Worcester Greenstar Highflow 440 User manual

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 T PE 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 S STEMS AND MAINS FED DOMESTIC HOT WATER

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.
THESE INSTRUCTIONS ARE APPLICABLE TO THE PRODUCT MODEL(S) STATED ON
THE FRONT COVER OF THIS MANUAL ONL AND MUST NOT BE USED WITH AN
OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPL IN THE UK & EIRE ONL AND MUST BE FOLLOWED EXCEPT
FOR AN STATUTOR OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED B A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTL COULD LEAD TO PROSECUTION.
IF OU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT
HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER,
PART OF THE BOSCH GROUP.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK OR A CERTIFICATE CONFIRMING COMPLIANCE WITH IS 813
EIRE ONLY) WITH THE USER OR AT THE GAS METER AFTER INSTALLATION OR
SERVICING.
WORCESTER, BOSCH GROUP:
MAIN RECEPTION: 01905 754624
MAIN FAX: [phone]
TECHNICAL: 08705 266241
SERVICE: 08547 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS
VALE RISE, TONBRIDGE, TN9 1TB
TEL: [phone]
www.tfc-group.co.uk
ABBREVIATIONS:
Ø Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
RS Room sealed flue
N/A Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
Store the app iance in a dry area prior to
insta ation.
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 installation.
A suitable truck should be used.
The boiler is secured to a wooden board with
screws. It is advised that no attempt should be
made to move the packaged appliance without
the use of a suitable truck.
Before removing the carton it is advised that the
top flaps are opened and the ancillary items
removed and set to one side.
The carton can now be lifted off the boiler.
Remove the plastic bag protecting the boiler
surfaces and place safely away from the working
area.
Remove the boiler (complete with board) from the
pallet before removing the securing screws.
The boiler is mounted on small wheels and can
now be slid off the board and guided into the
installation position.
Care should be taken not to damage anuy panels.
Two people are required to move the appliance
from the board into the installation position.
GENERAL HANDLING GUIDELINES:
 Lift only a manageable weight, or ask for help.
 When lifting, bend the knees, and keep the back
straight and feet apart.
 Do not lift and twist at the same time.
 Lift and carry items close to the body
 Wear protective clothing and gloves to protect
from any sharp edges
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply
Fuel supply

INSTALLATION & SERVICING INSTRUCTIONS CONTENTS
SAFETY &
REGULATIONS
FAULT FINDING
& DIAGRAMS
APPLIANCE
INFORMATION
PRE-
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
CONTENTS
1
6-720-611-730b (12.05)
SAFETY & REGULATIONS
SAFET PRECAUTIONS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LA OUT & COMPONENTS 5
PRE-INSTALLATION
CLEANING PRIMAR S STEMS 6
MAINS SUPPLIES 7-8
WATER S STEMS & 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 S STEM 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

SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS
SAFET PRECAUTIONS INSTALLATION REGULATIONS
2SAFET PRECAUTIONS &
INSTALLATION REGULATIONS
6-720-611-730b (12.05)
IF YOU SMELL GAS:
DON'T SMOKE OR STRIKE MATCHES.
DON'T TURN ELECTRICAL SWITCHES ON OR OFF.
DO PUT OUT NAKED FLAMES.
DO OPEN DOORS AND WINDOWS.
DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED.
DO TURN OFF THE CONTROL VALVE AT THE METER.
DO CALL YOUR GAS COMPANY.
BENCHMARK:
A Benchmark Log Book is provided by the manufacturer for the installer to complete including
their CORGI registration number to confirm that the boiler has been installed, commissioned
and serviced according to the manufacturers instructions.
IMPORTANT: The completed Benchmark Log Book will be required in the event of any warranty
work and may be required by the local Building Control Inspector.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the construction
process that contravene the COSHH Regulations (Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the
vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances, (halogenated
hydrocarbons containing chlorine or fluorine compounds) which can corrode the appliance and
invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer in accordance with these instructions and the relevant Installation Regulations.
Flue systems 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 invalidate the warranty. The manufacturer accepts no liability arising from any such
actions, excluding 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 correctly could lead to
prosecution.
This appliance must be installed only by a competent
person in accordance with, and comply to, the
current: Gas Safety (Installation & Use) Regulations
1998, IEE Regulations, Building Regulations,
Building Standards (Scotland) (Consolidation),
Building Regulations (Northern Ireland), local water
by-laws, Health & Safety Document 635 (The
Electricity at Work Regulations 1989), IS 813 (Eire)
and any other local requirements.
The relevant Standards should be followed,
including:
BS7074:1 : Code of practice for domestic and hot
water supply
BS6891 : Installation of low pressure gas pipework
up to 28mm (R1)
BS5546 : Installation of gas hot water supplies for
domestic purposes
EN:12828 : Central heating for domestic premises
BS5440:1 : Flues and ventilation for gas appliances
of rated heating not exceeding 70kW (net) : Flues
BS5440:2 : Flues and ventilation for gas appliances
of rated heating not exceeding 70kW (net) : Air
Supply
BS7593 : Treatment of water in domestic hot water
central heating systems
BS6798 : Installation of gas fired boilers of rated
input up to 70kW (net)
Where no specific instruction is given, reference
should be made to the relevant codes of Practice.
L.P.G. Installation:
An appliance using L.P.G. must not be installed in
a room or internal space below ground level unless
one side of the building is open to the ground.
Timber framed buildings:
Where the boiler is to be fitted to a timber framed
building the guidelines laid down in BS5440: Part
1 and IGE "Gas Installations in Timber Frame
Buildings should be adhered to.
Potable water:
All seals, joints, compounds (including flux and
solder) and components used as part of the
secondary domestic water system must be approved
by WRAS.
Central heating water:
Artificially softened water must not be used to fill
the CH system.

APPLIANCE
INFORMATION
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
water.
B - Mounting frame complete with pre-plumbing
manifold assembly.
C - Literature pack.
D - Filling link, built-in. (WRAS approved).
SPECIFICATIONS:
Pre-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.
Sealed primary system & pressure gauge display.
Pressure relief valve.
Flue gas temperature limiter.
Plate-type DHW heat exchanger.
Condensate trap & pump.
600mm
600mm
850mm
D
A
B
C
620mm

APPLIANCE
INFORMATION
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 net 50/30°C kW 30.9 30.9
Max. rated heat output net 80/60°C kW 29.2 29.2
Max. rated heat input net kW 29.5 29.5
Min. rated heat output net 40/30°C kW 8.4 11.6
Min. rated heat output net 50/30°C kW 8.3 11.4
Min. rated heat output net 80/60°C kW 7.4 10.5
Min. rated heat input net kW 7.6 10.8
Max. flow temperature °C 88 88
Max. permissible operating pressure bar 2.65 2.65
Domestic Hot Water
Max. rated heat input net kW 29.5 29.5
Max. rated heat output kW 29.2 29.2
Minimum flow rate to start l/min 2.3 2.3
Minimum pressure for 20 l/min (±15%) bar 1.5 1.5
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 (CVnet 34.02 MJ/m³) m³/h 3.1 -
Propane Gas (LPG) (CVnet 88 MJ/m³) kg/h - 2.3
Gas supply pressure
Natural Gas G20 (CVnet 34.02 MJ/m³) mb 20 -
LPG (Propane) Gas G31 (CVnet 88 MJ/m³) 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 heat output % 8.8 10.5
NOx - classification class 5 5
Condensate
Max. condensation rate l/h 2.5 2.5
pH value, approx. 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230
Frequency Hz 50 50
Max. power consumption W 107 107
Expansion Vessel
Charge Pressure bar 0.75 0.75
Total Capacity Itr 12 12
General Data
SEDBUK (Band A) % 91 92.2
Appliance protection rating (with programmer blanking plate fitted) IP 20 20
Appliance protection rating (with fascia programmer fitted) IP 20 20
Private ambient temperatures °C 0 - 50 0 - 50
Nominal capacity of appliance Itr 51 51
Noise output level (at maximum CH output) dB(A) 37 37
Weight (excluding packaging) kg 112 112

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS 5
LA OUT & COMPONENTS
LA OUT & 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 wiring.
1 CONTROLS SUPPORT FRAME
2 BOILER ON/OFF SWITCH
3 DHW TEMPERATURE CONTROL
4 CH TEMPERATURE CONTROL
5 BOSCH HEATRONIC SERIES CONTROL
BOARD
6 TANK TEMPERATURE SENSOR
7 TANK OVERHEAT THERMOSTAT
8 PRESSURE GAUGE
9 EXPANSION VESSEL
10 FILLING LOOP ISOLATION VALVE
11 WATER FLOW SENSOR TURBINE
12 DHW HEAT EXCHANGER
13 FILLING LOOP FLEXIBLE PIPE
14 BOILER/TANK DRAIN & CONNECTION
POINT FOR FILLING LOOP
15 DHW FLOW SENSOR
16 MOUNTING FRAME
17 CH FLOW ISOLATION VALVE
18 DHW OUTLET
19 GAS ISOLATION VALVE
20 MAINS WATER INLET ISOLATION VALVE
21 CH RETURN ISOLATION VALVE
22 RUNNER WHEEL
23 CONDENSATE PUMP ASSEMBL
24 CIRCULATING PUMP
25 DIVERTER VALVE
26 GAS VALVE
27 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.
7 719 002 434)
A - 93° ELBOW
B - ELBOW EXTENSION
C -LOCKRING
D - RETAINING RING
E - INNER WALL FLUE COLLAR
F - TERMINAL ASSEMBL
G -OUTER WALL FLUE COLLAR
OPTIONAL ACCESSORIES (not supp ied)
a - TR212E NIGHT SETBACK MODULE
Part No. 7 744 901 136
b - TWIN CHANNEL DIGITAL TIMER
Part No. 7 716 192 032
c - TR2 ROOM TEMPERATURE CONTROLLER
Part No. 7 744 901 137
d - FILLING LINK WITH PRESSURE GAUGE
Part No. 8-718-505-047
FLUE KITS:
Vertical 100mmØ Part No. 7 719 002 435
Vertical 125mmØ Part No. 7 719 002 437
Horizontal 125mmØ Part No. 7 719 002 436
NG to LPG CONVERSION KIT
Part No. 7 716 192 294
AB
CD
E
C
F
G
1
37
b
a
c
34
32
33
35
23
24
26
28
30
31
25
27
29
22
21
3
7
8
11
10
12
15
9
6
2
13
14
16
17
18
19
20
4
1
d
38
39
36
5
40

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6
CLEANING PRIMAR S STEMS
CLEANING PRIMAR S STEMS
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: All the following pre-installation sections must be read and requirements
met before starting boiler or flue installation.
6-720-611-730b (12.05)
IMPORTANT:
Debris from the system can damage the
boiler and reduce efficiency. Failure to comply
with the guidelines for the use of water
treatment with the appliance will invalidate
the appliance warranty.
BEFORE CLEANING THE S STEM:
ENSURE THE S STEM 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 add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
Circulate the flushing agent before the boiler is
fired up.
Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
Drain and thoroughly flush the system to remove
the flushing agent and any debris.

PRE-
INSTALLATION
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.
 External 5A fuse to BS1362.
 The appliance must be earthed.
 All pipes to the boiler must be cross-bonded.
 It must be possible to isolate the appliance from
the electric supply with at least a 3mm contact
separation in all poles supplying the appliance.
 Wiring between the appliance and the electrical
supply must comply with IEE wiring regulations
and any local regulations which may apply for
fixed wiring to a stationary appliance.
 Any system connected to the boiler must not
have a separate electricity supply.
 External controls must be double insulated mains
voltage with no earth requirement.
WATER SUPPLY:
 Connections to the water supply must not be
made without the authority of the local water
company.
 The appliance cold water supply should be the
first connection off 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 household appliances.
 Where the water main supply has a non-return,
back flow prevention valve fitted, a mini expansion
vessel (A) should be connected to the mains
water inlet pipe (B) between the non-return valve
(C) and the boiler (D) as shown opposite.
Use in hard water areas:
Normally there is no need for water treatment to
prevent scale formation as the maximum temperature
of the heat exchanger is limited by the electronic
control circuit.
In areas where the temporary water hardness
exceeds 200ppm, consideration may need to be
given to the fitting of a scale prevention device. In
such circumstances, the advice of the local water
authority should be sought.
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 192 105
B - Water Main supply pipe
C - Non-return valve
D - Boiler
D
C
A
B

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6-720-611-730b (12.05)6-720-611-730b (12.05)
8MAINS SUPPLIES
MAINS SUPPLIES
GAS SUPPLY:
 Boilers using NG must be connected to a
governed meter.
 LPG boilers must be connected to a regulator.
 Installation 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 to the demand from any other
appliance being served.