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  4. Greenstar Highflow 440
  5. Instruction Manual

Worcester Greenstar Highflow 440 Instruction Manual

Summary of Greenstar Highflow 440

  • Page 1

    Supplied by www.Heating spares.Co tel. 0161 620 6677 6-720-611-730b (12.05) instruction manual installation commissioning & servicing gb/ie the appliance 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 ...

  • Page 2

    Supplied by www.Heating spares.Co tel. 0161 620 6677 installation & servicing instructions contact information installation & servicing instructions contact information installation & servicing instructions 6-720-611-730b (12.05) please read these instructions carefully before starting installation....

  • Page 3

    Supplied by www.Heating spares.Co tel. 0161 620 6677 installation & servicing instructions contents saf et y & re gul at io ns fa ul t find in g & d ia g r am s appl ia n c e in for m at ion pr e- in s ta ll at io n in s ta ll at io n c o mmi s si o nin g s e rv ici ng & s par es con ve r s ion k it...

  • Page 4

    Supplied by www.Heating spares.Co tel. 0161 620 6677 saf et y & re gul at io ns installation & servicing instructions safety precautions installation regulations 2 safety precautions & installation regulations 6-720-611-730b (12.05) if you smell gas: don't smoke or strike matches. Don't turn electri...

  • Page 5

    Supplied by www.Heating spares.Co tel. 0161 620 6677 appl ia n c e in for m at ion installation & servicing instructions 3 general information general information 6-720-611-730b (12.05) standard package: a - floor standing gas fired combination boiler for central heating and mains fed domestic hot w...

  • Page 6

    Supplied by www.Heating spares.Co tel. 0161 620 6677 appl ia n c e in for m at ion installation & servicing instructions 4 technical data technical data 6-720-611-730b (12.05) description units natural gas l.P.G central heating max. Rated heat output net 40/30°c kw 31.2 31.2 max. Rated heat output n...

  • Page 7

    Supplied by www.Heating spares.Co tel. 0161 620 6677 appl ia n c e in for m at ion installation & servicing instructions 5 layout & components layout & components 6-720-611-730b (12.05) the diagram opposite shows the controls in the servicing position and excludes the outer case, inner covers and wi...

  • Page 8

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6 cleaning primary systems cleaning primary systems caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. Important: all the followi...

  • Page 9

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 7 mains supplies mains supplies electric supply: • supply: 230v - 50hz. • cable: pvc insulated 0.75mm² (24 x 0.2mm) temperature rated to 90°c. • protection ip20....

  • Page 10

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 6-720-611-730b (12.05) 8 mains supplies mains supplies gas supply: • boilers using ng must be connected to a governed meter. • lpg boilers must be connected to a...

  • Page 11

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 9 water systems & pipework primary system plastic pipework: • any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper or steel p...

  • Page 12

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 10 water systems & pipework filling primary systems: • the ch sealed system must be filled using a wras approved filling loop or comply with the diagram opposite...

  • Page 13

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 11 condensate & pressure relief pipework condensate & pressure relief pipework condensate pipework: • the condensate pipe must be a minimum of 21.5mmØ plastic pi...

  • Page 14

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 12 boiler location & clearances 6-720-611-730b (12.05) • this boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid non-combusti...

  • Page 15

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 13 boiler location & clearances boiler location & clearances shower / bathrooms: the boiler must not be installed in zones 0, 1 or 2 or in the shaded areas shown...

  • Page 16

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 14 mounting frame connections connections: water: 22mm and 15mm compression fittings gas: 22mm compression fitting. Pre-plumbing: • with the mounting frame (a) i...

  • Page 17

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 6-720-611-730b (12.05) 15 flue outlet positions flue outlet positions • flue terminals must be positioned to avoid combustion products entering into buildings. • the flue must be fitte...

  • Page 18

    Supplied by www.Heating spares.Co tel. 0161 620 6677 pr e- in s ta ll at io n installation & servicing instructions 16 room sealed flue options 6-720-611-730b (12.05) the diagrams (opposite) show the components used and the maximum flue length for each configuration of 100mm and 125mm flues. • only ...

  • Page 19

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 17 unpacking the boiler 6-720-611-730b (12.05) important: all the previous pre-installation sections must be read and requirements met before starting boiler or flue installation. Take care ...

  • Page 20

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 18 mounting frame fixing & flue opening 6-720-611-730b (12.05) caution: ensure there are no pipes, electric cables, damp proof course or other hazards before drilling. Safety: all relevant s...

  • Page 21

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 19 mounting frame connections 6-720-611-730b (12.05) caution: isolate the mains gas supply before starting any work and observe all relevant safety precautions. Gas and water connections: en...

  • Page 22

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 20 flue installation 6-720-611-730b (12.05) horizontal flue: (60/100mm diameter) for vertical flues and 80/125mmØ horizontal flues, please refer to separate flue kit instructions. Note: to e...

  • Page 23

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 21 flue installation flue installation 6-720-611-730b (12.05) 1 remove retaining screw (b) to swing control panel assembly (a) outwards to its full extent. 2 remove screws (c) from inside of...

  • Page 24

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 22 condensate, gas & water connections condensate, gas & water connections 6-720-611-730b (12.05) condensate connection: the condensate pump (g) fills up and periodically discharges through ...

  • Page 25

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 23 flue connections 6-720-611-730b (12.05) flue connections 1 align the flue retaining ring (d) to the boiler internal casing (b) locate screws (a) into keyhole slots (c) 2 rotate flue retai...

  • Page 26

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 24 pressure relief valve outlet 6-720-611-730b (12.05) pressure relief valve outlet fitting the relief valve drain pipe: connect a length of 15mm copper pipe (a) to the relief valve drain pi...

  • Page 27

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 25 electrics 6-720-611-730b (12.05) electrics danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Important: observe ele...

  • Page 28

    Supplied by www.Heating spares.Co tel. 0161 620 6677 in s ta ll at io n installation & servicing instructions 26 electrics 6-720-611-730b (12.05) electrics refit electric control panel covers: 1 refit panel (b) and secure with screw. 2 locate lugs at top edge of panel (a) and clip in at base. Fittin...

  • Page 29

    Supplied by www.Heating spares.Co tel. 0161 620 6677 c o mmi s si o nin g installation & servicing instructions 27 pre-commisioning checks 6-720-611-730b (12.05) pre-commisioning checks caution: isolate the mains supplies before starting any work and observe all relevant safety precautions. 1 check ...

  • Page 30

    Supplied by www.Heating spares.Co tel. 0161 620 6677 c o mmi s si o nin g installation & servicing instructions 28 filling the system 6-720-611-730b (12.05) filling the system 1 turn on the water main and open the system valves (align slot vertically). 2 open all radiator valves. 3 unscrew the tank ...

  • Page 31

    Supplied by www.Heating spares.Co tel. 0161 620 6677 c o mmi s si o nin g installation & servicing instructions 29 starting the appliance 6-720-611-730b (12.05) starting the appliance important: never run the appliance when the appliance/system is unpressurised or empty. Switching the appliance on/o...

  • Page 32

    Supplied by www.Heating spares.Co tel. 0161 620 6677 c o mmi s si o nin g installation & servicing instructions 30 water treatment 6-720-611-730b (12.05) water treatment important: debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use o...

  • Page 33

    Supplied by www.Heating spares.Co tel. 0161 620 6677 c o mmi s si o nin g installation & servicing instructions 31 finishing commissioning 6-720-611-730b (12.05) finishing commissioning 1 engage top panel (a) onto rear retainers (b) and lower front of panel into position. Secure with screws (c). 2 s...

  • Page 34

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 32 6-720-611-730b (12.05) inspection & service inspection & service important: any service work must be carried out by competent registered engineers, such as british gas or corgi regi...

  • Page 35

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 33 inspection & service 6-720-611-730b (12.05) inspection & service component access: 1 grip the outer sides of the front panel (a) and pull up and away from retaining lugs (b). 2 remo...

  • Page 36

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s erv ici ng & s par es installation & servicing instructions 34 inspection & service 6-720-611-730b (12.05) inspection & service checking the ionisation current: select service function 3.3 (use the service function procedure as described in serv...

  • Page 37

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 35 inspection and service 6-720-611-730b (12.05) inspection and service burner: check that the boiler is completely isolated from the gas supply. 1 remove the clips (a) and unscrew the...

  • Page 38

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par e s installation & servicing instructions 36 replacement parts 6-720-611-730b (12.05) replacement parts important: any service work must be carried out by competent registered engineers, such as british gas or corgi registere...

  • Page 39

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 6-720-611-730b (12.05) 37 replacement parts replacement parts fan assembly: undo lower pipe union on gas pipe (e). Remove fan lead and earth connector. The earth connector has a positi...

  • Page 40

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par e s installation & servicing instructions 38 replacement parts 6-720-611-730b (12.05) replacement parts sensors: check that the appliance is electrically isolated. Central heating flow temperature sensor (a): pull off the con...

  • Page 41

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 39 replacement parts 6-720-611-730b (12.05) replacement parts domestic hot water heat exchanger: before removing the heat exchanger shut the inlet valves, drain the hot water circuits ...

  • Page 42

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par e s installation & servicing instructions 40 replacement parts 6-720-611-730b (12.05) replacement parts electrode assembly: switch off the master switch. Isolate appliance from the power supply. Move control panel into servic...

  • Page 43

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 41 setting the gas/air ratio 6-720-611-730b (12.05) important: the appliance is set at the factory and adjustment to the co2 settings (gas/air ratio) is only required where the applian...

  • Page 44

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par e s installation & servicing instructions 42 setting the gas/air ratio 6-720-611-730b (12.05) setting the gas/air ratio 5 measure the co 2 level. Prise off the seal on the gas flow restrictor. Adjust the gas flow restrictor (...

  • Page 45

    Supplied by www.Heating spares.Co tel. 0161 620 6677 s e rv ici ng & s par es installation & servicing instructions 43 6-720-611-730b (12.05) short parts list short parts list 1 burner: part no. 8 718 006 658 0 (gc no. E27 200) 2 fan assembly: part no. 8 717 204 373 0 (gc no. E74 539) 3 circulating ...

  • Page 46

    Supplied by www.Heating spares.Co tel. 0161 620 6677 con ve r s ion k its installation & servicing instructions 44 l.P.G. Conversion 6-720-611-730b (12.05) change code plug: 1 unclip cover panel (a) from base as shown 2 unscrew and remove panel (b). 3 remove and dispose of old code plug. 4 replace w...

  • Page 47

    Supplied by www.Heating spares.Co tel. 0161 620 6677 fa ul t find in g & d ia g r am s installation & servicing instructions 45 electrical wiring diagram 6-720-611-730b (12.05) 1. Terminal block, 230vac mains supply. 2. Roomstat link. 3. Earth connection. 4. Fuse, slow 2.5a. 5. Transformer. 6. Maste...

  • Page 48

    Supplied by www.Heating spares.Co tel. 0161 620 6677 fa ul t find in g & d ia g r am s installation & servicing instructions 46 central heating function 6-720-611-730b (12.05) note: the sequence ensures that the condensate siphon is not empty after long off periods. Central heating function main swi...

  • Page 49

    Supplied by www.Heating spares.Co tel. 0161 620 6677 fa ul t find in g & d ia g r am s installation & servicing instructions 47 domestic hot water flow function 6-720-611-730b (12.05) domestic hot water flow function note: this diagram is a simplification of the function of the boiler (for example; ...

  • Page 50

    Supplied by www.Heating spares.Co tel. 0161 620 6677 fa ul t find in g & d ia g r am s installation & servicing instructions 48 fault finding 6-720-611-730b (12.05) note ; this fault finding information is for guidance only. Worcester bosch cannot be held responsible for costs incurred by persons no...

  • Page 51

    Supplied by www.Heating spares.Co tel. 0161 620 6677 fa ul t find in g & d ia g r am s installation & servicing instructions 49 fault finding 6-720-611-730b (12.05) fault finding check, repair/replace as necessary: transformer. All connections to control board. Otherwise replace control board. Gas v...

  • Page 52: Instruction Manual

    Supplied by www.Heating spares.Co tel. 0161 620 6677 6-720-611-730b (12.05) worcester, 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-bo...