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.

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6-720-611-730b (12.05)
9
WATER S STEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
 Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of copper
or steel pipe connected to the boiler.
 Do not use plastic pipework on sealed systems.
 Plastic pipework used for underfloor heating
must be correctly controlled with a thermostatic
blending valve limiting the temperature of the
circuits to approx. 50°C. The pipework from the
boiler to the blending valve must be in copper
or steel (protected from corrosion).
PRIMARY SYSTEM/CONNECTIONS/VALVES:
 Do not use galvanised pipes or radiators.
 All system connections, taps and mixing valves
must be capable of sustaining a pressure of 3
bar.
 Radiator valves should conform to BS2767:10.
 All other valves should conform to BS1010.
 On new installations TRVs must be used on all
radiators except the radiator where the room
thermostat is sited, this must be fitted with
lockshield valves and left open. All installations
should have TRV's fitted to radiators within 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 more than 100 litres
or exceeds 2.65bar at maximum heating
temperature an extra expansion vessel (B) must
be fitted as close as possible to the appliance
in the central heating return.
 Pressurise the extra expansion vessel (B) to the
same figure as the expansion vessel built into
the appliance.
WATER S STEMS & PIPEWORK
TYPICAL SEALED SYSTEM:
A - Appliance expansion vessel
B - Extra expansion vessel
C - Automatic bypass valve
D - Drain cock
L - Lockshield valve
P - Pressure relief discharge
R - Radiators
T - TRV
D
R R
R R
B
P
D
C
TLTL
TL TL
A

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6-720-611-730b (12.05)
10 WATER S STEMS & PIPEWORK
FILLING PRIMARY SYSTEMS:
 The CH sealed system must be filled using a
WRAS approved filling loop or comply with the
diagram opposite for system fill.
 The filling point must be at low level and must
never be a permanent direct fixing to the mains
water supply.
SHOWERS/BIDETS:
 If a shower head can be immersed in water or
comes closer than 25mm from the top edge of
a bath or shower tray spill over level then an anti-
siphon device must be fitted to the shower hose.
 Bidets with direct hot & cold mains water can
be 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 must be capable of
sustaining a pressure up to 10 bar.
 Hot water temperature and flow rate are affected
by the size and insulation of pipework making
up the distribution system and are controlled by
the hot water tap and the water main inlet
pressure. A mixing valve can be fitted if a more
permanent setting is required.
 If using more than one outlet at once causes
water flow starvation, fit flow balancing valves
or Ball-O-Fix valves to the appropriate outlets.
WATER S STEMS & PIPEWORK
Heating return
Hose
return
Non return
valve
Non return
valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary hose

PRE-
INSTALLATION
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 pipe.
 The condensate pipework must fall at least
50mm per metre towards the outlet and
should take the shortest practicable route
and not exceed 3 metres outside the building.
The pipework must follow one of the options
shown opposite (into a serviceable internal trap
(min. 75mm) such as a sink/washing machine)
and discharge direct into a vent stack (E) min.
450mm above pipe invert or into a gulley (D)
below ground but above the water level.
a - Internal sink/washing machine drain.
b - Internal waste drainage system.
c - Soil/vent stack.
d - External drainage system.
e - External condensate absorption point.
 Use waterproof pipe insulation in exposed
positions and for external pipework.
A -Condensate from boiler.
B -Sink.
C -21.5mmØ plastic condensate waste pipe.
D -Gully.
E -Internal soil and vent stack.
F - Servicable condensate trap (75mm min).
G -300mm x 100mmØ sealed plastic tube.
H -Ground level.
J - Drainage holes 50mm from base of tube
(12mmØ at 25mm centres) facing away from
building.
K -Limestone chippings.
PRESSURE RELIEF PIPEWORK:
IMPORTANT: The pressure relief valve is a
safety device for the boiler and if activated
may discharge boiling water or steam
through the relief valve drain pipe.
Care should taken when siting the outlet
pipe so that it does not cause an obstruction
or discharge above a window, entrance or
other public access where it could cause a
hazard.
 The pressure relief drain pipe (M) should be at
least 15mm diameter copper pipe and run
downwards away from the boiler and discharge
away from any electrics or other hazard,
preferably to an external drain or soakaway.
 Pipe (M) should be finished with a partial bend,
near the outlet to face the external wall (as
shown) to help prevent freezing.
Use waterproof pipe insulation in exposed
positions and for external pipework.
L - Outside wall.
M - Drain pipe.
N - External drain.
b
cd
a
e
A
B
C
D
F
75mm min. 75mm
min.
A
BC
F
D
Invert
75mm min.
E
A
C
F450mm
min.
75mm min.
D
A
C
F
25mm
min.
400mm
min.
500mm min.
G
K
J
H
75mm min.
A
C
F
M
N
L
M

PRE-
INSTALLATION
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-combustible surface at least the
same size as the boiler and capable of supporting
the boiler weight.
 The boiler is not suitable for external installation
unless a suitable enclosure is provided.
 THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
Compartments:
Follow the requirements of BS6798 and BS5440
Part 2 and note:
 Minimum clearances must be maintained.
 An access door is 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 separate the boiler from
the airing space.
a: INSTALLATION CLEARANCES:
Diagram 'a' shows the minimum space required to
install the boiler only.
b: SERVICE CLEARANCES:
Diagram 'b' opposite shows the minimum space
required to service the boiler only.
c: UNVENTED COMPARTMENT
CLEARANCES:
Diagram 'c' shows the minimum space required to
install and service the boiler inside an unvented
compartment.
*
Space required for unvented areas with a removable
door or panel.
**
This space can be reduced to 5 mm for one
side only as long as both the side clearances add
up to the total of both the side measurements
shown or more.
d: AIRING CUPBOARD CLEARANCES:
Diagram 'd' opposite shows the minimum space
required to install and service the boiler within an
airing cupboard.
e: VENTING COMPARTMENTS:
If the clearances are less than those stated for
options 'c' & 'd' (above) then ventilation must be
provided as described in BS 5440.
A minimum of 2 air vents (C) must be fitted, one at
low level and another at high level onto the same
wall using the same air for circulation.
Minimum free air required for venting:
For air directly from outside: 148cm2 per vent.
For air from internal space/room: 296cm2 per vent.
BOILER LOCATION &
CLEARANCES
600mm
800mm 800mm
900mm
50mm
100mm**
100mm**
200mm*
25mm 100mm
200mm
100mm
25mm
100mm
625mm 800mm
A
600mm
100mm
100mm
800mm
1200mm
600mm
15mm
5mm
5mm
610mm
1200mm
a: INSTALLATION CLEARANCES
b: SERVICE CLEARANCES
c: UNVENTED
COMPARTMENT CLEARANCES
C
B
D
2300mm
e: VENTING
COMPARTMENTS
1450mm
865mm
d: AIRING CUPBOARD
CLEARANCES

PRE-
INSTALLATION
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 on the diagrams
opposite.
IMPORTANT: any switch or appliance control
using mains electricity must not be able to
be touched by a person using the bath or
shower.
Electrical switches, fused spur and socket
outlets must not be situated in the bathroom.
600mm
2250mm
600mm
750mm
A
1 1 23
2
3
0
2250mm
750mm
3
600mm
600mm radius
A
A - Bath or shower cubicle (zone 0)
1 1 22 3
0

PRE-
INSTALLATION
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) installed, pipework
can be connected to the valves on the plumbing
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 be installed at a later date.
RUNNING PIPES BEHIND THE BOILER:
 The frame should sit against the wall (not the
skirting board) with enough room for the
pipework.
 Do not cross a pipe over another.
 The area around a rear flue outlet must be
avoided.
MOUNTING FRAME
CONNECTIONS
22mm
15mm
C
A
B

PRE-
INSTALLATION
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 fitted and terminated in
accordance with the recommendations of
BS5440 : Part 1.
 The flue must not cause an obstruction.
 Discharge from the flue outlet must not be a
nuisance.
 Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a nuisance,
for example, near security lighting.
 There should be no restriction preventing the
clearance of combustion products from the
terminal.
 The air inlet/outlet duct and the terminal of the
boiler must not be closer than 25mm to any
combustible material. Detailed recommendations
on protection of combustible materials are given
in BS 5440:1
 A protective terminal guard must be fitted if the
terminal is 2m or less above a surface where
people have access.
The guard must be spaced equally (minimum
50mm) around the flue and fixed to the wall with
plated screws.
See 'Contact Information' on the inside front
cover for flue guard information.
Minimum dimensions of flue terminal positions for balanced room sealed flues with fanned
draught:
DRWG.
REF:
TERMINAL POSITION KW INPUT EXPRESSED IN NET) DISTANCE
A1Directly below an opening, air brick, opening windows, etc. 300mm
B1Above an opening, air brick, opening window, etc. 300mm
C1 Horizontally to an opening, air brick, opening window, etc. 300mm
D Below gutters, soil pipes or drain pipes 75mm
E Below eaves 200mm
F2Below balconies or car port roof (lowest point) 200mm
G From a vertical drain pipe or soil pipe 150mm
H From an internal or external corner or to a boundary alongside the terminal **300mm
I Above ground, roof or balcony 300mm
J From a surface or boundary facing the terminal **600mm
K From a terminal facing the terminal 1200mm
L2From an opening in the car port (e.g. door, window) into the dwelling 1200mm
M Vertically from a terminal on the same wall 1500mm
N Horizontally from a terminal on the same wall 300mm
O From a vertical non-combustible structure on the roof *
P Above intersection with roof *
Q Adjacent to windows or openings on pitched or flat roofs 600mm
R Below windows or openings on a pitched roof only 2000mm
1In addition, the terminal should not be nearer than 15 mm (fanned draught) to an opening
in the building fabric formed for the purpose of accommodating a built-in element such as a
window frame.
2Not recommended.
* See instructions supplied with vertical flue kits.
** Care should be taken to ensure the siting of a terminal does not cause a nuisance to adjoining
properties.
boundary
F
L
G
I
A
B
I
H
JC
PD,E
P
O
H
H
P
N
M
K
R
P
P
Q
Q
Q

PRE-
INSTALLATION
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 straight flue sections can be reduced in
length by cutting.
 The flue terminal end can be fitted from the
inside or outside of the building.
 Horizontal 125mm and Vertical 100mm and
125mm flue kits are available with separate
instructions. Contact your supplier or Worcester
Bosch.
IMPORTANT:
All horizontal sections must rise away from
the boiler by 52mm per metre 3°) to allow
the condensate to drain back to the boiler.
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90° & 45°
D - Flue bend 45°
E - Vertical Terminal
Ca cu ating the f ue ength:
Measure the total flue length required, noting that
the maximum straight flue length including the
terminal is:
Horizontal 60/100mm : 4000mm
Horizontal 80/125mm : 13000mm
Vertical 60/100mm : 6400mm
Vertical 80/125mm : 15000mm
Then reduce 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 : 1000mm
Horizontal & Vertical 80/125mm : 1030mm
Flue Terminal lengths:
Horizontal 60/100mm : 800mm
Horizontal 80/125mm : 1200mm
Vertical 60/100mm : 1140mm
Vertical 80/125mm : 1365mm
ROOM SEALED FLUE OPTIONS
E
D
C
A
B
A
B
A
B
A
C
B
A
D D
B
A
C C
B
A
C C
B
A
C C C
E
B
D
D
C
E
B
C
L=100mmØ 250 - 600mm
L=125mmØ 350 - 1200mm
L
100mmØ x4
125mmØ x12
L
L=100mmØ 400 - 4000mm
L=125mmØ 350 - 13000mm
L=100mmØ 2000mm
L=125mmØ 11000mm
100mmØ x2
125mmØ x10
L
100mmØ x2
125mmØ x10
L=100mmØ 2000mm
L=125mmØ 11000mm
L=125mmØ 9000mm
125mmØ x8
L
L=125mmØ 9000mm
125mmØ x8
Min.
120mm
L
L=125mm 7000mm
125mmØ x6
Min.
120mm
L
L=100mmØ 4400mm
L=125mmØ 13000mm
100mmØ x4
125mmØ x12
Min.
120mm
L
L=100mmØ 2400mm
L=125mmØ 11000mm
100mmØ x2
125mmØ x10
Min.
120mm
L
L

INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS 17
UNPACKING THE BOILER
6-720-611-730b (12.05)
IMPORTANT: A the previous Pre-Insta ation sections must be read and
requirements met before starting boi er or f ue insta ation.
Take care not to damage the boi er pane s or
the f oor and note that the boi er may contain
some water due to factory testing.
Unpacking:
1 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.
2
Before removing the carton it is advised that
the top flaps are opened and the ancillary items
(A, B & C) are removed and set to one side.
3 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 2 screws at the rear of the board
securing the board to the pallet.
Slide the boiler and board off the pallet.
4 Grip the outer sides of the front panel (D) and
pull up and away from retaining lugs (E).
Remove securing screw at the front of the
boiler.
Remove remaining screws at the rear of the
boiler.
The boiler is mounted on small wheels and
two people are recommended to move the boiler
from the board taking care not to damage the
panels or the floor.
5 Remove the split bracket (F) from the boiler
pipework by releasing the two retaining screws.
At all times the correct method for handling
heavy objects should be strictly observed.
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
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
A - Mounting frame
B - Installation pack
C - Literature pack
UNPACKING THE BOILER
3
1
5
2
A
B
C
D
4
E
F

INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
18 MOUNTING FRAME FIXING &
FLUE OPENING
6-720-611-730b (12.05)
CAUTION: Ensure there are no pipes,
e ectric cab es, damp proof course or other
hazards before dri ing.
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
MOUNTING FRAME/PIPEWORK POSITIONS:
A - Mounting frame.
B - Manifold connections.
C - Mounting frame fixing point.
D - Wall.
E - Gas and water pipework (not supplied).
F - Boiler.
FIXING THE MOUNTING FRAME:
Position the mounting frame (A) on the floor
against the wall with manifold connections (B)
facing away from the wall (D) ensuring there is
enough space for the pipework (E).
Allow the minimum space from each side of the
frame (A) for the boiler overhang (F) and 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 site.
FLUE OPENING:
Follow the diagram opposite to mark the centre
of the flue (1, & 2) for rear opening, (2 & 3) for
side opening or (1 & 4) for top opening.
Measurements shown include the minimum
service clearances.
* IMPORTANT: for horizontal flues, increase
this height by 52mm for every 1000mm of
horizontal length that the flue opening is away
from the boiler
NOTE: all horizontal flue sections must rise away
from the boiler by 52mm per meter to ensure that
condensate flows back into the boiler for safe
discharge via the condensate waste pipe.
Cover the mounting frame manifold assembly
(A) to protect the valves.
Make an opening (X, or Z) through the wall
using a core drill or similar at a size relative to
the wall thickness as shown below:
Wall Flue opening
thickness 60/100mmØ
150 - 240mm 125mmØ
240 - 330mm 130mmØ
330 - 420mm 135mmØ
420 - 500mm 140mmØ
Where the flue terminal can only be fitted from
inside the building, increase the opening to
15 mmØ to allow the optional weather collar
to fit through the opening.
Clear away any debris.
MOUNTING FRAME FIXING &
FLUE OPENING
2
1
3
4
38mm
Z
X
Y
123 343
123
730*
+18
XY Z
All dimensions in mm
110 65 98.5 65 65
CB A
A
D
E
267
B B
21
FDD