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Worcester GREENSTAR HIGHFLOW 440CDI ERP, Инструкция по установке, наладке и обслуживанию

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SERVICING AND SPARES

Greenstar Highflow CDi 

ErP

 - 6720818077 (2016/04)

38

6.9.2

PCB Control board

Access to boiler control components

▶ Remove the screws [1] to release the cover from the controller.

PCB Fuse

▶ Remove the fuse [2] and replace with a spare that is clipped on the 

inside of the controller cover.

PCB

▶ Disconnect all electrical connections from the control board. 
▶ Remove the screws [3] retaining the rear panel of the control and 

remove the panel. 

▶ After re-assembly check CO/CO

2

 levels as described in the section 

“Setting the air/gas ratio” on page 36.

Fig. 59 PCB

6.9.3

Fan assembly:

▶ Undo lower pipe union on gas pipe [5]. 
▶ Twist the mixer unit [4] with gas pipe [5] to separate from fan [1]. 
▶ Remove fan lead and earth connector.

The earth connector has a positive clip fixing. 

▶ Remove fixing screws [3] attaching fan [1] to the burner cover [2]. 
▶ Remove fan [1].
▶ After re-assembly check that the CO/CO

2

 levels are as described in 

the section “Setting the air/gas ratio”.

Flap Valve:

▶ Undo lower pipe union on gas pipe [5].
▶ Remove pipe [5] by pushing upwards and towards the rear of the 

boiler.

▶ Twist the mixer unit [4] with gas pipe [5] to separate from the fan 

[1]. 

▶ Remove flap valve [6] from within fan intake [1] and replace. 

▶ After re-assembly check that the CO/CO

2

 levels are as described in 

the section “Setting the air/gas ratio” on page 36.

Fig. 60 Fan assembly

6.9.4

Condensate pump

▶ Disconnect electrical connections in control box, see wiring 

schematic in the ‘Fault finding and Diagrams’ section 7, page 43.

▶ Rotate the 15mm flexible tube [1] anti-clockwise and pull up to 

remove from the pump.

▶ Remove black flexible pipe [2] from condensate pump. Take care as 

there maybe condensate remaining in the pipe.

▶ Carefully remove the condensate pump [3] from the boiler and pour 

any excess condensate into a suitable container for safe disposal.

Fig. 61 Condensate pump

Do not attempt to service the fan assembly and flap 
valve if a CO/CO

2

 analyser is not available

.

6720818077-22.1Wo

T2.5A   H250V F1

T500mA  L250V F3

Spare Fuse order
T1.6A  L250V F2

1

2

3

Ensure the flap valve is fitted correctly with rubber flap 
upwards.

6720818079-10.1Wo

1

2

3

4

5

6

6720818079-12.1Wo

1

2

3

Содержание GREENSTAR HIGHFLOW 440CDI ERP

Страница 1: ...665 00 1Wo For sealed central heating systems and mains fed domestic hot water 6 720 818 077 2016 04 The appliances are for use with Natural Gas or L P G Cat II 2H3P type C13 C33 C53 Natural Gas Highf...

Страница 2: ...r treatment 27 5 4 Starting the appliance 27 5 4 1 Switching the appliance on off 27 5 4 2 Initialization 28 5 4 3 Display messages 28 5 5 Checking gas inlet pressure 28 5 5 1 Measuring the inlet pres...

Страница 3: ...used symbols These instructions are applicable to the Worcester appliance model s stated on the front cover of this manual only and must not be used with any other make or model of appliance These in...

Страница 4: ...repairs must only be performed by a competent registered gas engineer such as a Gas Safe registered engineer or British Gas engineer Advisetheusertohavethesystemservicedannuallybyacompetent registered...

Страница 5: ...28mm R1 BS5546 Installation of gas hot water supplies for domestic purposes EN12828 Central heating for domestic premises BS5440 1 Fluesandventilationforgasappliancesofratedheatingnot exceeding 70kW n...

Страница 6: ...eat exchanger STANDARD PACKAGE Fig 1 Standard package 1 Floor standing gas fired combination boiler for central heating and domestic hot water 2 Mounting frame complete with pre plumbing manifold asse...

Страница 7: ...ow rate Max 10 minutes from lighting The Gas Rate provided assumes the accepted NG averaged CV of 1040Btu ft3 38 76Mj m3 Natural gas network gas m3 h 3 19 4 29 Test gas G20 1014Btu ft3 37 78MJ m3 m3 h...

Страница 8: ...for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet P1 kW 9 6 9 6 10 0 10 0 Useful efficiency At rated heat output and high tempe...

Страница 9: ...i ErP 9 2 4 Layout and components Fig 2 Appliance layout 1 2 3 4 5 6 max 2 3 1 0 4 bar reset eco 1 2 3 4 e 6 max min 2 3 4 5 8 6 7 13 12 11 10 9 14 1 30 31 32 33 34 35 37 36 29 38 28 20 22 21 23 24 25...

Страница 10: ...flow sensor turbine 20 Boiler tank drain connection point for filling loop 21 DHW Temperature sensor 22 CH Flow isolation valve 23 DHW Outlet 24 Gas isolation valve 25 Mains water inlet isolation valv...

Страница 11: ...to BS EN50525 External 3A fuse to BS1362 The appliance must be earthed This appliance must not be connected to a three phase supply IPX4D The wiring between the appliance and the electrical supply mu...

Страница 12: ...sel 2 must be fitted as close as possible to the appliance in the central heating return Pressurise the extra expansion vessel 2 to the same value as the built in expansion vessel refer to table 6 Tec...

Страница 13: ...a minimum and any internal burrs on cut pipe work should be removed so that the internal pipe section is as smooth as possible Fitting an external air break Refer to figure 8 when a rain water down pi...

Страница 14: ...EN 1451 The connection to the PRV must be made in copper pipe Plastic pipework must be properly supported with a maximum 300 mm between supports to prevent sagging and run downwards away from the boil...

Страница 15: ...e boiler space by a non combustible partition as described in BS 6798 Fig 13 Airing cupboard clearances 3 6 3 Vented compartments If the clearances available are less than those stated for an unventil...

Страница 16: ...e accessible provision must be made for service and inspection Voids containing concealed flues must have at least one inspection hatch no less than 300mm square Flue joints within the void must not b...

Страница 17: ...NSTALLATION 6720818077 2016 04 Greenstar Highflow CDi ErP 17 350 mm 570 mm Flat roof 300 mm 500 mm Pitched roof 120 mm 120 mm 2 3 4 5 6 10 9 8 7 1 L L L L L L L L L L 6720648568 17 1Wo 120 mm 120 mm 1...

Страница 18: ...0mm to room sealed flue or 1 500 to an open flue 15 200mm below eaves and 75mm below gutters pipe and drains 16 The dimension below eaves balconies and car ports can be reduced to 25mm as long as the...

Страница 19: ...ny or overhang 9 1 200mm from an opening in a car port on the same wall e g door or window leading into the dwelling 10 600mm distance to a surface facing a terminal unless it will cause a nuisance BS...

Страница 20: ...mage the panels or the floor Slide the boiler off the pallet Pull the plastic strip plug 6 down to remove from the boiler pipe work GENERAL HANDLING GUIDELINES Lift only a manageable weight or ask for...

Страница 21: ...e 2 Manifold connections 3 Mounting frame fixing point 4 Wall 5 Gas and water pipe work not supplied 6 Boiler 4 3 Flue opening location Follow the figure 21 page 22 to mark the centre of the flue 1 2...

Страница 22: ...is Floor standing boiler NOTICE FLUE LENGTH Do not exceed the maximum straight length for a horizontal or vertical flue or a 60mm plume management system if used as stated in the relevant Installation...

Страница 23: ...r of debris and manoeuvre the boiler rear wheels onto the outer rails of the mounting frame 6 Take care when moving the boiler to position the front wheels onto the rails and align the gas water conne...

Страница 24: ...and Safety Executive guidance HSG85 UsingtestequipmentapprovedtoGS38confirmthat the electricity supply is disconnected The mains electrical supply to the boiler and system wiring centre must be commo...

Страница 25: ...imer ST10 Remove link Connect room thermostat LIVE supply to terminal LS Connect room thermostat LIVE return to terminal LR Connect room thermostat NEUTRAL to terminal NS Connect EARTH wire to the ear...

Страница 26: ...lling loop Refit tank drain cap The Automatic Air Vent will release any air trapped in the boiler Vent all radiators retighten the vent when completed Check the system and correct any leaks Fig 32 Int...

Страница 27: ...ppliance on off Turn on mains power supply Fig 34 3 Amp fused double pole isolator Turn on any external controls Set the TRV controls to maximum Set the clock programmer to continuously ON and the roo...

Страница 28: ...n except reset button Key acknowledgement after pressing two buttons simultaneously Table 14 Special display messages 1 2 3 4 5 6 max 2 3 1 0 4 bar 1 reset eco 1 2 3 4 e 6 max min 6720818977 15 1Wo 10...

Страница 29: ...mode the control will return to normal operation after 15 minutes Re seal the screw in the gas inlet pressure test point 5 5 2 Checking the gas rate The gas rate should be measured at the gas meter af...

Страница 30: ...st have been calibrated as specified by the manufacturer Theinstallermustbecompetentinthe use of the analyser Check and zero the analyser in fresh air as specified by the manufacturer The air gas rati...

Страница 31: ...how signs of leakage Refill and re pressurise if applicable as described in Commissioning 4 Operate the appliance and take note of any irregularities Call up the last fault stored by the Bosch Heatron...

Страница 32: ...Fig 44 Access for servicing 6 4 Fan pressure test Remove the test point cover Connect a manometer to the fan pressure test point 1 Set the boiler to maximum output After measurement replace test poin...

Страница 33: ...r button for more than 10 seconds Turn the temperature control to maximum and the boiler will go to maximum output Run the boiler at maximum output for at least 10 minutes After 10 minutes check the C...

Страница 34: ...ction Angle the trap backwards and remove from the boiler Release the cap and dispose of the debris into a suitable container Replace the cap Before replacing the trap fill with at least 250ml of clea...

Страница 35: ...fitted Fig 52 Remove metal plate Using the cleaning blade working from the bottom to the top to loosen any deposits in the heat exchanger Fig 53 Using the brush clean the heat exchanger from top to b...

Страница 36: ...the air gas ratio To set the maximum CO2 To adjust the CO2 it will be necessary to first operate the boiler at maximum output Press and hold down the Service engineer button 1 for 10 seconds Turn temp...

Страница 37: ...cehasstopped and remove the hose Fig 58 Draining the boiler GAS TYPE CO2 setting max CO2 setting min The CO2 should be measured after 10 minutes Greenstar HF 440CDi ErP Natural Gas 9 4 0 2 8 6 0 2 LPG...

Страница 38: ...lower pipe union on gas pipe 5 Remove pipe 5 by pushing upwards and towards the rear of the boiler Twist the mixer unit 4 with gas pipe 5 to separate from the fan 1 Remove flap valve 6 from within fa...

Страница 39: ...t electrical plugs 1 and 2 Remove the four Allen screws 6 and pull the pump head off Re assembly is a reverse of this procedure Fig 63 Pump and pump head removal 6 9 8 Sample points Air sampling point...

Страница 40: ...Unplug the connection to the pressure relief valve Release the pressure gauge from the clips on the rear of the control panel 6 9 12 Expansion vessel Drain the appliance Move the control panel into s...

Страница 41: ...ove the clips 3a castellated nuts 3b and springs 3c from the studs 3 Remove the nut 4a from the rear stud 4 Disconnect the mixer unit from the fan Remove the connector and earth wire from the fan Remo...

Страница 42: ...Flow NTC 8 714 500 087 0 GC No E74 536 Heat exchanger overheat stat 8 714 500 056 GC No H08 291 DHW NTC 8 716 142 302 0 GC No 375 696 Tank NTC 8 716 142 319 0 GC No 379 785 Tank OH stat 8 716 103 217...

Страница 43: ...l Live Neutral Live Colour sequence 7 8 9 B B 4 2 1 A F PRE WIRED LINK Wall plate contacts for Sense controls B B DHW TEMPERATURE CONTROL Earth PUMP SUPPLY FAN Colour sequence EXTERNAL FROST STAT OPTI...

Страница 44: ...ax BURNER LIT YES NO YES YES GREEN LIGHT ON Burner stabilises 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...

Страница 45: ...tank temperature Is it still near set point GAS VALVE OFF Continue fan 40 seconds Continue pump 15 seconds Tank satisfied Modulate fan heat input to charge tank to temperature set by user control 65 7...

Страница 46: ...od Internal boiler temperature rises above 12 C Central heating demand switches off Pump switches off after pump overrun period Central heating demand is activated Pump runs upto 3 minutes to dissipat...

Страница 47: ...l connections of EMS controls if fitted connections on the control board replace control board b1 Code plug not detected Insert code plug correctly test and replace as necessary b2 b3 b4 b5 b6 Data er...

Страница 48: ...s Cause Solution Green Red Off Off Mains supply not connected Power failure Connect mains supply Check mains and fuse circuit breaker Flashing Flashing Dry run possible air in pump Pump restarts autom...

Страница 49: ...6720818077 2016 04 Greenstar Highflow CDi ErP 49 Notes...

Страница 50: ...d 1RW UHTXLUHG RLOHU LQWHUORFN 3URYLGHG ALL SYSTEMS 7KH V VWHP KDV EHHQ XVKHG DQG FOHDQHG LQ DFFRUGDQFH ZLWK 6 DQG ERLOHU PDQXIDFWXUHU V LQVWUXFWLRQV Yes KDW V VWHP FOHDQHU ZDV XVHG KDW LQKLELWRU ZDV...

Страница 51: ...SKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDWH 2 SSP AND 2 W PLQ UDWH KHUH 3RVVLEOH 2 SSP AND 2 RPPHQWV 6LJQDWXUH SERVICE 04 DWH QJLQHHU QDPH RPSDQ QDPH 7HOHSKRQH 1R DV VDIH UHJLVWHU 1R 5HFRUG W PD UDW...

Страница 52: ...orcester Bosch Group is a brand name of Bosch Thermotechnology Ltd worcester bosch co uk 6 720 818 077 2016 04 WORCESTER BOSCH GROUP TECHNICAL SUPPORT 0330 123 3366 APPOINTMENTS 0330 123 9339 SPARES 0...

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