Worcester Greenstar Highflow 440CDi ERP Installation, Commissioning And Servicing Instructions

Floor standing rsf gas fired condensing combination boiler

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Page 1 Installation, Commissioning and Servicing Instructions Floor standing RSF gas fired condensing combination boiler Greenstar Highflow 440CDi & 550CDi For sealed central heating systems and mains fed domestic hot water The appliances are for use with: Natural Gas or L.P.G. (Cat. II 2H3P type C13, C33 & C53) Natural Gas: Highflow 440CDi , GC number 47-406-89...
Page 2: Table Of Contents
Contents Contents KEY TO SYMBOLS AND SAFETY PRECAUTIONS ... . 3 SERVICING AND SPARES ......31 Key to symbols .
Page 3: Key To Symbols And Safety Precautions
Failure to install correctly could lead to prosecution. • CAUTION indicates a situation that could result in minor to medium injury. If you are in any doubt, contact the Worcester Technical help-line (0330 123 3366). • WARNING indicates a situation that could result in severe injury or death.
Page 4: Safety Precautions
▶ Refer to the manufacturer’s information when installing other Fitting and modification components with Worcester equipment within the system. Fitting the appliance and any controls to the appliance may only be Handover to the user carried out by a competent engineer in accordance with the current Gas When handing over, instruct the user how to operate the heating system Safety (Installation and Use) Regulations.
Page 5 KEY TO SYMBOLS AND SAFETY PRECAUTIONS Installation regulations Current Gas Safety (Installation and Use) Regulations: All gas appliances must be installed by a competent, registered gas engineer, such as a Gas Safe registered engineer or British Gas engineer in accordance with the current regulations. Failure to install appliances correctly could lead to prosecution.
Page 6: Appliance Information
APPLIANCE INFORMATION APPLIANCE INFORMATION General information BOILER FEATURES AND CHECKLIST STANDARD PACKAGE: • Pre-wired and pre-plumbed 6 0 0 m • Galvanised steel inner frame 6 0 0 • Digital control system • Sense II Intelligent controls • Automatic ignition •...
Page 7: Technical Data
APPLIANCE INFORMATION Technical data DESCRIPTION UNITS Natural Gas L.P.G 440CDi 550CDi 440CDi 550CDi Central Heating Max. rated heat output net 40/30°C 31.2 32.8 31.2 32.8 Max. rated heat output net 50/30°C 30.9 32.5 30.9 32.5 Max. rated heat output net 80/60°C 29.2 30.6 29.2...
Page 8: Product Data On Energy Consumption
APPLIANCE INFORMATION Product data on energy consumption The following product data satisfies the requirements of the EU Regulations No. 811/2013, No. 812/2013, No. 813/2013 and No. 814/2013 supplementing Directive 2010/30/EU. Product data Symbol Unit 7731600098 7731600099 7731600100 7731600101 Product type –...
Page 9: Layout And Components
APPLIANCE INFORMATION Layout and components reset 6720818077-01.1Wo Fig. 2 Appliance layout 6720818077 (2016/04) - Greenstar Highflow CDi...
Page 10 APPLIANCE INFORMATION Control panel 230V master switch for ON/OFF Burner ON indicator light (green) Service menu button Service engineer button CH Temperature control 230V mains ON/OFF indicator & fault diagnostic light Position for optional programmer DHW Temperature control Not used ECO button Reset button System pressure gauge...
Page 11: Pre-Installation
▶ It is recommended that a primary water filter is fitted softener, to the primary water filling point of the heating system. to the system. Worcester offers two filters that helps Alternatively there are water softening/treatment devices that do not remove both magnetite and non-magnetic debris;...
Page 12: Water Supply
PRE-INSTALLATION 3.2.3 Water supply SEALED PRIMARY SYSTEM: WATER MAINS PRESSURE: • Where the system volume is more than 100 litres or exceeds 2.5 bar at maximum heating temperature an additional expansion vessel [2] • Minimum mains water pressure, for maximum performance refer to must be fitted as close as possible to the appliance in the central table 6 - Technical data.
Page 13: Condensate Pipe Work
PRE-INSTALLATION Condensate pipe work 3.4.2 External connections NOTICE: Freezing conditions NOTICE: ▶ Pipe work length should be kept to a minimum and ▶ Where a new or replacement boiler is being installed, the route as vertical as possible. access to an internal “gravity discharge” point should be one of the factors considered in determining ▶...
Page 14: Pressure Relief Pipe Work
PRE-INSTALLATION Pipe drainage will be improved if the end is cut at 45° as opposed to a 400mm min. straight cut. 25mm min. 500mm min. 25mm min. Fig. 9 External disposal Continued - Key to condensate illustrations Pipe work transition Insulate and increase pipe size External rain water pipe into foul water External air break...
Page 15: Boiler Location And Clearances
PRE-INSTALLATION Boiler location and clearances 3.6.2 Airing cupboard clearances The dimensions below show the minimum space required to install and • This is a floor-standing boiler and is only suitable for installing on the service the boiler within an airing cupboard. floor, internally in a property If a compartment is built around the boiler after installation, then the •...
Page 16: Rooms Containing A Bath Or Shower
PRE-INSTALLATION 3.6.4 Rooms containing a bath or shower Flue options NOTICE: Any switch or appliance control using mains CAUTION: Non accessible flue systems: electricity must not be within reach of a person using the ▶ Where a flue system is not going to be accessible, bath or shower.
Page 17 PRE-INSTALLATION 350 mm - 570 mm 120 mm 500 mm 300 mm Flat roof 120 mm 120 mm 120 mm 120 mm 6720818077 (2016/04) - Greenstar Highflow CDi...
Page 18: Flue Terminal Positions
PRE-INSTALLATION Flue terminal positions All measurements in millimetres 52mm 104mm 1,500 1,500 300 300 300 300 1,200 Boundary Line Fig. 16 Flue terminal positions NOTICE: ▶ All measurements are the minimum clearances required. ▶ Terminals must be positioned so to avoid combustion products entering the building. ▶...
Page 19: Plume Management Terminal Positions
PRE-INSTALLATION Plume management terminal positions All measurements in millimetres Plume re-direction: Flue terminal guard 7 716 191 176 ±45° 180° Flue Exhaust Outlet 1,500 ±80° Air Intake 5 0 0 ±80° 1,200 Boundary Line Fig. 17 Plume terminal positions 4. 1,200mm between terminals facing each other. Maximum and minimum plume management lengths: 5.
Page 20: Installation
INSTALLATION INSTALLATION CAUTION: ROOF SPACE ▶ THIS BOILER IS NOT SUITABLE FOR ROOF SPACE INSTALLATION. NOTICE: Boiler start up ▶ All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Unpacking the boiler NOTICE: BOILER HANDLING ▶...
Page 21: Mounting Frame Fixing And Flue Opening
INSTALLATION Mounting frame fixing and flue opening Fixing the mounting frame ▶ Position the mounting frame [1] on the floor against the wall with WARNING: Damage to property! manifold connections [2] facing away from the wall [4] ensuring Damage caused by drilling into pipes, electrical cables, there is enough space for the pipe work [5].
Page 22: Flue Measuring And Cutting
INSTALLATION All dimensions in millimetres Flue Length guide Flue length range (mm) Number of extensions - 265 None 310 - 530 None 530 - 750 None 750 - 1260 1260 - 1480 1480 - 2210 2210 - 2430 2430 - 3160 3160 - 3380 3380 - 4000 Table 13 Flue extension guidance up to 4000mm...
Page 23: Condensate, Gas And Water Connections
INSTALLATION Condensate, gas and water connections 4.5.1 Condensate connection The condensate pump fills up and periodically discharges through the ▶ Ensure all pipe work is clean. flexible condensate pipe [8] between 200mm to 4500mm from floor ▶ Tighten up the flat sealing connections to secure: level.
Page 24: Electrical
INSTALLATION Electrical CAUTION: ISOLATE THE 230V ELECTRICITY SUPPLY ▶ Ensure that the electricity supply is safely Isolated and secured to prevent inadvertent re-connection. Information on safe isolation can be found in the Health and Safety Executive guidance HSG85. Using test equipment approved to GS38 confirm that the electricity supply is disconnected ▶...
Page 25: Pcb Connections
These cable clamps are for 230 volt connections only Worcester, Bosch Group cannot be held responsible for wiring errors. 2. EMS connection BB for controllers and outdoor sensor ▶ EMS connection for intelligent controllers, e.g. Wave, Sense etc.
Page 26: Commissioning
COMMISSIONING COMMISSIONING Pre-commissioning checks Filling the system ▶ Pull the upper edges of the front panel towards you and lift off the CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY bottom lugs. ▶ Ensure that the electricity supply is safely Isolated ▶ Turn on the water main and open the system valves (align slot and secured to prevent inadvertent re-connection.
Page 27: Water Treatment
▶ In cases where all attempts to find a micro leak have ▶ Turn on mains power supply. failed, Worcester, Bosch Group supports the use of Fernox F4 leak sealer. Fig. 34 3 Amp fused double pole isolator ▶...
Page 28: Initialization
COMMISSIONING ▶ Turn the temperature control [10] to maximum. The burner on Special messages Description indicator [13] illuminates green when the burner has lit. Key acknowledgement after pressing button longer than 3 seconds The boiler runs for 15 minutes at minimum heating (save function) output to fill the condensate trap.
Page 29: Checking The Gas Rate
COMMISSIONING ▶ Measure the pressure with the boiler running at maximum. Regulator Gas Control L.P.G. – Refer to figure 33 for control panel guide valve < 4.0mbar – Press Service engineer button [11] for more than ten seconds and set Central Heating temperature to maximum. difference –...
Page 30: Co And Combustion Check
Check and zero the analyser in fresh air as specified by the manufacturer. ▶ The air/gas ratio valve is factory set and must not be adjusted during commissioning unless this action is recommended following contact with the Worcester, Bosch Group help line 0330 123 3366. Zero the analyser Set boiler to >...
Page 31: Finishing Commissioning
SERVICING AND SPARES Finishing commissioning SERVICING AND SPARES At the time of commissioning, complete all relevant Inspection and service sections of the Benchmark Checklist located on the inside back pages of this document. CAUTION: ISOLATE THE GAS SUPPLY ▶ Ensure that the gas supply is safely Isolated and 1.
Page 32: Service Function
SERVICING AND SPARES Service function Setting boiler to maximum: ▶ When running in the Service engineer mode, the boiler will operate both the Central Heating and DHW circuits. ▶ It will be necessary to run water through the DHW circuit to ensure that the boiler will not cycle during Service mode.
Page 33: Checking The Flue Integrity
▶ Re-check the fan pressure readings. If the boiler, after completing the above checks, fails the fan pressure test then contact Worcester, Bosch Group for advice. ▶ After the measurements are taken switch the boiler off. ▶ Disconnect the manometer and replace the test point cover.
Page 34: To Check The Flap Valve In The Fan Intake
SERVICING AND SPARES Fig. 48 Burner removal 6.7.2 To check the flap valve in the fan intake ▶ Refer to section 6.9.3 on page 38 for access to the fan intake. ▶ Carefully withdraw the flap valve from fan intake tube and check for soiling and splits, clean or replace as required.
Page 35 SERVICING AND SPARES If the Heat Exchanger requires cleaning: ▶ Using the cleaning blade, working from the bottom to the top, to loosen any deposits in the heat exchanger. ▶ Remove the condensate trap. ▶ Remove the cleaning access cover [1] and seal [2]. 6720818079-23.1Wo Fig.
Page 36: Re-Assembly Of The Burner Cover
SERVICING AND SPARES ▶ Pour water into the top of the heat exchanger to flush out the debris. 6.7.5 Re-assembly of the burner cover NOTICE: Burner gasket seal ▶ Always replace the burner seal with a new one when the joint has been disturbed. ▶...
Page 37: Replacement Parts
SERVICING AND SPARES ▶ If further adjustment is required, remove the combustion chamber Replacement parts cover and set adjuster [3] as necessary CAUTION: Isolate the boiler ▶ Replace the cover and check the maximum CO again ▶ Turn off the gas supply and isolate the mains Max adjustment electrical supply before starting any work and Max mode...
Page 38: Pcb Control Board
SERVICING AND SPARES 6.9.2 PCB Control board Flap Valve: Access to boiler control components ▶ Undo lower pipe union on gas pipe [5]. ▶ Remove the screws [1] to release the cover from the controller. ▶ Remove pipe [5] by pushing upwards and towards the rear of the boiler.
Page 39: Diverter Valve Motor
SERVICING AND SPARES 6.9.5 Diverter valve motor ▶ Ensure that the appliance is in service mode (there is no need to drain the appliance). ▶ Disconnect the connector [2] from diverter valve motor [1]. ▶ Pull the motor [1] to you, the assembly will slide free from the valve. ▶...
Page 40: 6.9.10 Domestic Hot Water Heat Exchanger
SERVICING AND SPARES Flue Temperature limiter [9] 6.9.13 Pressure relief valve PRV: ▶ Remove the connector. ▶ Drain the appliance. ▶ Using a small terminal screwdriver, prise the sensor and grommet ▶ Disconnect the drain pipe from the valve [4] from the plastic housing.
Page 41: 6.9.15 Gas Valve
SERVICING AND SPARES 6.9.15 Gas valve 6.9.17 Burner ▶ Check that the gas cock is turned off. WARNING: Burner ▶ Disconnect the black rubber tube [1] from the gas valve. ▶ Do not remove the burner unless a new gasket is ▶...
Page 42: Short Parts List
SERVICING AND SPARES 6.10 Short parts list Burner Burner seal Fan 440 CDi 8 737 703 148 8 711 004 168 0 8 716 117 325 GC No. E27 200 GC No. E27 201 GC No. E74-539 Fan 550 CDi Pump Diverter valve assembly 8 718 644 395 0...
Page 43: Fault Finding And Diagrams
ST18 Purple Black of the control panel White 230V~ Yellow White Pink Yellow WORCESTER 24V CONTROLS Black Green OPTION, PLUG IN POINT Orange (under blanking cover on fascia) Violet EMS BUS contacts Blue (for Sense controls) Black...
Page 44: Central Heating Function
FAULT FINDING AND DIAGRAMS Central heating function - 6720818077 (2016/04) Greenstar Highflow CDi...
Page 45: Dhw Function
FAULT FINDING AND DIAGRAMS DHW function 6720818077 (2016/04) - Greenstar Highflow CDi...
Page 46: Protection Function
FAULT FINDING AND DIAGRAMS Protection function AUTOMATIC INTERNAL FROST FUNCTION Internal boiler Internal boiler Pump switches off temperature Pump runs temperature after a 3 minute between rises above 9°C overrun period 8°C & 5°C Boiler automatic frost function (monitors internal boiler primary temperature) Internal boiler Central heating...
Page 47: Fault Finding
FAULT FINDING AND DIAGRAMS Fault finding ▶ This fault finding information is for guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not deemed to be competent. ▶ The electronic control system for this boiler incorporates a blue central indicator. This normally confirms the permanent mains supply, but, by flashing during a fault, provides a guide to the cause as listed.
Page 48: Condensate Pump Indicator Lights
FAULT FINDING AND DIAGRAMS Condensate pump Indicator lights The condensate pump has indicator lights [1] which show operation status or a fault condition. Fig. 69 Condensate pump indicator lights CONDENSATE PUMP - OPERATING LIGHTS AND FAULT CONDITIONS: Ready for operation = Steady green light Fault = Red light Pump running = Flashing green light Operating lamps...
Page 49 Notes 6720818077 (2016/04) - Greenstar Highflow CDi...
Page 50: Gas Boiler System Commissioning Checklist
GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Optimum start control Fitted...
Page 51 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % SERVICE 03 SERVICE 04 ² % ²...
Page 52 0330 123 9119 TRAINING: 0330 123 0166 SALES: 0330 123 9669 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 0330 123 9559 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 6 720 818 077 (2016/04)

This manual is also suitable for:

Greenstar highflow550cdi erp

Worcester Greenstar Highflow 440CDi ERP Installation, Commissioning And Servicing Instructions

1 Key to Symbols and Safety Precautions

2 Appliance Information

3 Pre-Installation

4 Installation

5 Commissioning

6 Servicing and Spares

7 Fault Finding and Diagrams