Worcester GREENSTARHIGHFLOW 440 CDi User manual

UK/IE
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
8 716 115 219b (09.2008)
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C93)
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 440CDi & 550CDi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
FLOOR STANDING RSF GAS-FIRED CONDENSING COMBINATION
BOILER

INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
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 ONLY AND MUST NOT BE USED WITH ANY
OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK/IE ONLY AND MUST BE FOLLOWED EXCEPT
FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT REGISTERED ENGINEER,
SUCH AS A BRITISH GAS OR OTHER CORGI REGISTERED PERSONNEL.
IF YOU 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 (AT THE BACK OF THIS MANUAL) 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: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS
VALE RISE, TONBRIDGE, TN9 1TB
TEL: [phone]
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 appliance in a dry area prior to
installation.
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that at least 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 any
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
COMMERCIAL INSTALLATION:
IF INSTALLING A GROUP OF APPLIANCES TOGETHER, ON COMMERCIAL PREMISES,
THAT TOTALS MORE THAN 70KW, THEN THE APPLIANCES MUST BE INSTALLED IN
ACCORDANCE WITH THE REQUIREMENTS OF IGE/UP/10 THEREFORE A COMMERCIAL
GAS QUALIFICATION WILL BE REQUIRED.

INSTALLATION & SERVICING INSTRUCTIONS CONTENTS
SAFETY &
REGULATIONS
FAULT FINDING
& DIAGRAMS
APPLIANCE
INFORMATION
PRE-
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
CONVERSION
KITS
CONTENTS
1
8 716 115 219b (09.2008)
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS 5
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7
WATER SYSTEMS & PIPEWORK 9
CONDENSATE PIPEWORK 11
PRESSURE RELIEF PIPEWORK 12
BOILER LOCATION & CLEARANCES 13
MOUNTING FRAME CONNECTIONS 14
TERMINAL OUTLET POSITIONS 17
ROOM SEALED FLUE OPTIONS 18
INSTALLATION
UNPACKING THE BOILER 19
MOUNTING FRAME FIXING / FLUE OPENING 20
MOUNTING FRAME CONNECTIONS 21
FLUE LENGTHS/FLUE MEASURING & CUTTING 22
FLUE MEASURING & CUTTING 23
FLUE INSTALLATION 25
STANDARD FLUE INSTALLATION 26
EXTENDED FLUE INSTALLATION 27
FLUE TERMINAL PLUME MANAGEMENT 28
CONDENSATE, GAS & WATER CONNECTIONS 29
PRESSURE RELIEF VALVE OUTLET 30
ELECTRICAL 31
COMMISSIONING
PRE-COMMISSIONING CHECKS 32
FILLING THE SYSTEM 33
WATER TREATMENT 34
STARTING THE APPLIANCE 35
FINISHING COMMISSIONING 36
SERVICING & SPARES
INSPECTION AND SERVICE 37
REPLACEMENT OF PARTS 41
SETTING THE GAS/AIR RATIO 46
SHORT PARTS LIST 47
CONVERSION KITS
L.P.G. CONVERSION 48
FAULT FINDING & DIAGRAMS
ELECTRICAL WIRING DIAGRAM 49
CENTRAL HEATING FUNCTION 50
DHW FUNCTION 51
FAULT FINDING 52
BENCHMARK LOG BOOK AT REAR OF MANUAL

SAFETY PRECAUTIONS INSTALLATION REGULATIONS
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.
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has been instructed
in, understands and is aware of the boiler’s operating conditions and effects.
BENCHMARK:
A Benchmark Log Book is provided, at the back of this manual, 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, 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 other 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 by a
competent registered engineer, such as British
Gas or other CORGI registered personnel, 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
heating and hot water supply
BS6891 : Installation of low pressure gas
pipework up to 32mm (R11/4)
BS 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.
IMPORTANT:
Artificially softened water must not be used
to fill the central heating system.
SAFETY &
REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS
2SAFETY PRECAUTIONS &
INSTALLATION REGULATIONS
8 716 115 219b (09.2008)

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS 3
GENERAL INFORMATION
GENERAL INFORMATION
8 716 115 219b (09.2008)
STANDARD PACKAGE:
A - Floor standing gas fired combination
boiler for central heating and domestic
hot water.
B - Mounting frame complete with pre-
plumbing manifold assembly.
C - Literature pack.
D - Condensate waste pipe & non-return valve
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
A
B
C
D

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
4
TECHNICAL DATA
TECHNICAL DATA 8 716 115 219b (09.2008)
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 32.5
Max. rated heat output net 80/60°C kW 29.2 30.6 29.2 30.6
Max. rated heat input net kW 29.6 31 29.6 31
Min. rated heat output net 40/30°C kW 8.4 11 11.6 13.4
Min. rated heat output net 50/30°C kW 8.3 10.9 11.4 13.2
Min. rated heat output net 80/60°C kW 7.4 9.7 10.5 12.1
Min. rated heat input net kW 7.6 10 10.8 12.5
Max. flow temperature °C88888888
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5
Domestic Hot Water
Max. rated heat input net kW 29.6 41.5 29.5 41.5
Max. rated heat output kW 29.5 41.1 29.2 41.1
Minimum flow rate to start l/min 2.3 2.8 2.3 2.8
Minimum pressure for max flow rate 20 l/min (±15%) bar 1.5 - 1.5 -
Minimum pressure for max flow rate 25 l/min (±15%) bar - 1.7 - 1.7
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m2/h 3.1 4.4 -
Propane Gas (LPG) kg/h - 2.3 3.2
Gas supply pressure
Natural Gas G20 mb 20 20 -
LPG (Propane) Gas G31 mb - 37 37
Flue
Flue Gas Temp. 80/60°C, rated min. load °C 67/55 67/55 67/55 67/55
Flue Gas Temp. 40/30°C, rated min. load °C 43/32 43/32 43/32 43/32
CO2level at max. rated heat output % 9.4 9.4 10.8 10.8
CO2level at min. rated heat output % 8.6 9.0 10.4 10.4
NOx- classification class 5 5 5 5
Condensate
Max. condensation rate l/h 2.7 3.7 2.7 3.7
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption W 164 206 164 206
Expansion Vessel
Charge Pressure bar 0.75 0.75 0.75 0.75
Total Capacity Itr 12 12 12 12
General Data
SEDBUK (Band A) % 90.8 90.8 92.2 92.2
Appliance protection rating IP x4D x4D x4D x4D
Appliance protection rating (with mechanical timer fitted into fascia) IP 20 20 20 20
Permissable ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 -50
Nominal capacity of appliance Itr 51 51 51 51
Noise output level (at maximum CH output) dB(A) 37 37 37 37
Weight (excluding packaging) kg 112 112 112 112
DESCRIPTION UNITS Natural Gas L.P.G
440CDi 550CDi 440CDi 550CDi

APPLIANCE
INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS 5
LAYOUT & COMPONENTS
LAYOUT & COMPONENTS
8 716 115 219b (09.2008)
A
B
C
D
E
F
2
3
4
5
14
10
11
13
7
8
9
12
6
The diagram opposite shows the controls in
the servicing position and excludes the outer
case, inner covers and wiring.
1 CONTROL PANEL
2 MASTER SWITCH FOR ON/OFF
3 BURNER ON INDICATOR LIGHT (GREEN)
4 SERVICE BUTTON
5 CENTRAL HEATING BOOST BUTTON
6 DISPLAY
7 RESET BUTTON
8 ECO BUTTON
9 NOT USED
10 CH TEMPERATURE CONTROL
11 MAINS ON/OFF INDICATOR & FAULT
DIAGNOSTIC LIGHT
12 DHW TEMPERATURE CONTROL
13 SYSTEM PRESSURE GAUGE
14 POSITION FOR OPTIONAL PROGRAMMER
15 TANK TEMPERATURE SENSOR
16 TANK OVERHEAT THERMOSTAT
17 DHW HEAT EXCHANGER
18 FILLING LOOP ISOLATION VALVE
19 WATER FLOW SENSOR TURBINE
20 BOILER/TANK DRAIN & CONNECTION
POINT FOR FILLING LOOP
21 DHW FLOW SENSOR
22 CH FLOW ISOLATION VALVE
23 DHW OUTLET
24 GAS ISOLATION VALVE
25 MAINS WATER INLET ISOLATION VALVE
26 CH RETURN ISOLATION VALVE
27 RUNNER WHEEL ON MOUNTING FRAME
28 OPTIONAL FILLING LINK WITH PRESSURE
GAUGE: PART NO: 7 716 192 599
29 CIRCULATING PUMP
30 CONDENSATE PUMP ASSEMBLY
31 GAS VALVE
32 EXPANSION VESSEL
33 AIR/GAS ADJUSTMENT SCREW (SEALED)
34 HEAT CELL
35
36 GAS BURNER/SPARK ELECTRODES
37 COMBUSTION AIR MODULATING FAN
38 FLUE BLANKING PLATES
39 CASING SUPPORT STRUT
40 CASE ‘KNOCK-OUT’ PANEL-FLUE
41 AUTO AIR VENT
42 SYSTEM PRESSURE RELIEF VALVE
43 HEAT STORE
100mmØ HORIZONTAL FLUE
COMPONENTS (Kit Part No. 7 716 191 155)
A - 93° ELBOW
B - ADAPTOR
C - CONNECTOR
D - INNER WALL FLUE COLLAR
E - TELESCOPIC TERMINAL ASSEMBLY
F - OUTER WALL FLUE COLLAR
FLUE KITS:
Vertical 100mmØ Part No. 7 716 191 156
Vertical 125mmØ Part No. 7 716 191 158
Horizontal 125mmØ Part No. 7 716 191 157
1
1
41
15 16
17 18 19
20
22
21
23 24 25 26 27
28
29
31
32
33
34
35
36
37
38
39
40
42
43
30

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
6
CLEANING PRIMARY SYSTEMS
CLEANING PRIMARY SYSTEMS
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: All the following pre-installation sections must be read and
requirements met before starting boiler or flue installation.
8 716 115 219b (09.2008)
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 SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK ARE
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
8 716 115 219b (09.2008)
7
MAINS SUPPLIES
MAINS SUPPLIES
ELECTRICAL SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm (24 x
0.2mm) temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• It must be possible to isolate the appliance
from the electric supply with at least a
3mm contact separation in both 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.
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
2

PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)8 716 115 219b (09.2008)
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.