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Worcester Greenstar Highflow 440, Instruction Manual, Page: 3 / 52

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Worcester Greenstar Highflow 440 Instruction Manual Download Page 3

INSTALLATION & SERVICING INSTRUCTIONS

CONTENTS

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CONTENTS

1

6-720-611-730b (12.05)

SAFETY & REGULATIONS

SAFETY PRECAUTIONS 

2

INSTALLATION REGULATIONS

2

APPLIANCE INFORMATION

GENERAL INFORMATION

3

TECHNICAL DATA

4

LAYOUT & COMPONENTS

5

PRE-INSTALLATION

CLEANING PRIMARY SYSTEMS

6

MAINS SUPPLIES

7-8

WATER SYSTEMS & PIPEWORK

9-10

CONDENSATE & PRESSURE RELIEF PIPEWORK

11

BOILER LOCATION & CLEARANCES

12-13

MOUNTING FRAME CONNECTIONS

14

FLUE OUTLET POSITIONS

15

FLUE OPTIONS

16

INSTALLATION

UNPACKING THE BOILER

17

MOUNTING FRAME FIXING / FLUE OPENING

18

MOUNTING FRAME CONNECTIONS

19

FLUE INSTALLATION

20-21

CONDENSATE, GAS & WATER CONNECTIONS

22

FLUE CONNECTIONS

23

PRESSURE RELIEF VALVE OUTLET

24

ELECTRICS

25-26

COMMISSIONING

PRE-COMMISSIONING CHECKS

27

FILLING THE SYSTEM

28

STARTING THE APPLIANCE

29

WATER TREATMENT

30

FINISHING COMMISSIONING

31

SERVICING & SPARES

INSPECTION AND SERVICE

32-35

REPLACEMENT OF PARTS

36-40

SETTING THE GAS/AIR RATIO 

41-42

SHORT PARTS LIST

43

CONVERSION KITS

L.P.G. CONVERSION

44

FAULT FINDING & DIAGRAMS

ELECTRICAL WIRING DIAGRAM

45

CENTRAL HEATING FUNCTION

46

DOMESTIC HOT WATER FLOW FUNCTION

47

FAULT FINDING

48- 49

Summary of Contents for Greenstar Highflow 440

Page 1: ...PPLIANCE IS FOR USE WITH NATURAL GAS OR L P G Cat II 2H3P TYPE C13 C33 NATURAL GAS G20 GC NUMBER 47 311 82 LIQUID PETROLEUM GAS G31 GC NUMBER 47 311 83 GREENSTAR HIGHFLOW 440 FLOOR STANDING RSF GAS FIRED COMBINATION BOILER FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER ...

Page 2: ...adiator Valve IP Ingress Protection RS Room sealed flue N A Not allowed SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom Store the appliance in a dry area prior to installation THIS BOILER IS NOT SUITABLE FOR ROOF SPACE INSTALLATION IMPORTANT HANDLING INSTRUCTIONS It is advised that two people are involved in the transfer of the packaged appliance from the van to the point of ...

Page 3: ...NTING FRAME CONNECTIONS 14 FLUE OUTLET POSITIONS 15 FLUE OPTIONS 16 INSTALLATION UNPACKING THE BOILER 17 MOUNTING FRAME FIXING FLUE OPENING 18 MOUNTING FRAME CONNECTIONS 19 FLUE INSTALLATION 20 21 CONDENSATE GAS WATER CONNECTIONS 22 FLUE CONNECTIONS 23 PRESSURE RELIEF VALVE OUTLET 24 ELECTRICS 25 26 COMMISSIONING PRE COMMISSIONING CHECKS 27 FILLING THE SYSTEM 28 STARTING THE APPLIANCE 29 WATER TRE...

Page 4: ... statutory rights SERVICING Advise the user to have the system regularly serviced by a competent qualified engineer such as British Gas or CORGI registered personnel using approved spares to help maintain the economy safety and reliability of the appliance IMPORTANT The service engineer must complete the Service Record in the Benchmark Log Book after each service Failure to install appliances corr...

Page 5: ...e wired and pre plumbed Galvanised steel inner frame Bosch Heatronic control system Automatic ignition Direct burner ignition electrodes Built in frost thermostat Built in fault finding diagnostics Modulating automatic gas valve Combustion air fan with speed regulator CH temperature sensor control DHW flow sensor temperature control Integral water circulating pump with anti seizure protection Seal...

Page 6: ...2 MJ m m h 3 1 Propane Gas LPG CVnet 88 MJ m kg h 2 3 Gas supply pressure Natural Gas G20 CVnet 34 02 MJ m mb 20 LPG Propane Gas G31 CVnet 88 MJ m mb 37 Flue Flue Gas Temp 80 60 C rated min load C 67 55 67 55 Flue Gas Temp 40 30 C rated min load C 43 32 43 32 Residual delivery pressure inc pressure drop in air intake duct Pa 80 80 CO2 level at max rated heat output 9 2 10 8 CO2 level at min rated ...

Page 7: ... CONDENSATE TRAP 28 AIR GAS ADJUSTMENT SCREW SEALED 29 HEAT EXCHANGER 30 RETAINING CLIP FOR EXPANSION TANK 31 GAS BURNER 32 COMBUSTION AIR FAN 33 FLUE BLANKING PLATE 34 CASING SUPPORT STRUT 35 FLUE GAS SAMPLING POINT 36 PRESSURE RELIEF VALVE 37 CASE KNOCK OUT PANEL FLUE 38 AUTO AIR VENT 39 DHW WATER STORAGE TANK 40 DATA LABEL 100mmØ HORIZONTAL CONDENSEFIT HIGHFLOW FLUE COMPONENTS Kit Part No 7 719...

Page 8: ...NING THE SYSTEM ENSURE THE SYSTEM AND PIPEWORK IS IN GOOD WORKING ORDER USE THE EXISTING BOILER CIRCULATING PUMP WHERE POSSIBLE OR USE A POWER FLUSHING MACHINE TO AID THE CLEANSING PROCEDURE BEFORE INSTALLING A NEW BOILER CLEANING THE PRIMARY SYSTEM Fill the system with cold mains water to the recommended pressure and check for leaks Open all drain cocks and drain the system Close drain cocks and ...

Page 9: ...the water main where possible Water Mains Pressure Minimum dynamic mains water pressure 1 2 bar for maximum performance Maximum mains fed water pressure 10 bar If necessary fit a pressure reducing valve 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...

Page 10: ...n and connection of the gas supply to the boiler must be in accordance with BS6891 Under no circumstances should the diameter of the gas supply pipe be less than that of the appliance inlet connection The meter or regulator and pipework to the boiler must be checked preferably by the gas supplier to ensure it is in good working order and can meet the gas flow and pressure requirements in addition ...

Page 11: ...ther valves should conform to BS1010 On new installations TRV s must be used on all radiators except the radiator where the room thermostat is sited this must be fitted with lockshield valves and left open All installations should have TRV s fitted to radiators within the sleeping accommodation Drain cocks are required at all the lowest points on the system Air vents are required at all high point...

Page 12: ...e used with the approval of the local water authority and must be the over rim flushing type with shrouded outlets to prevent the fitting of hand held sprays DOMESTIC HOT WATER Taps and mixing valves must be capable of sustaining a pressure up to 10 bar Hot water temperature and flow rate are affected by the size and insulation of pipework making up the distribution system and are controlled by th...

Page 13: ... vent stack F Servicable condensate trap 75mm min G 300mm x 100mmØ sealed plastic tube H Ground level J Drainage holes 50mm from base of tube 12mmØ at 25mm centres facing away from building K Limestone chippings PRESSURE RELIEF PIPEWORK 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 Car...

Page 14: ...COMPARTMENT CLEARANCES Diagram c shows the minimum space required to install and service the boiler inside an unvented compartment 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 d AIRING CUPBOARD CLEARANCES Diagram d opposite show...

Page 15: ... 2 or in the shaded areas shown on the diagrams opposite 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 600mm 2250mm 600mm 750mm A 1 1 2 3 2 3 0 2250mm 750mm 3 600mm 600mm radius A A Bath or shower cubicle zone 0 1 1 2 2 3 0 ...

Page 16: ...umbing manifold The system can be filled without the boiler being connected using an optional charging link assembly B The valves can be closed enabling the DHW and CH systems to be tested The boiler can be installed at a later date RUNNING PIPES BEHIND THE BOILER The frame should sit against the wall not the skirting board with enough room for the pipework Do not cross a pipe over another The are...

Page 17: ...ith fanned draught DRWG REF TERMINAL POSITION KW INPUT EXPRESSED IN NET DISTANCE A1 Directly below an opening air brick opening windows etc 300mm B1 Above an opening air brick opening window etc 300mm C1 Horizontally to an opening air brick opening window etc 300mm D Below gutters soil pipes or drain pipes 75mm E Below eaves 200mm F2 Below balconies or car port roof lowest point 200mm G From a ver...

Page 18: ...ight flue length including the terminal is Horizontal 60 100mm 4000mm Horizontal 80 125mm 13000mm Vertical 60 100mm 6400mm Vertical 80 125mm 15000mm Then reduce the total straight flue length for each extra flue bend excluding the flue elbow by 2000mm for 90 1000mm for 45 Flue Extension lengths Horizontal Vertical 60 100mm 1000mm Horizontal Vertical 80 125mm 1030mm Flue Terminal lengths Horizontal...

Page 19: ...g the board to the pallet Slide the boiler and board off the pallet 4 Grip the outer sides of the front panel D and pull up and away from retaining lugs E Remove securing screw at the front of the boiler Remove remaining screws at the rear of the boiler The boiler is mounted on small wheels and two people are recommended to move the boiler from the board taking care not to damage the panels or the...

Page 20: ...s from the site FLUE OPENING Follow the diagram opposite to mark the centre of the flue 1 2 for rear opening 2 3 for side opening or 1 4 for top opening 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 a...

Page 21: ...BSERVE ALL RELEVANT SAFETY PRECAUTIONS GAS AND WATER CONNECTIONS Ensure all pipework is clean and each pipe is in the correct position as shown opposite Push in each pipe in turn and tighten the fitting to secure A CH flow 22mm B DHW flow 15mm C Gas inlet 22mm D Mains water inlet 15mm E CH return 22mm F Mounting frame MOUNTING FRAME CONNECTIONS F A B C D E 22mm 15mm ...

Page 22: ...uare taking care not to distort the tubes Remove any burrs REDUCING AN EXTENDED FLUE LENGTH Only cut straight extension tubes Mark flue to measure and cut both inner and outer tubes square taking care not to distort the tubes Remove any burrs ASSEMBLING THE FLUE 1 Slide inner collar G onto terminal H 2 Additional extensions or bends Push fit all extensions bends terminal together and secure connec...

Page 23: ...nhooked by removing the retaining screw on the hinge lowered and moved to the side Take care not to overstretch the flexible pipe connections 5 Release four screws H to remove the inner case cover J CONVERT FROM REAR FLUE OUTLET 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 Remove one of the outer casing knock ou...

Page 24: ...ny external condensate pipework should be protected with weather resistant insulation to help prevent freezing CAUTION ISOLATE THE MAINS GAS AND WATER SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS GAS AND WATER CONNECTIONS Remove the transit bungs L from the gas water connections A B C D E on the boiler and mounting frame Note that surplus water may be present due to ...

Page 25: ...screws A to secure flue H to boiler internal casing B 3 Insert and push elbow E into flue adapter F 4 Pull the elbow extension tube G and clip to flue elbow E ensuring that the sealing rings J are still in contact with the inner flue tube 5 Refit inner case cover L Secure using 4 screws K 6 Swing expansion vessel M inwards and secure with clip N 7 Ensure that the slope of the terminal outlet outsi...

Page 26: ...h of 15mm copper pipe A to the relief valve drain pipe B 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 Auto air vent Remove the auto air vent cap C and discard B C A C ...

Page 27: ...move link F from connector block ST4 Connect NEUTRAL wire to terminal Ns Connect LIVE wire to terminal Ls Connect SWITCHED LIVE wire to terminal LR 10 External 230v programmer DHW CH Remove links F G from connector blocks ST4 and ST8 Connect NEUTRAL wire to ST4 terminal Ns Connect LIVE wire to ST4 terminal Ls Connect CH SWITCHED LIVE to ST4 terminal LR Connect DHW SWITCHED LIVE to ST8 RH pole 11 1...

Page 28: ...dge of panel A and clip in at base Fitting an optional programmer 3 Pull tab C to remove the programmer blanking plate D 4 Attach programmer connector E onto circuit board F at ST5 shown with a clock symbol 5 Locate programmer lower lug G into control panel slot H and check for trapped wires before clipping the top lug of the programmer J into the control panel 3 D C A B 1 2 F E G H J 5 4 ...

Page 29: ...ections and rectify any leaks 3 Check the flue is correctly fitted and the connections are secure 4 Check the condensate pipework is correctly fitted and connected 5 Check the CH circulating pump is set to 3 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 th...

Page 30: ...he expansion vessel to allow for pressure adjustment if required 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 6 Briefly open the pressure relief valve to test its operation 7 Close the tank drain valve Disconnect the integral filling loop ...

Page 31: ...bar IMPORTANT Do not continue commissioning until the correct gas pressure is achieved Measure the gas rate at the gas meter after 10 minutes operation at maximum see Technical Data in the Appliance Information section Switching on the central heating 3 Turn the CH flow temperature control G clockwise Display C shows the CH flow temperature Control No CH flow temperature 1 approx 35 C 2 approx 43 ...

Page 32: ...reezing conditions to the heating system in accordance with the manufacturers instructions 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 Unscrew the tank drain cap and connect the integral filling loop Open the flow and tank drain valves as sho...

Page 33: ...G Hook top edge of panel F onto the retaining ledge H Lower into position to secure HANDOVER Complete the Benchmark log book Set up the controls and show the user how to operate all the controls shown in the User Guide Instruct the customer how to repressurise the system If the appliance is unused and exposed to freezing conditions advise the customer of the precautions necessary to prevent damage...

Page 34: ... the appliance is clear See Boiler Location Clearances under the Pre Installation section for compartment clearances Check all the joints and connections in the system and remake any that show signs of leakage Refill and re pressurise the system See Filling the System and Water Treatment under the Commissioning section Operate the appliance and take note of any irregularities Call up the last faul...

Page 35: ... to swing control panel assembly D outwards to its full extent 3 Pull clip E outwards to release expansion vessel F 4 Swing expansion vessel F outwards 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 5 Release four screws G to remove th...

Page 36: ...t at max rated heat output using an electronic manometer See Setting the gas air ratio The heat exchanger should only be cleaned if the pressure is 2 2mbar or less 3 Remove the cleaning access cover B seal C and metal plate D securing it if present 4 Unscrew the condensation trap and place a suitable container underneath To Remove Condensate trap Remove access panel E at the base of the inner casi...

Page 37: ... the components Do not use a wire brush Re assemble burner in reverse order using a new seal G Adjust gas air ratio See Setting the gas air ratio MAX PRESSURE When the heating system water is at maximum temperature 2 65 bar must not be exceeded If this pressure is exceeded then an extra expansion vessel must be fitted into the system return as close as possible to the appliance If the system does ...

Page 38: ...connector earth lead 3 Remove retaining screw F to swing control panel assembly A outwards to its full extent Unscrew earth lead 4 Remove retaining screw G and lift control panel assembly A away from the support hinge 5 Unscrew fixing screws H from cover plate Prise off cover plate J Pull off transformer K Remove PCB holder L Remove the PCB control board M Fuses Remove the connections cover The fu...

Page 39: ... Take care as there may be condensate remaining in the pipe Carefully remove the condensate pump G from the boiler and pour any excess condensate into a suitable container for safe disposal Circulating pump Unscrew the pump union nut N remove clip P at pump outlet Carefully remove the pump M and disconnect the electric leads Alternatively Release the 4 Allen screws Q to remove and replace the pump...

Page 40: ...e supplied Re assemble Tank overheat thermostat D Remove screws retaining plastic cover Remove cover and disconnect 2 electrical connections Unscrew 2 hexagon studs Replace sensor coating surface with paste supplied Re assemble Flow sensor flow regulator assembly E Shut off mains water at inlet valve and drain DHW circuit Disconnect inline connector Remove 2 retaining clips F Remove flow sensor as...

Page 41: ...uired by the system Pressure relief valve Drain the appliance Disconnect drain pipe from valve D Undo nut retaining valve to flow pipe Remove valve Replace sealing washer and fit a new valve Condensate trap Move control and pressure vessel into service position Remove inner case door Remove access panel E at the base of the inner casing Remove screw retaining trap F and push trap downwards until c...

Page 42: ...fully the rear securing nut E Remove the burner coverplate F Remove the burner skin G Re assemble the new burner in reverse order inspect seal H for damage and replace if necessary Check CO2 settings See setting the gas air ratio Primary heat exchanger Isolate appliance from the power supply Turn off all isolation valves Drain down appliance Move control and pressure vessel into service position T...

Page 43: ...ied out by a competent person equipped with a combustion analyser conforming to BS 7927 and competent in its use 1 Switch off the appliance at the master switch Remove the outer case Switch on the appliance at the master switch Unscrew sealing plug from flue gas testing point A Connect testing probe to the flue gas testing point 2 Press and hold button B until the display C shows button B will ill...

Page 44: ...ated heat output Measure the CO level If the CO level is over 200ppm the gas volumetric flow rate is too high Reduce the gas flow rate on the gas flow restrictor F until the CO level is below 100ppm Re adjust the CO2 level if necessary Re check the levels at min and max rated heat output and re adjust if necessary 8 Turn the temperature control E anti clockwise as far as the stop so the display sh...

Page 45: ...hanger Part No 8 722 963 858 0 GC No H08 291 10 Thermistor sensor Tank Part No 8 716 142 319 0 GC No 379 785 11 Overheat thermostat Tank Part No 8 716 103 217 0 GC No E82 394 12 DHW thermister Part No 8 716 142 302 0 GC No 375 696 13 Heat exchanger Part No 8 715 406 975 0 GC No H21 236 14 Gas valve Part No 8 747 003 773 0 GC No H08 337 15 Condensing Pump Part No 8 717 204 445 GC No H21 238 16 Pres...

Page 46: ...1 L P G code plug number 422 Reposition panel B and secure with screw Clip cover panel A back into place Change gas pipe 5 Rotate gas pipe D anti clockwise pull upwards and remove gas pipe 6 Replace with new conversion gas pipe E push downwards and rotate clockwise to lock into position Conversion label Replace existing label with new conversion label Adjust the CO level See Setting the gas air ra...

Page 47: ...Flow turbine Pin 16 black Pin 19 red Pin 20 yellow 22 Central heating NTCsensor Pin 12 red Pin 13 red 23 Flame sensing electrode Pin 11 blue 24 Flue gas temp limiter Pin 6 orange 25 Heatex temp limiter Pin 5 green 26 Under floor module Pin 3 black Pin 4 red 27 Fan condensate pump 230 VAC 28 Solenoid valve 1 Pin 7 brown Pin 8 brown 29 Solenoid valve 2 Pin 9 violet Pin 10 violet 30 Connector for pro...

Page 48: ...lises at start speed for 5 10 seconds Fan reduces over 15 seconds Fan min speed for 90 seconds Boiler unused for long period Boiler operates to match system load and CH control setting CH demand satisfied Gas valve closes Red light OFF Pump and fan run for up to 3 mins YES NO Fan run to purge gas from burner 5th Attempt NO LOCKOUT YES Burner remains OFF until flow temperature is below set value Pu...

Page 49: ...demand Hot water demand overrides all other demands Pump ON Diverter valve to hot water position Ignition sequence Modulate fan heat input to charge tank to temperature set by user control 65 C 75 C Minimum heat input until 50 C if boiler unused for long period Tank satisfied Check tank temperature Is it still near set point Ignition sequence Modulate fan heat input to maintain delivered temperatu...

Page 50: ... and connections Fan Otherwise replace control board Safety overheat thermostat for underfloor heating system if fitted Otherwise fit link Mains supply to condensate pump Condensate Pump unit Continuity of all cables to pump unit Tank sensor is correctly fixed to tank Wiring and connections to sensor CH flow sensor 8000 20000 ohms at room temperature Wiring and connections to sensor All air vented...

Page 51: ... at ST4 CH channel of facia mounted programmer if fitted CH control knob position Flow turbine Demand signal from DHW timer or link fitted at ST 8 DHW channel of facia mounted programmer if fitted 230V fuse S11 Transformer Otherwise replace control board Fan fan harness Sensors not fixed or out of specification Gas pressure blockage Water pressure blockage C02 mix Flue blockage Spark electrodes ca...

Page 52: ...orcester Bosch Group Cotswold Way Warndon Worcester WR4 9SW INSTRUCTION MANUAL INSTALLATION COMMISSIONING SERVICING Part Number Worcester Bosch Group is a trading name of BBT Thermotechnology UK Ltd www worcester bosch co uk ...

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