Worcester Greenstar Highflow 440 Instruction Manual

Floor standing rsf gas-fired combination boiler

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Page 1 GREENSTAR HIGHFLOW 440 INSTRUCTION MANUAL INSTALLATION COMMISSIONING & SERVICING Supplied By www.heating spares.co Tel. 0161 620 6677...
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 Supplied By www.heating spares.co Tel. 0161 620 6677...
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 5 Supplied By www.heating spares.co Tel. 0161 620 6677...
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 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 7 Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 10 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 11 • Do not use galvanised pipes or radiators. TYPICAL SEALED SYSTEM: Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 12 Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel.
Page 16 Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
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 21 Supplied By www.heating spares.co Tel. 0161 620 6677...
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: Supplied By www.heating spares.co Tel.
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 25 Supplied By www.heating spares.co Tel. 0161 620 6677...
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 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 28 Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
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 33 Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
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: Supplied By www.heating spares.co Tel.
Page 37 Do not use a wire brush. Supplied By www.heating spares.co Tel. 0161 620 6677...
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. Supplied By www.heating spares.co Tel. 0161 620 6677...
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): Supplied By www.heating spares.co Tel. 0161 620 6677...
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'. Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 42 Supplied By www.heating spares.co Tel. 0161 620 6677...
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 Supplied By www.heating spares.co Tel. 0161 620 6677...
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? Supplied By www.heating spares.co Tel. 0161 620 6677...
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...
Page 51 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 52 INSTRUCTION MANUAL INSTALLATION COMMISSIONING & SERVICING Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. Supplied By www.heating spares.co Tel. 0161 620 6677...