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Worcester GREENSTAR HIGHFLOW 440CDI ERP Installation, Commissioning And Servicing Instructions

Manual is about: Floor standing RSF gas fired condensing combination boiler

Summary of GREENSTAR HIGHFLOW 440CDI ERP

  • Page 1

    Installation, commissioning and servicing instructions floor standing rsf gas fired condensing combination boiler greenstar highflow 440cdi erp & 550cdi erp 6720648665-00.1w o for sealed central heating systems and mains fed domestic hot water 6 72 0 818 077 (2016/04) the appliances are for use with...

  • Page 2

    Contents greenstar highflow cdi erp - 6720818077 (2016/04) 2 contents 1 key to symbols and safety precautions . . . . . . . . . . . . 3 1.1 key to symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 safety precautions  . . . . . . . . ...

  • Page 3

    Key to symbols and safety precautions 6720818077 (2016/04) - greenstar highflow cdi erp 3 1 key to symbols and safety precautions 1.1 key to symbols warnings the following keywords are defined and can be used in this document: • notice indicates a situation that could result in damage to property or...

  • Page 4

    Key to symbols and safety precautions greenstar highflow cdi erp - 6720818077 (2016/04) 4 1.2 safety precautions instructions for the target group these installation instructions are intended for registered gas fitters, plumbers, heating engineers and electricians. All instructions must be observed....

  • Page 5

    Key to symbols and safety precautions 6720818077 (2016/04) - greenstar highflow cdi erp 5 installation regulations current gas safety (installation and use) regulations: all gas appliances must be installed by a competent, registered gas engineer, such as a gas safe registered engineer or british ga...

  • Page 6

    Appliance information greenstar highflow cdi erp - 6720818077 (2016/04) 6 2 appliance information 2.1 general information boiler features and checklist • pre-wired and pre-plumbed • galvanised steel inner frame • digital control system • sense ii intelligent controls • automatic ignition • direct bu...

  • Page 7

    Appliance information 6720818077 (2016/04) - greenstar highflow cdi erp 7 2.2 technical data description units natural gas l.P.G 440cdi erp 550cdi erp 440cdi erp 550cdi erp central heating max. Rated heat output net 40/30°c kw 31.2 32.8 31.2 32.8 max. Rated heat output net 50/30°c kw 30.9 32.5 30.9 ...

  • Page 8

    Appliance information greenstar highflow cdi erp - 6720818077 (2016/04) 8 2.3 product data on energy consumption the following product data satisfies the requirements of the eu regulations no. 811/2013, no. 812/2013, no. 813/2013 and no. 814/2013 supplementing directive 2010/30/eu. Product data symb...

  • Page 9

    Appliance information 6720818077 (2016/04) - greenstar highflow cdi 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 26 27 15 16 17 18 19 42 45 39 40...

  • Page 10

    Appliance information greenstar highflow cdi erp - 6720818077 (2016/04) 10 1 control panel 2 230v master switch for on/off 3 burner on indicator light (green) 4 service menu button 5 service engineer button 6 ch temperature control 7 230v mains on/off indicator & fault diagnostic light 8 position fo...

  • Page 11

    Pre-installation 6720818077 (2016/04) - greenstar highflow cdi erp 11 3 pre-installation 3.1 cleaning primary systems before cleaning the system: ▶ ensure that the system and pipe work is in good working order. ▶ where possible keep the existing boiler/circulating pump in place when flushing the sys...

  • Page 12

    Pre-installation greenstar highflow cdi erp - 6720818077 (2016/04) 12 3.2.3 water supply water mains pressure: • minimum mains water pressure, for maximum performance refer to table 6 - technical data. • maximum mains fed water pressure 10 bar. If necessary fit a pressure reducing valve. • where the...

  • Page 13

    Pre-installation 6720818077 (2016/04) - greenstar highflow cdi erp 13 3.4 condensate pipe work 3.4.1 internal connections in order to minimise risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order of priority. Wherever...

  • Page 14

    Pre-installation greenstar highflow cdi erp - 6720818077 (2016/04) 14 pipe drainage will be improved if the end is cut at 45° as opposed to a straight cut. Fig. 9 external disposal condensate soak away • the condensate drainage pipe may be run above or below ground to the soak away. The examples sho...

  • Page 15

    Pre-installation 6720818077 (2016/04) - greenstar highflow cdi erp 15 3.6 boiler location and clearances • this is a floor-standing boiler and is only suitable for installing on the floor, internally in a property • install onto a rigid non-combustible surface at least the same size as the boiler an...

  • Page 16

    Pre-installation greenstar highflow cdi erp - 6720818077 (2016/04) 16 3.6.4 rooms containing a bath or shower an appliance fitted with a mechanical, rf mechanical timer, or a clip-in weather compensating controller may be only installed outside the shaded area. An appliance fitted with a blanking pa...

  • Page 17

    Pre-installation 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 6720648568-17.1w o 120 mm 120 mm 120 mm.

  • Page 18

    Pre-installation greenstar highflow cdi erp - 6720818077 (2016/04) 18 3.8 flue terminal positions fig. 16 flue terminal positions key to illustration 1. 300mm adjacent to a boundary line. 2. The dimension below eaves, gutters, pipes and drains can be reduced to 25mm, as long as the flue terminal is ...

  • Page 19

    Pre-installation 6720818077 (2016/04) - greenstar highflow cdi erp 19 3.9 plume management terminal positions fig. 17 plume terminal positions key to illustration 1. This feature allows some basic plume re-direction options on a standard telescopic horizontal flue terminal. 300mm minimum clearances ...

  • Page 20

    Installation greenstar highflow cdi erp - 6720818077 (2016/04) 20 4 installation 4.1 unpacking the boiler unpacking: ▶ undo the ties securing the carton to the pallet. If a sharp implement is used, care must be taken not to pierce the carton or cause injury. ▶ before removing the carton it is advise...

  • Page 21

    Installation 6720818077 (2016/04) - greenstar highflow cdi erp 21 4.2 mounting frame fixing and flue opening safety all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. Running pipes behind the boiler: • the frame s...

  • Page 22

    Installation greenstar highflow cdi erp - 6720818077 (2016/04) 22 all dimensions in millimetres fig. 21 boiler flue outlet positions [*] increase this height by 52mm for every metre of horizontal flue length that the boiler is away from the flue opening 4.4 flue measuring and cutting flue length gui...

  • Page 23

    Installation 6720818077 (2016/04) - greenstar highflow cdi erp 23 4.5 condensate, gas and water connections 4.5.1 condensate connection the condensate pump fills up and periodically discharges through the flexible condensate pipe [8] between 200mm to 4500mm from floor level. After this point the con...

  • Page 24

    Installation greenstar highflow cdi erp - 6720818077 (2016/04) 24 4.7 electrical list of wiring connections access to electrical connections ▶ remove boiler casing to access control panel. ▶ remove screw [1] and swing the control panel into the service position. Fig. 25 control box in service positi...

  • Page 25

    Installation 6720818077 (2016/04) - greenstar highflow cdi erp 25 4.7.1 pcb connections 1. 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 wire to the earth connector block n...

  • Page 26

    Commissioning greenstar highflow cdi erp - 6720818077 (2016/04) 26 5 commissioning 5.1 pre-commissioning checks ▶ check that the service and water pipes [1] are connected to the correct valve on the manifold; a - ch flow (22mm) b - dhw flow (22mm) c - gas inlet (22mm) d - mains water inlet (22mm) e ...

  • Page 27

    Commissioning 6720818077 (2016/04) - greenstar highflow cdi erp 27 5.3 water treatment ensure that the system has been cleaned as on page 11 of these instructions. Inhibitor (central heating): ▶ check drain cocks are closed and all radiator valves are open before adding a suitable inhibitor compatib...

  • Page 28

    Commissioning greenstar highflow cdi erp - 6720818077 (2016/04) 28 ▶ turn the temperature control [10] to maximum. The burner on indicator [13] illuminates green when the burner has lit. Fig. 36 operating the boiler ▶ if the boiler fails to light, the blue power indicator [9] and reset button [5] wi...

  • Page 29

    Commissioning 6720818077 (2016/04) - greenstar highflow cdi erp 29 ▶ measure the pressure with the boiler running at maximum. – refer to figure 33 for control panel guide – press service engineer button [11] for more than ten seconds and set central heating temperature to maximum. – the service engi...

  • Page 30

    Commissioning greenstar highflow cdi erp - 6720818077 (2016/04) 30 5.6 co and combustion check the following combustion and flue integrity checks are mandatory and these values must be recorded on the benchmark check list, at the back of this manual. Once the gas rate and pressure have been confirme...

  • Page 31

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 31 5.7 finishing commissioning 1. Engage top panel [2] onto rear retainers [3] and lower front of panel into position. ▶ secure the top panel with the two screws [4]. 2. Swing the control panel assembly [5] into the boiler. ▶ sec...

  • Page 32

    Servicing and spares greenstar highflow cdi erp - 6720818077 (2016/04) 32 6.2 service function setting boiler to maximum: ▶ press and hold the service engineer button [11] for 10 seconds and set central heating temperature to maximum. The service engineer button will illuminate continually. The boil...

  • Page 33

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 33 ▶ if the manometer reading is in the white area of the chart the heat exchanger/exhaust path/condensate trap does not require attention. ▶ if the manometer reading is in the black area of the chart then carry out the following...

  • Page 34

    Servicing and spares greenstar highflow cdi erp - 6720818077 (2016/04) 34 fig. 48 burner removal 6.7.2 to check the flap valve in the fan intake ▶ refer to section 6.9.3 on page 38 for access to the fan intake. ▶ carefully withdraw the flap valve from fan intake tube and check for soiling and splits...

  • Page 35

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 35 if the heat exchanger requires cleaning: ▶ remove the condensate trap. ▶ remove the cleaning access cover [1] and seal [2]. Fig. 51 remove cover ▶ press at the bottom to remove the metal plate [3], if fitted. Fig. 52 remove me...

  • Page 36

    Servicing and spares greenstar highflow cdi erp - 6720818077 (2016/04) 36 ▶ pour water into the top of the heat exchanger to flush out the debris. Fig. 55 ▶ refit the cleaning access cover assembly in reverse order, the metal plate [3] first, then the new seal [2], lastly the access cover [1]. ▶ ref...

  • Page 37

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 37 ▶ if further adjustment is required, remove the combustion chamber cover and set adjuster [3] as necessary ▶ replace the cover and check the maximum co 2 again fig. 57 setting air/gas ratio to set the minimum co 2 : ▶ turn the...

  • Page 38

    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 control...

  • Page 39

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 39 6.9.5 diverter valve motor ▶ ensure that the appliance is in service mode (there is no need to drain the appliance). ▶ disconnect the connector [2] from diverter valve motor [1]. ▶ pull the motor [1] to you, the assembly will ...

  • Page 40

    Servicing and spares greenstar highflow cdi erp - 6720818077 (2016/04) 40 flue temperature limiter [9] ▶ remove the connector. ▶ using a small terminal screwdriver, prise the sensor and grommet from the plastic housing. Take care not to damage the plastic housing. Domestic hot water temperature sens...

  • Page 41

    Servicing and spares 6720818077 (2016/04) - greenstar highflow cdi erp 41 6.9.15 gas valve ▶ check that the gas cock is turned off. ▶ disconnect the black rubber tube [1] from the gas valve. ▶ remove the solenoid connections [2] at the side of the gas valve. ▶ release the gas inlet union [3] at the ...

  • Page 42

    Servicing and spares greenstar highflow cdi erp - 6720818077 (2016/04) 42 6.10 short parts list burner 8 737 703 148 gc no. E27 200 burner seal 8 711 004 168 0 gc no. E27 201 fan 440 cdi 8 716 117 325 gc no. E74-539 fan 550 cdi 8 718 644 395 0 gc no. N/a pump 8 716 117 455 gc no. J25 460 diverter va...

  • Page 43

    Fault finding and diagrams 6720818077 (2016/04) - greenstar highflow cdi erp 43 7 fault finding and diagrams 7.1 electrical wiring diagram t2.5 a, h 230 v fs fr np lp l n s n l s l r st8 st9 st17 st18 st5 st4 st10 mains supply spark transformer flame sense electrode spark electrodes flow ntc flow tu...

  • Page 44

    Fault finding and diagrams greenstar highflow cdi erp - 6720818077 (2016/04) 44 7.2 central heating function boiler in standby . Blue light on central hea ting demand fan to start speed. Gas valve open. Pump on. Diverter valve to ch position. 5th attempt? Fan run to purge gas from burner . Minimum h...

  • Page 45

    Fault finding and diagrams 6720818077 (2016/04) - greenstar highflow cdi erp 45 7.3 dhw function boiler in standby or ch demand. Blue light on hot water demand (overrides all other demands). Gas valve off until temperature drops to set level. Delivered temperature too high. End of demand. No yes che...

  • Page 46

    Fault finding and diagrams greenstar highflow cdi erp - 6720818077 (2016/04) 46 7.4 protection function internal boiler temperature between 8°c & 5°c boiler automatic frost function (monitors internal boiler primary temperature) internal boiler temperature below 5°c internal boiler temperature rises...

  • Page 47

    Fault finding and diagrams 6720818077 (2016/04) - greenstar highflow cdi erp 47 7.5 fault finding preliminary checks: preliminary electrical system checks are the first electrical checks to be carried out during a fault finding procedure. On completion of the service/fault finding task which has req...

  • Page 48

    Fault finding and diagrams greenstar highflow cdi erp - 6720818077 (2016/04) 48 7.6 condensate pump indicator lights the condensate pump has indicator lights [1] which show operation status or a fault condition. Fig. 69 condensate pump indicator lights 6720818077-27.1w o condensate pump - operating ...

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    6720818077 (2016/04) - greenstar highflow cdi erp 49 notes.

  • Page 50

    $oolqvwdoodwlrqvlq(qjodqgdqg:dohvpxvwehqrwl¿hgwr/rfdo$xwkrulw\%xloglqj&rqwuro/$%&hlwkhugluhfwo\ruwkurxjkd &rpshwhqw3huvrqv6fkhph$%xloglqj5hjxodwlrqv&rpsoldqfh&huwl¿fdwhzloowkhqehlvvxhgwrwkhfxvwrphu zzzfhqwudokhdwlqjfrxn ‹+hdwlqjdqg+rwzdwhu,qgxvwu\&rxqflo++,& this commissioning checklist is to be com...

  • Page 51: Service 01

    $oolqvwdoodwlrqvlq(qjodqgdqg:dohvpxvwehqrwl¿hgwr/rfdo$xwkrulw\%xloglqj&rqwuro/$%&hlwkhugluhfwo\ruwkurxjkd &rpshwhqw3huvrqv6fkhph$%xloglqj5hjxodwlrqv&rpsoldqfh&huwl¿fdwhzloowkhqehlvvxhgwrwkhfxvwrphu ‹+hdwlqjdqg+rwzdwhu,qgxvwu\&rxqflo++,& zzzfhqwudokhdwlqjfrxn it is recommended that your heating syste...

  • Page 52

    Worcester, bosch group cotswold way, warndon, worcester wr4 9sw. Tel. 0330 123 9559 worcester, 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: 0330 12...