Worcester Greenstar Highflow 550CDi Instruction Manual Download Page 3

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INSTALLATION & SERVICING INSTRUCTIONS

CONTENTS

AFET

Y &

REGUL

TIONS

& DIA

GRAMS

APPLIANCE

INF

ORMA

TION

PRE-

INS

TALL

TION

INS

TALL

TION

SER

VICING

& SP

ARES

ONVERSION

KIT

CONTENTS

8 716 115 219c (03.2010)

SAFETY & REGULATIONS

SAFETY PRECAUTIONS

INSTALLATION REGULATIONS

APPLIANCE INFORMATION

GENERAL INFORMATION

TECHNICAL DATA

LAYOUT & COMPONENTS

PRE-INSTALLATION

CLEANING PRIMARY SYSTEMS

MAINS SUPPLIES

WATER SYSTEMS & PIPEWORK

CONDENSATE PIPEWORK

PRESSURE RELIEF PIPEWORK

BOILER LOCATION & CLEARANCES

MOUNTING FRAME CONNECTIONS

TERMINAL OUTLET POSITIONS

ROOM SEALED FLUE OPTIONS

INSTALLATION

UNPACKING THE BOILER

MOUNTING FRAME FIXING / FLUE OPENING

MOUNTING FRAME CONNECTIONS

FLUE LENGTHS/FLUE MEASURING & CUTTING

FLUE MEASURING & CUTTING

FLUE INSTALLATION

STANDARD FLUE INSTALLATION

EXTENDED FLUE INSTALLATION

FLUE TERMINAL PLUME MANAGEMENT

CONDENSATE, GAS & WATER CONNECTIONS

PRESSURE RELIEF VALVE OUTLET

ELECTRICAL

COMMISSIONING

PRE-COMMISSIONING CHECKS

FILLING THE SYSTEM

WATER TREATMENT

STARTING THE APPLIANCE

FINISHING COMMISSIONING

SERVICING & SPARES

INSPECTION AND SERVICE

REPLACEMENT OF PARTS

SETTING THE GAS/AIR RATIO

SHORT PARTS LIST

CONVERSION KITS

L.P.G. CONVERSION

FAULT FINDING & DIAGRAMS

ELECTRICAL WIRING DIAGRAM

CENTRAL HEATING FUNCTION

DHW FUNCTION

FAULT FINDING

BENCHMARK LOG BOOK AT REAR OF MANUAL

Summary of Contents for Greenstar Highflow 550CDi

Page 1: ...L GAS GREENSTAR HIGHFLOW 440CDi GC NUMBER 47 406 24 GREENSTAR HIGHFLOW 550CDi GC NUMBER 47 406 25 LIQUID PETROLEUM GAS GREENSTAR HIGHFLOW 440CDi GC NUMBER 47 406 26 GREENSTAR HIGHFLOW 550CDi GC NUMBER...

Page 2: ...e 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 at least two people...

Page 3: ...TIONS 18 INSTALLATION UNPACKING THE BOILER 19 MOUNTING FRAME FIXING FLUE OPENING 20 MOUNTING FRAME CONNECTIONS 21 FLUE LENGTHS FLUE MEASURING CUTTING 22 FLUE MEASURING CUTTING 23 FLUE INSTALLATION 25...

Page 4: ...ms must not be modified in any way other than as described in the fitting instructions Any misuse or unauthorised modifications to the appliance flue or associated components and systems could invalid...

Page 5: ...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 Mod...

Page 6: ...ltr min 14 19 6 14 19 6 Time to heat tank 15 C to 65 C mins 13 13 13 13 Gas flow rate Max 10 minutes from lighting Natural Gas G20 m2 h 3 1 4 4 Propane Gas LPG kg h 2 3 3 2 Gas supply pressure Natural...

Page 7: ...DHW OUTLET 24 GAS ISOLATION VALVE 25 MAINS WATER INLET ISOLATION VALVE 26 CH RETURN ISOLATION VALVE 27 RUNNER WHEEL ON MOUNTING FRAME 28 OPTIONAL FILLING LINK WITH PRESSURE GAUGE PART NO 7 716 192 599...

Page 8: ...ARE 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 SY...

Page 9: ...s 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 as...

Page 10: ...on 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 connectio...

Page 11: ...n the sleeping accommodation Drain cocks are required at all the lowest points on the system Air vents are required at all high points on the system SEALED PRIMARY SYSTEM Where the system volume is mo...

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...

Page 13: ...outlet and should take the shortest practicable route The pipework must follow one of the options shown opposite or discharge directly into a vent stack min 450mm above pipe invert or into a gully be...

Page 14: ...ny electrics or other hazard preferably to an external drain or soakaway Pipe A should be finished with a partial bend near the outlet to face the external wall as shown to help prevent freezing A Dra...

Page 15: ...required to install service and maintain the boiler and any ancillary equipment If fitting the boiler into an airing cupboard use a non combustible perforated material maximum hole sizes of 13mm to se...

Page 16: ...de the shaded area Additional RCD Residual Current Device protection may be required Refer to the latest IEE wiring regulations 4 AIRING CUPBOARD CLEARANCES Diagram d opposite shows the minimum space...

Page 17: ...ng 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...

Page 18: ...0mm to an open flue 7 1 500mm between a vertical flue terminal and a window or dormer window 8 400mm from a pitched roof or in regions with heavy snow fall 500mm 9 The flue cannot be lower than 1 000m...

Page 19: ...measurement can be reduced to 150mm providing the flue exhaust outlet has a 300mm clearance Plume kits running horizontally must have a 10 degree fall back to the boiler for proper disposal of conden...

Page 20: ...duce 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 950mm Horizontal Vertical 80 12...

Page 21: ...pallet Slide the boiler and board off the pallet 4 Grip the outer sides of the front panel pull and lift away from retaining lugs Remove securing screw at the front of the boiler from the pallet Remov...

Page 22: ...minimum service clearance as shown Ensure the mounting frame is level and mark fixing points C Secure mounting frame A to the floor using appropriate fixings not supplied Clear any debris from the sit...

Page 23: ...AND OBSERVE 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...

Page 24: ...th for a horizontal 60 100mm flue or a 60mm plume management system if used as stated in this Instruction Manual or Flue Manual Cutting the flue to an exact measure is not normally required as the tel...

Page 25: ...al assembly and discard To use terminal A without cutting remove the location lug D on the inner flue tube E and remove any burrs To reduce the terminal length further 4 Mark the length required for t...

Page 26: ...INSTRUCTIONS 24 FLUE MEASURING CUTTING 8 716 115 219c 03 2010 FLUE MEASURING CUTTING FLUE OUTLETS L or P 1 Remove seal B from flue adaptor A 2 Cut square to mark as shown deburr and clean 3 Replace se...

Page 27: ...sion 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 H to remove the...

Page 28: ...slide the outer wall seal K onto terminal B 3 Position terminal B through the flue opening in the wall to the outside of the building by the distance shown and then pull back to create a seal The flu...

Page 29: ...he boiler inner casing E Secure using three hexagonal bolts F 4 Push fit adaptor G into elbow H until secured by the clip 5 Push fit the adaptor G into the inner flue extension B and push elbow H into...

Page 30: ...1 Remove screws A and terminal end B 2 Spread the extra grease supplied into the groove that runs around the terminal outlet C to ensure a good seal is retained 3 Rotate the detached end section B to...

Page 31: ...r discharge into any open source including sink bath shower bidet toilet etc Note Any external condensate pipework should be protected with weather resistant insulation to help prevent freezing The fl...

Page 32: ...a length of 15mm copper pipe A to the P R V drain pipe B The P R V drain pipe B should be at least 15mm diameter and run down away from any electrics or other hazard IMPORTANT The pressure relief val...

Page 33: ...e clamp C into the control panel 6 Mains power 230 Volt connection ST10 Separate wires from cable end and strip to 6mm Connect LIVE wire to terminal L Connect NEUTRAL wire to terminal N Connect EARTH...

Page 34: ...matches that of the gas supply Turn on the main gas supply check the gas pipework connections and rectify any leaks 3 Check the flue is correctly fitted and the connections are secure 4 Check the con...

Page 35: ...Schraeder type valve is fitted to the 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 pressur...

Page 36: ...s are open Add a suitable inhibitor or combined inhibitor anti freeze if the system is exposed to freezing conditions to the heating system in accordance with the manufacturers instructions The inhibi...

Page 37: ...ter Measure the pressure with the boiler running at maximum Check the gas supply working pressure at the gas valve inlet point N G minimum 17 19 mbar nominal 18 mbar L P G 35 39 mbar nominal 37 mbar T...

Page 38: ...ler Secure with screw E 3 Locate bottom corners of the front panel F into retainers G Push top of door to engage clips HANDOVER Complete the Benchmark log book at the rear of the manual Set up the con...

Page 39: ...DHW circuits This is to allow sufficient time for setting procedure It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle on low heating demands Press and...

Page 40: ...at the terminal and terminal guard if fitted are clear and undamaged If the appliance is in a compartment or cupboard check that the specified service space around the appliance is clear See Boiler Lo...

Page 41: ...MITS IN THE SECTION AIR GAS RATIO NOTE Use a new seal when reassembling 4 Loosen any deposits in the heat exchanger from top to bottom using the cleaning blade Clean the heat exchanger from top to bot...

Page 42: ...ot 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 not retain the pressure the ex...

Page 43: ...he water circuits PCB CONTROL BOARD TRANSFORMER Access to boiler control components Remove screws A to release the cover from the controller PCB Fuse Remove the fuse B and replace with a spare that ar...

Page 44: ...densate tank 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 disposa...

Page 45: ...e with paste 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 s...

Page 46: ...on connection at the top of the vessel Set the pressure of the new vessel to that required by the system Pressure relief valve Drain the appliance Disconnect drain pipe from valve D Undo nut retaining...

Page 47: ...n 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 the new seal H for damage and replace if necessary After re...

Page 48: ...e gas valve Measure the inlet pressure it should be between 17 19mbar nominally 18 mbar for Natural Gas and between 35 39mbar nominally 37mbar for LPG 2 To adjust the CO2 it will be necessary to first...

Page 49: ...sensor primary Part No 8 714 500 087 0 GC No E74 536 9 Temperature limit Flue or heat exchanger Part No 8 722 963 858 0 GC No H08 291 10 Thermistor sensor DHW Part No 8 716 142 302 0 GC No 375 696 11...

Page 50: ...ode plug number 440CDi 1701 550CDi 1703 Refit panel B and secure with three screws A Change gas pipe 4 Rotate gas pipe D anti clockwise pull upwards and remove gas pipe 5 Replace with new conversion g...

Page 51: ...er option used with MT10 timer Neutral Live Neutral Live Colour sequence 7 8 9 230V AC 9V 25V B B 4 2 1 A F FLUE OVERHEAT STAT PRE WIRED LINK Wall plate contacts for FX controls B B DHW TEMPERATURE CO...

Page 52: ...u p r e n r u b m o r f h t 5 t p m e t t A LO K C T U O r e n r u B s e s i l i b a t s t r a t s t a r o f d e e p s 0 1 5 s d n o c e s F n a s e c u d e r r e v o 5 1 s d n o c e s r e l i o B d...

Page 53: ...e h d e r e v i l e d n i a t n i a m t e s e r u t a r e p m e t l o r t n o c r e s u y b 5 4 5 6 C n a f e t a l u d o M o t t u p n i t a e h c o t k n a t e g r a h t e s e r u t a r e p m e t l...

Page 54: ...of the pump inlet alarm level exceeded in the tank and removal or rinsing out of dirt foreign bodies BOILER FAULTS AND CONDITIONS Display code Fault description Check repair replace as necessary A5 Ta...

Page 55: ...manufacturer record the following CO2 OR CO ppm OR CO CO2 Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been ins...

Page 56: ...ignature SERVICE 7 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number CORGI ID Number Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed...

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Page 60: ...ester Bosch Group Cotswold Way Warndon Worcester WR4 9SW Tel 0844 892 9900 Fax 01905 754619 Worcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 8 716 115 219c 03...

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