Setting The Hot Water Temperature

    In this state the boiler will not fire when there is a DHW demand but will produce a limited amount of warm water depending on store temperature. During this demand the boiler pump will be operated. WORCESTER BOSCH GREENSTAR HIGHFLOW 440 OPERATING THE APPLIANCE 6 720 611 731a (08.04)

  • Page 64: Summer Mode, Hot Water Only

    If the fault remains and cannot be cleared: Call Worcester Heat Systems Ltd. for assistance, giving a description of the fault and, if possible the fault code from the fascia display. OPERATING THE APPLIANCE WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04)

  • Page 65: Tips On Energy Saving

    WORCESTER BOSCH GREENSTAR HIGHFLOW 440 TIPS ON ENERGY SAVING 6 720 611 731a (08.04)
  • Page 66 The minimum level of control for a combi boiler or fully pumped system is a programmer, interlocking room thermostat and thermostatic radiator valves. TIPS ON ENERGY SAVING WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04)
  • Page 67 If you decide to turn off radiators in unused rooms, spare bedrooms etc., you may experience slightly lower room temperatures in rooms adjacent to unheated rooms. WORCESTER BOSCH GREENSTAR HIGHFLOW 440 TIPS ON ENERGY SAVING 6 720 611 731a (08.04)

  • Page 68: Maintaining Your Appliance

    Worcester Bosch service contract, please tick the appropriate box on your warranty registration card. If your Greenstar Highflow 440 should fail to operate correctly or requires servicing please contact the Worcester Bosch Service Department, see inside front cover for details.

  • Page 69: Fault Finding

    Momentary power failure master switch, wait a few does not respond seconds then switch on again Check setting Hot water temperature Hot water temperature too low dial set too low WORCESTER BOSCH GREENSTAR HIGHFLOW 440 FAULT FINDING 6 720 611 731a (08.04)

  • Page 70: Fault Or Breakdown

    (no hot water and/or heating). Invoices for attendance and repair work carried out on this appliance by any third party will not be accepted. FAULT OR BREAKDOWN WORCESTER BOSCH GREENSTAR HIGHFLOW 440 6 720 611 731a (08.04)

  • Page 71: Your Guarantee

    This guarantee applies only to equipment purchased and used in the United Kingdom. This guarantee does not affect your statutory rights. WORCESTER BOSCH GREENSTAR HIGHFLOW 440 YOUR GUARANTEE 6 720 611 731a (08.04)

  • Page 72: Guarantee Registration

    Guarantee Registration Card within 14 days of purchase. Returning the card will register you as the owner of your new Greenstar Highflow 440 appliance and will assist us in maintaining an effective and efficient customer service by establishing a reference and permanent record for your boiler.
  • Page 73 USER INSTRUCTIONS & CUSTOMER CARE GUIDE EXCELLENCE COMES AS STANDARD Worcester Heat Systems Ltd (Bosch Group) Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 www.worcester-bosch.co.uk 6 720 611 731a (08.04)

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