Worcester GREENSTARHIGHFLOW 440 CDi User manual

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UK/IE
USER INSTRUCTIONS & CUSTOMER CARE GUIDE
8 716 115 220a (07.2008)
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C53)
NATURAL GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-24
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-25
LIQUID PETROLEUM GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-26
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-27
GREENSTAR
HIGHFLOW 440/550CDi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
FLOOR STANDING RSF GAS-FIRED CONDENSING COMBINATION
BOILER

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USER INSTRUCTIONS & CUSTOMER
CARE GUIDE
CONTACT INFORMATION
USER INSTRUCTIONS & CUSTOMER CARE GUIDE
8 716 115 220a (07.2008)
PLEASE READ THESE INSTRUCTIONS
CAREFULLY BEFORE OPERATING YOUR
BOILER
THESE INSTRUCTIONS ARE APPLICABLE TO
THE WORCESTER, BOSCH GROUP BOILER
MODEL(S) STATED ON THE FRONT COVER
OF THIS MANUAL ONLY AND MUST NOT BE
USED WITH ANY OTHER MAKE OR MODEL OF
BOILER.
THE INSTRUCTIONS APPLY IN THE UK ONLY
AND SHOULD BE FOLLOWED EXCEPT FOR
ANY STATUTORY OBLIGATION.
IF YOU ARE IN ANY DOUBT CONTACT THE
WORCESTER, BOSCH GROUP TECHNICAL
SUPPORT.
DISTANCE LEARNING AND TRAINING
COURSES ARE AVAILABLE FROM
WORCESTER, BOSCH GROUP.
THIS BOILER MUST BE INSTALLED BY A
CORGI REGISTERED, COMPETENT PERSON.
FAILURE TO INSTALL CORRECTLY COULD
LEAD TO PROSECUTION.
PLEASE LEAVE THIS GUIDE, THE
INSTALLATION INSTRUCTIONS AND THE
COMPLETED BENCHMARK CHECKLIST
WITH THE USER.
NOTE: THE BENCHMARK CHECKLIST AND
SERVICE INTERVAL RECORD CAN BE
FOUND AT THE REAR OF THE
INSTALLATION, COMMISSIONING AND
SERVICE INSTRUCTIONS.
ABBREVIATIONS USED IN THIS BOOK:
NG - Natural Gas
LPG - Liquid Petroleum Gas
CH - Central Heating
SEDBUK - Seasonal Efficiency of Domestic
Boilers in the United Kingdom
WORCESTER BOSCH:
TECHNICAL: 08705 266241
SERVICE: 08457 256206
LITERATURE: 01905 752556
SALES: 01905 752640
WEBSITE: www.worcester-bosch.co.uk

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USER INSTRUCTIONS & CUSTOMER CARE GUIDE
MAINTENANCE ENERGY
SAVING
USING YOUR
APPLIANCE INTRODUCTION
GUARANTEE
1
CONTENTS
8 716 115 220a (07.2008)
CONTENTS
INTRODUCTION
SAFETY PRECAUTIONS 2
GENERAL INFORMATION 3
GENERAL NOTES 4-5
USING YOUR APPLIANCE
CONTROLS 6-7
OPERATING THE APPLIANCE
Switching the appliance on/off 8
Setting the central heating temperature 8
Controlling central heating 8
Frost protection 9
Controlling the hot water temperature 9
ECO indicator 9
Fault condition 10
MAINTENANCE
MAINTAINING YOUR BOILER 11
FAULT FINDING 12
FAULT OR BREAKDOWN 13
ENERGY SAVING
TIPS ON ENERGY SAVING 14-15
GUARANTEE
YOUR GUARANTEE 16
GUARANTEE REGISTRATION 17
Dedicated to heating comfort
Thank you for purchasing a Greenstar gas-fired condensing combination boiler manufactured
by Worcester, Bosch Group. The company prides itself on manufacturing boilers to the
strictest quality control standards throughout every stage of production.
Worcester, Bosch Group has led the field in innovative boiler design and performance for
more than 40 years. This heritage means all products are of exceptional quality and proven
reliability.
The Greenstar range in particular is extremely energy efficient, offering you economical
running costs and value for money. It sits in SEDBUK Band A, and is therefore amongst
the top energy rated boilers available.
There is also the reassurance of our no-nonsense 2 years parts and labour guarantee -
backed up by Worcester Total Cover, an optional complete maintenance scheme to keep
your boiler operating at peak condition and efficiency.
To find out more about Worcester, Bosch Group log onto www.worcester-bosch.co.uk .

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INTRODUCTION
8 716 115 220a (07.2008)
SAFETY PRECAUTIONS
2
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.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within
the vicinity of the boiler.
Chemically aggressive substances can corrode the boiler and invalidate any warranty.
FITTING & MODIFICATIONS
Fitting the boiler, any controls to the boiler and removal of the outer casing may only be
carried out by a competent engineer in accordance with the Gas Safety (Installation and Use)
Regulations.
Flue systems must not be modified in any way other than as described in the Installation
instructions and any misuse or unauthorised modifications to the boiler, flue or associated
components and systems could invalidate the warranty. The manufacturer accepts no liability
arising from any such actions. This does not affect your statutory rights.
SAFETY PRECAUTIONS

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INTRODUCTION
GENERAL INFORMATION 3
SERVICING
The boiler must be serviced regularly by a competent, qualified person, such as a Worcester
service engineer or alternatively a British Gas or other CORGI registered person.
Always use original spares, to help maintain the economy, safety and reliability of the boiler
and to have the Service Record completed in the Benchmark checklist.
IMPORTANT:- Ensure that the service engineer completes the Service Record in the
Benchmark checklist after each service.
The completed Benchmark checklist will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
NOTE:
BENCHMARK STANDARD
‘Benchmark’ is a code of practice for correctly installing, commissioning and servicing of
domestic water heating boilers.
A Benchmark Checklist is provided by the manufacturer for the installer to complete ALL
details together with their CORGI registration number and sign to confirm that the boiler has
been installed and commissioned according to the manufacturer’s instructions.
HEALTH & SAFETY
The boiler contains no asbestos and no substances used in the construction process that
contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations
1988).
The Benchmark checklist and service interval record can be found at the
rear of the Installation, Commissioning and Servicing Instructions.
GENERAL INFORMATION

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INTRODUCTION
8 716 115 385a (07.200)
GENERAL NOTES
4
To get the best from your boiler please read
these instructions carefully.
SEALED HEATING SYSTEMS
This boiler is fitted to a sealed heating system
which is pre-pressurised. Your installer will
advise you of the minimum and maximum
pressure which should be indicated on the
pressure gauge.
Check regularly that the pressure is maintained
and contact your installer or maintenance
engineer if a permanent significant drop in
pressure is indicated on the pressure gauge.
If the system loses pressure it should be re-
pressurised and the cause of the fall
investigated.
CENTRAL HEATING SYSTEMS
During the first few hours of operation of the
central heating system, check that all radiators
are being heated evenly. If the top of a radiator
is at a lower temperature than the bottom
then it should be vented by releasing air
through the venting screw at the top of the
radiator. Ask your installer to show you how
this is done.
This boiler is fitted to a sealed system;
repeated venting will reduce the quantity of
water in the system and this must be
replenished for safe and satisfactory operation
of the boiler.
Should water leaks be found in the system or
if excessive venting is required, then a service
engineer must be contacted to inspect the
installation and rectify any fault.
Only additives that are compatible with
aluminium may be used in the system. Any
incompatible additive used will invalidate the
guarantee.
CONDENSATE DRAIN
This is a condensing boiler and the terminal
will, at times give out a plume of water vapour.
This is quite normal.
The boiler also produces quantities of
condensate which is discharged regularly by
a trap within the boiler via a pump and pipe
to drain. This pipe must not be blocked or
altered in any way.
CLEARANCES - SERVICE
Your installer will have provided adequate
space around the boiler for safety and servicing
access. Do not restrict this space with the
addition of cupboards, shelves etc. next to
the boiler.
ROOM THERMOSTAT
A room temperature controller and
programmer should be fitted to control the
central heating. Refer to the instructions
supplied with the thermostat for information
on siting and setting.
THERMOSTATIC RADIATOR VALVES
RVs should fitted to all but one of the radiators
(or at least those in the sleeping
accommodation). The radiator without the
TRV must be in the same room as the room
thermostat, and must be uncontrolled and
unrestricted. The thermostatic radiator valves
should conform to the requirements of
BS2767:10.
GENERAL NOTES
600mm
15mm
5mm
5mm
610mm
1200mm
865mm

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INTRODUCTION
8 716 115 220a (07.2008) GENERAL NOTES 5
GENERAL NOTES
BOILER CLEARANCES -
UNVENTILATED COMPARTMENT
The diagram opposite shows the minimum
space required to install and service the boiler
inside an unventilated compartment.
* Space required for unventilated areas with
a removable door or panel, but 600mm to a
fixed surface for servicing.
** This space can be reduced to 50mm for
one side only as long as both side clearances
add up to the total of both the side
measurements shown, or more.
Two examples are shown opposite, refer to
the ‘Installation, commissioning and servicing
instruction manual’ for further information.
Do not add cupboards, shelves etc. to restrict
the space around the boiler.
VENTILATION
This is a room sealed boiler and does not
require any air for combustion from inside the
property.
In spite of the requirements of BS 6798 and
BS 5440 there is no need for ventilation
openings to be provided in the compartment
because of the low heat loss from the boiler
casing, if the clearances shown are maintained.
BOILER CLEARANCES -
AIRING CUPBOARD
If the boiler is fitted into an airing cupboard
then the diagram opposite shows the minimum
clearances required around the boiler and
also the clearances for any shelf constructed
above the boiler.
If a compartment is built around the boiler
after installation, then the compartment must
be separated from the boiler space by a non-
combustible partition as described in BS 6798.
WARNING
Do not operate the boiler if the flue terminal
fitted on the outside wall or roof is obstructed
or damaged.
PUMP ANTI-SEIZURE
If there has been no heating demand for 24
hours, the boiler will run the system pump for
a few seconds. This is to reduce the possibility
of pump seizure during long periods of
inactivity which are usually more frequent
during the summer months.
25mm 100mm
200mm
100mm
25mm
100mm
1050mm
625mm 800mm
800mm
50mm
100mm**
100mm**
200mm*
900mm
800mm

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USING YOUR
APPLIANCE
8 716 115 220a (07.2008)
CONTROLS
6
CONTROLS
A
D
F
L
J
C
B
I
E
H
M
G
K
A - MASTER SWITCH FOR ON/OFF
B - MAINS ON/OFF INDICATOR + FAULT DIAGNOSTIC LIGHT
C - CENTRAL HEATING TEMPERATURE CONTROL
D - BURNER ON INDICATOR LIGHT (GREEN)
E - FAULT RESET BUTTON
F - SERVICE BUTTON
G - DOMESTIC HOT WATER TEMPERATURE CONTROL
H - ECO BUTTON
I - SYSTEM PRESSURE GAUGE
J - POSITION FOR OPTIONAL PROGRAMMER
K - DISPLAY
L - CENTRAL HEATING BOOST BUTTON
M- NOT USED

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USING YOUR
APPLIANCE
8 716 115 220a (07.2008) CONTROLS 7
CONTROLS
TO ACCESS THE CONTROLS
Pull the centre top of the cover panel to
allow the cover to open.
TO ACCESS THE FILLING LOOP
CONNECTION
Pull the front panel away from the boiler
and lift up.
LIFT
Filling
Loop
connection
PULL
CONTROLS
COVER
2
1

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USING YOUR
APPLIANCE
8OPERATING THE APPLIANCE 8 716 115 220a (07.2008)
OPERATING THE APPLIANCE
SWITCHING THE APPLIANCE ON/OFF
Switching on
Switch on the appliance by pressing the
master switch.
The indicator light shows blue
• The boiler runs for 15 minutes at minimum
heating output to fill the condensate trap, the
display (K) alternates between ‘-II-’ and the
central heating flow temperature. This occurs
every time the mains supply has been interrupted.
Switching off
Switch off the appliance by pressing the
master switch. The blue indicator light goes
out.
SETTING THE CENTRAL HEATING
TEMPERATURE
Turn the central heating temperature
control to the desired level, between 35°C
and 88°C.
When the burner is lit, the green indicator
light underneath the on/off switch is
illuminated.
CONTROLLING CENTRAL HEATING
Set the timer to the correct time.
Set room thermostat to the desired room
temperature.
Set the thermostatic radiator valves to the
desired settings.
*---
1---
2---
3---
4---
5---
6---
Max ---
OFF
35 ºC
40 ºC
50 ºC
65 ºC
75 ºC
85 ºC
88 ºC
APPROXIMATE TEMPERATURES

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USING YOUR
APPLIANCE
OPERATING THE APPLIANCE
8 716 115 220a (07.2008)
OPERATING THE APPLIANCE
9
FROST PROTECTION
If heating is NOT required:
Leave master switch on.
Turn the central heating temperature
control to
If the temperature falls to 5 °C inside the
boiler, the boiler will fire to prevent the
possibility of freezing.
Add a suitable anti-freeze fluid to the water
in the central heating system.
If remote pipework is likely to be subjected
to freezing conditions, ensure the installer
has fitted a frost thermostat in the area to
protect the pipework.
CONTROLLING THE HOT WATER
TEMPERATURE
The hot water temperature can be set to
between approx. 45 °C and 65 °C using
the temperature control
ECO INDICATOR
NOTE: If your boiler has an in-built fascia
mounted programmer and the mains supply
is interupted, the ECO button will need to
be reset by pressing and holding for three
seconds.
When the ECO button IS lit the pre-heated
tank of hot water is turned off, but the boiler
will supply hot water as a normal Combi boiler.
It will take longer to obtain hot water at the
tap in ECO mode as the boiler is not
maintaining a supply of hot water for
immediate use.
When the ECO button is NOT lit the boiler is
in pre-heat mode for hot water.
Hot water will now be available at the tap
almost immediately as the boiler constantly
maintains a tank of hot water ready for use.
---
1---
2---
3---
4---
5---
6---
Max. ---
45 ºC
50 ºC
52 ºC
54 ºC
56 ºC
58 ºC
60 ºC
65 ºC
APPROXIMATE TEMPERATURES
Min.

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USING YOUR
APPLIANCE
OPERATING THE APPLIANCE 8 716 115 220a (07.2008)
OPERATING THE APPLIANCE
10
FAULT CONDITION
In the unlikely event of a fault occurring while
the appliance is in operation:
The reset button will flash once per second
and the mains indicator (blue light) will flash
also. The display shows a fault code.
To reset boiler press the reset button.
The reset button will no longer be illuminated
and the mains indicator will stop flashing.
The boiler will function normally, dependent
on programmer and room thermostat settings.
If the fault remains and cannot be cleared by
pressing the reset button, or if fault persists
contact British Gas for assistance, giving a
description of the fault and, if possible, the
fault code from the display.

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MAINTENANCE
8 716 115 220a (07.2008) MAINTAINING YOUR BOILER 11
Your new Greenstar gas-fired boiler represents
a long term investment in a reliable, high
quality product.
In order to realise its maximum working life,
and to ensure it continues to operate at peak
efficiency and performance, it is essential that
your boiler receives regular servicing and
maintenance checks from a competent person
beyond the initial 2 year guarantee period.
If you would like to know more about a
Worcester, Bosch Group service contract,
please tick the appropriate box on your
warranty registration card.
If your Greenstar gas-fired boiler should fail
to operate correctly or requires servicing
please contact the Worcester, Bosch Group
Service Department (see inside front cover
for details).
Details of the boiler including the Gas Council
number can be found under the controls cover
flap on the boiler.
MAINTAINING YOUR BOILER

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MAINTENANCE
12 FAULT FINDING 8 716 115 220a (07.2008)
FAULT FINDING
PROBLEM CAUSE REMEDY
This table gives information on basic operating system problems.
In the unlikely event of a boiler fault please read the following page thoroughly before contacting
Worcester, Bosch Group.
Desired room
temperature is not
reached
Thermostatic radiator
valve(s) set too low
Increase thermostatic radiator
valve setting(s)
Temperature control for CH
flow on boiler set too low
Increase CH flow temperature
control setting
Air trapped in heating
system
Bleed radiators and recharge
heating system
Desired room
temperature exceeded by
large amount
Radiators are too hot Turn down thermostatic radiator
valves / room thermostat Reduce
central heating temperature on
boiler
Heating stays on for too
long
Clock is incorrectly set Check setting
No on/off indicator Momentary power failure Switch off boiler at master switch,
wait a few seconds then switch
on again
Hot water temperature
too low
Temperature set too low
Programmer setting
Water flow at tap too high
Check setting
Check setting
Reduce flow rate at tap
Hot water temperature
too high
Temperature set too high Check setting

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MAINTENANCE
FAULT OR BREAKDOWN
8 716 115 220a (07.2008)
13
This boiler is supported in the UK and Eire by Worcester, Bosch Group.
Specially trained, Worcester, Bosch Group Service Engineers are available to attend a breakdown
occurring on this boiler.
No charge will be made for parts and/or labour providing:
An boiler fault is found and the boiler has been installed within the past 24 months.
Reasonable evidence of this must be supplied on request. i.e. the Benchmark Checklist.
A call-out charge will be made where:
The boiler has been installed for over 24 months.
OR
Evidence cannot be provided that the first year service inspection has been carried out
(i.e. an entry in the Benchmark Checklist).
OR
Our Field Service Engineer finds no fault with the boiler (see Note).
OR
The cause of breakdown is misuse or with other parts of your plumbing/heating system, or
with equipment not supplied by Worcester, Bosch Group.
NOTE: NO BOILER FAULT IS FOUND ON OVER 30% OF SERVICE CALL OUTS.
Please read this guide carefully to gain a good understanding of the operation of your boiler.
In the case of a suspected fault, refer to the fault finding section of this guide.
If in doubt contact our Technical Support
In the event of an boiler fault or breakdown please contact our Service Department. Your
service administrator will arrange for an engineer to call with the minimum of delay; under
normal circumstances this will be from 1 - 3 working days (excluding weekends) for priority
breakdown situations (no hot water and/or heating).
Invoices for attendance and repair work carried out on this boiler by any third party will not
be accepted.
FAULT OR BREAKDOWN

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ENERGY
SAVING
TIPS ON ENERGY SAVING 8 716 115 220a (07.2008)
14
TIPS ON ENERGY SAVING
HEATING ECONOMICALLY
The boiler is designed to provide a high level of comfort while keeping gas consumption and
the resulting environmental effect as low as possible. The gas supply to the burner is controlled
according to the level of demand for heat. The boiler continues to operate with a low flame
if the demand for heat reduces. The technical term for this process is modulating control.
Modulating control reduces temperature fluctuations and provides even distribution of heat
throughout the home. This means that the boiler may stay on for relatively long periods but
will use less gas than a boiler that continually switches on and off.
CENTRAL HEATING SYSTEMS WITH ROOM THERMOSTATS/THERMOSTATIC RADIATOR
VALVES
The temperature control on the boiler should be set to the maximum.
The temperature of each room can be set individually (except primary room with the room
thermostat) using the thermostatic radiator valves.
ROOF INSULATION
Around 30% of the heat loss from a property is through the roof. Replace any old insulation
with new insulation, preferably of around 200mm thickness or more.
WINDOW FRAMES
Single glazed windows, particularly those with steel frames, can lose a great deal of heat.
Consideration should be given to replacement with PVCu or wooden framed double glazed
units.
CURTAINS
Lined curtains, or heavier full length curtains can provide excellent insulation. However, always
ensure that the curtains do not drape over radiators.

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ENERGY
SAVING
8 716 115 220a (07.2008) TIPS ON ENERGY SAVING 15
TIPS ON ENERGY SAVING
DRAUGHTS
Try to ensure that draughts around doors, windows, letterboxes and keyholes etc. are reduced
by using a suitable draught excluder. Warning - Do not block or seal any air vents that are
installed to ensure the central heating boiler operates safely.
ROOM THERMOSTATS
Reducing the setting of the room thermostat by 1°C can reduce fuel consumption by up to
10%.
NEW CONTROL SYSTEMS
Upgrade your heating control system if necessary with the latest equipment available. The
minimum level of control is a programmer, interlocking room thermostat and thermostatic
radiator valves.
RADIATORS
More often than not radiators will be sited underneath a window, so the warm air from the
radiator heats the colder incoming air from the window. The performance of the radiator will
be affected if the curtains are allowed to drape over the radiator or shelves are fitted above
it. The positioning of furniture and tables in front of the radiator should also be avoided.
It is advisable to manually adjust all radiator thermostatic valves every 2-3 months to prevent
them sticking. It is also important that the plastic tops of all valves are always in position and
not cracked or damaged to prevent accidents. Care should be taken when vacuum cleaning
carpets to avoid damage to valves and pipework.
The heating system and the outputs of the radiators have been carefully selected by your
installer. The temperature obtainable in any given room is dependent on all radiators being
operated at the same time. If you decide to turn off radiators in unused rooms, spare bedrooms
etc., you may experience slightly lower room temperatures in rooms adjacent to unheated
rooms.

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GUARANTEE
16 YOUR GUARANTEE 8 716 115 220a (07.2008) 16
YOUR GUARANTEE
This boiler is guaranteed against faulty material or workmanship for a period of 2 years
from the date of installation subject to the following terms and conditions:
Your Guarantee Registration Card must be returned within 30 days for the second year of
your guarantee to become valid.
During the period of this guarantee any components of the unit which are proven to be
faulty or defective in manufacture will be exchanged or repaired free of charge by Bosch
Thermotechnology Ltd.
The householder may be asked to prove the date of installation, that the boiler was correctly
commissioned and, where appropriate, the first year’s service inspection has been carried
out to the satisfaction of Bosch Thermotechnology Ltd., when requested. These should be
part of the Benchmark Checklist.
Any product or part returned for servicing under the guarantee must be accompanied by
a claim stating the model, serial number & date of installation.
Bosch Thermotechnology Ltd., will not accept responsibility for damage caused by faulty
installation, neglect, misuse or accidental damage or the non-observance of the instructions
contained in the Installation Commissioning and Servicing Instructions and User Instructions
and Customer Care Guide.
The boiler has been used only for the normal domestic purposes for which it was designed.
This guarantee does not affect your statutory rights.Your Guarantee Registration Card must
be returned within 30 days for the second year of your guarantee to become valid.
This guarantee applies only to equipment purchased and used in the United Kingdom and
Eire.
This guarantee does not affect your statutory rights.

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GUARANTEE
GUARANTEE REGISTRATION
8 716 115 220a (07.2008)
17
You should complete and return the postpaid
Guarantee Registration Card within 30 days
of purchase.
Returning the card will register you as the
owner of your new Greenstar boiler and will
assist us in maintaining an effective and
efficient customer service by establishing a
reference and permanent record for your
boiler.
This does not affect your statutory rights.
MODEL:
SERIAL No.
(See identity label inside the appliance casing)
TYPE / SIZE:
DATE OF INSTALLATION:
NAME OF INSTALLER:
TELEPHONE NUMBER OF INSTALLER:
For your own record:
Please ensure that the Benchmark Checklist has been completed
by your installer or service engineer.
GUARANTEE REGISTRATION

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Dedicated to heating comfort
Worcester, Bosch Group
Cotswold Way, Warndon, Worcester WR4 9SW
Tel. [phone] Fax. [phone]
Worcester, Bosch Group is a brand name of
Bosch Thermotechnology Ltd.
worcester-bosch.co.uk
8 716 115 220a (07.2008)