Worcester GREENSTAR HIGHFLOW 440CDi Instruction Manual
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Worcester GREENSTAR HIGHFLOW 440CDi Instruction Manual

Floor standing rsf gas-fired condensing combination boiler installation commissioning & servicing
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INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
FLOOR STANDING RSF GAS-FIRED CONDENSING COMBINATION
BOILER
GREENSTAR
HIGHFLOW 440CDi & 550CDi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
8 716 115 219c (03.2010)
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
UK/IE

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Do you have a question about the GREENSTAR HIGHFLOW 440CDi and is the answer not in the manual?

Questions and answers

ralph schuster
March 1, 2025

does the 440 cdi have a hot water tank

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1 comments:
Mr. Anderson
March 1, 2025

No, the Worcester Greenstar Highflow 440CDi does not require an external hot water tank or cylinder, as it is a combination boiler that integrates everything into a single unit.

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Summary of Contents for Worcester GREENSTAR HIGHFLOW 440CDi

  • Page 1 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...
  • Page 2 THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT REGISTERED ENGINEER, WEBSITE: worcester-bosch.co.uk SUCH AS A BRITISH GAS OR OTHER GAS SAFE REGISTERED PERSONNEL. IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT WATER TREATMENT: HELPLINE. FERNOX 01799 550811 DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER, fernox.com...

  • Page 3: Table Of Contents

    CONTENTS SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION TECHNICAL DATA LAYOUT & COMPONENTS PRE-INSTALLATION CLEANING PRIMARY SYSTEMS MAINS SUPPLIES WATER SYSTEMS & PIPEWORK CONDENSATE PIPEWORK PRESSURE RELIEF PIPEWORK BOILER LOCATION & CLEARANCES MOUNTING FRAME CONNECTIONS TERMINAL OUTLET POSITIONS ROOM SEALED FLUE OPTIONS INSTALLATION UNPACKING THE BOILER...

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS INSTALLATION REGULATIONS IF YOU SMELL GAS: Failure to install appliances correctly could lead to prosecution. DO NOT SMOKE OR STRIKE MATCHES. DO NOT TURN ELECTRICAL SWITCHES ON OR OFF. This appliance must be installed by a competent registered engineer, such as British PUT OUT NAKED FLAMES.

  • Page 5: General Information

    GENERAL INFORMATION 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.

  • Page 6: Technical Data

    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 30.6...

  • Page 7: Layout & Components

    LAYOUT & COMPONENTS 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...

  • Page 8: Cleaning Primary Systems

    CLEANING PRIMARY SYSTEMS IMPORTANT: All the following pre-installation sections must be read and IMPORTANT: requirements met before starting boiler or flue installation. 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 CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK will invalidate the appliance warranty.

  • Page 9: 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.
  • Page 10 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. •...

  • Page 11: Water Systems & Pipework

    WATER SYSTEMS & PIPEWORK PRIMARY SYSTEM PLASTIC PIPEWORK: • Any plastic pipework must have a polymeric barrier with 600mm (minimum) length of copper connected to the boiler. • Plastic pipework used for underfloor heating must be correctly controlled with a thermostatic blending valve limiting the temperature of the circuits to approx.
  • Page 12 WATER SYSTEMS & PIPEWORK FILLING PRIMARY SYSTEMS: • The CH sealed system must be filled using Water main a WRAS approved filling loop or comply Heating return supply with the diagram opposite for system fill. return return • The filling point must be at low level and valve valve Hose...

  • Page 13: Condensate Pipework

    CONDENSATE PIPEWORK IMPORTANT: Visible air break • Ensure there are no at plug hole blockages in the pipe run • Sink with Care should be taken when Condensing integral siting a soak-away to avoid Boiler 100mm overflow obstructing existing services Insulation or •...

  • Page 14: Pressure Relief Pipework

    PRESSURE RELIEF PIPEWORK 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. • The pressure relief drain pipe (A) should be at least 15mm diameter copper pipe and run downwards away from the boiler and discharge away from any electrics or...

  • Page 15: Boiler Location & Clearances

    BOILER LOCATION & CLEARANCES • This boiler is only suitable for installing 1: INSTALLATION CLEARANCES internally within a property at a suitable 610mm location onto a fixed rigid non-combustible 1200mm surface at least the same size as the boiler 600mm and capable of supporting the boiler weight.

  • Page 16: Boiler Location

    BOILER LOCATION & CLEARANCES 4: AIRING CUPBOARD CLEARANCES 4: AIRING CUPBOARD CLEARANCES: Diagram 'd' opposite shows the minimum 800mm 625mm space required to install and service the boiler within an airing cupboard. 5: VENTING COMPARTMENTS: If the clearances are less than those stated for options '3' &...

  • Page 17: Mounting Frame Connections

    MOUNTING FRAME CONNECTIONS CONNECTIONS: Water: 22mm 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).

  • Page 18: Terminal Outlet Positions

    TERMINAL OUTLET POSITIONS All measurements in millimetres Dormer Window 1,500 Velux Window Drainpipe 1,200 1,500 Boundary Window NOTE: All measurements are the minimum clearances required. Terminals must be positioned so to avoid combustion products entering the building. Key to illustration 8.

  • Page 19: Terminal Outlet Positions

    PLUME MANAGEMENT KIT POSITIONS All measurements in millimetres Plume management deflector: 180° Flue Exhaust Outlet Air Intake 1,200 Balcony Window Window Window Door Boundary Drainpipe NOTE: All measurements are the minimum clearances required. Terminals must be positioned so to avoid combustion products entering the building.

  • Page 20: Room Sealed Flue Options

    ROOM SEALED FLUE OPTIONS L= Ø100mm 140 - 530mm L= Ø125mm 9000mm L= Ø125mm 350 - 1200mm The diagrams (opposite) show the components used and the maximum flue length for each configuration of Ø100mm and Ø125mm flues. Min. • Only straight flue sections can be reduced 120mm in length by cutting.

  • Page 21: Unpacking The Boiler

    UNPACKING THE BOILER IMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. Take care not to damage the boiler panels or the floor and note that the boiler may contain some water due to factory testing. Unpacking: Undo the ties securing the carton to the pallet...

  • Page 22: Mounting Frame Fixing / Flue Opening

    All dimensions in mm MOUNTING FRAME FIXING & FLUE OPENING CAUTION: Ensure there are no pipes, electric cables, damp proof course or other hazards before drilling. SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.

  • Page 23: Mounting Frame Connections

    MOUNTING FRAME CONNECTIONS CAUTION: ISOLATE THE MAINS GAS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. GAS AND WATER CONNECTIONS: Ensure all pipework is clean and each pipe is in the correct position as shown opposite. Push in each pipe in turn and tighten the fitting to secure.

  • Page 24: Flue Lengths/Flue Measuring & Cutting

    FLUE LENGTHS HORIZONTAL FLUE: (60/100mm diameter) For vertical flues and 80/125mmØ horizontal flues, please refer to separate Flue manuals. Ø60/100mm HORIZONTAL TELESCOPIC FLUE LENGTHS: The maximum effective straight flue lengths (L) are stated opposite for the relevant appliance and must not be exceeded. Measure the total straight length (L) along the flue route, then add the following EFFECTIVE MAXIMUM STRAIGHT FLUE...

  • Page 25: Flue Measuring & Cutting

    FLUE MEASURING & CUTTING Flue bends: Connecting flue bends increases the effective pipe length and an allowance must be made for the different connectors. 950mm The example opposite shows dimensions 1145mm for two 90° bends connected to a standard flue extension. Adjusting the standard terminal length: Extend tube (A) by withdrawing from tube (B) to achieve the flue length required,...
  • Page 26 FLUE MEASURING & CUTTING FLUE OUTLETS (L or P): Remove seal (B) from flue adaptor (A). Cut square to mark, as shown, deburr and clean. Replace seal (B). FLUE MEASURING & CUTTING INSTALLATION & SERVICING INSTRUCTIONS 8 716 115 219c (03.2010)

  • Page 27: Flue Installation

    FLUE INSTALLATION Remove retaining screw (A) to swing control panel assembly (B) outwards to its full extent. Remove screws (C) from inside of casing. Lift front of top panel (D) to release. Pull forwards to disengage rear retainer (E), then lift panel (D) away from boiler. Pull clip (F) outwards to release the expansion vessel(G).

  • Page 28: Standard Flue Installation

    STANDARD FLUE INSTALLATION NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products.

  • Page 29: Extended Flue Installation

    EXTENDED FLUE INSTALLATION NOTE: to ease assembly of the flue components, grease seals lightly with the solvent-free grease supplied. 52mm 104mm Check all the seals are seated properly in the grooves provided and are in good condition. All flue joints must be sealed to prevent leakage of condensate and flue products.

  • Page 30: Flue Terminal Plume Management

    FLUE TERMINAL PLUME MANAGEMENT The flue discharge can be redirected allowing some plume management control, alternatively, a complete plume management system can be fitted to the flue terminal. Redirecting the flue discharge: Important: should you wish to use the plume deflector please use the additional grease enclosed to ensure that an adequate seal is retained.

  • Page 31: Condensate, Gas & Water Connections

    CONDENSATE, GAS & WATER CONNECTIONS CONDENSATE CONNECTION: The condensate pump (G) fills up and periodically discharges through the flexible condensate pipe (H) between 200mm to 4500mm from floor level. After this point the condensate flows, due to gravity, down the Max.

  • Page 32: Pressure Relief Valve Outlet

    PRESSURE RELIEF VALVE OUTLET Fitting the pressure relief valve drain pipe: Connect a length of 15mm copper pipe (A) to the P.R.V drain pipe (B). The P.R.V drain pipe (B) should be at least 15mm diameter and run down away from any electrics or other hazard.

  • Page 33: Electrical

    Connect room thermostat NEUTRAL to terminal Ns 9 Refit all panels Refer to manufacturers instructions when connecting external parts to the wiring centre. Worcester, Bosch Group cannot be held responsible for wiring errors. ELECTRICAL INSTALLATION & SERVICING INSTRUCTIONS 8 716 115 219c (03.2010)

  • Page 34: Pre-Commissioning Checks

    PRE-COMMISIONING CHECKS CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Check that the service and water pipes are connected to the correct valve on the manifold; A - CH flow (22mm) B - DHW flow (22mm) C - Gas inlet (22mm) D - Mains water inlet (22mm) E - CH return (22mm)

  • Page 35: Filling The System

    FILLING THE SYSTEM Turn on the water main and open the system valves (align slot vertically). Open all radiator valves. Unscrew the tank drain cap and connect the integral filling loop between the Flow valve and the Tank drain valve. Open the flow and tank drain valves.

  • Page 36: Water Treatment

    WATER TREATMENT 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. FLUSHING (Central Heating): Switch off the boiler. Open vented systems only: turn off the water to the system header tank.

  • Page 37: Starting The Appliance

    STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance or system is empty or unpressurised. Switching the appliance on/off: Turn on mains power supply. Turn on any external controls. Set the TRV controls to maximum. Set the clock/programmer to continuously ON and the room thermostat to maximum temperature.

  • Page 38: Finishing Commissioning

    FINISHING COMMISSIONING NOTE: At the time of commissioning, complete all relevant sections of the Benchmark Checklist located on the inside back pages of this document. Engage top panel (A) onto rear retainers (B) and lower front of panel into position. Secure with screws (C).

  • Page 39: Inspection And Service

    INSPECTION & SERVICE CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY IMPORTANT: Any service work must be IMPORTANT: AFTER REPLACEMENT OF ANY COMPONENTS ALWAYS CHECK FOR carried out by competent registered GAS TIGHTNESS WHERE RELEVANT AND CARRY OUT FUNCTIONAL CHECKS AS engineers, such as British Gas or other DESCRIBED IN COMMISSIONING.
  • Page 40 INSPECTION & SERVICE SERVICE INSPECTION: Grip the outer sides of the front panel (A) pull and lift away from retaining lugs (B). Remove retaining screw (C) to swing control panel assembly (D) outwards to its full extent. Pull clip (E) outwards to release expansion vessel (F).
  • Page 41 INSPECTION & SERVICE IMPORTANT: AFTER COMPLETING THE APPLIANCE SERVICE THE CO/CO MUST BE CHECKED AND SET TO THE LIMITS IN THE SECTION “AIR/GAS RATIO”. If the Heat Exchanger requires cleaning: An accessory kit is available (No. 840) specifically designed for cleaning the heat exchanger.
  • Page 42 INSPECTION AND SERVICE Burner: NOTE: On re-assembly, replace the seal Check that the boiler is completely isolated from the gas supply. Remove the clips (A) and unscrew the castellated nuts (B). Remove springs. Unscrew and remove the two hexagon screws (C) securing the fan. Slacken fully the rear securing bolt (D).

  • Page 43: Replacement Of Parts

    REPLACEMENT PARTS CAUTION: TURN OFF THE GAS SUPPLY AND ISOLATE THE MAINS ELECTRICAL SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. DRAIN THE BOILER/SYSTEM WHERE NECESSARY AND PROTECT ANY ELECTRICS IMPORTANT: Any service work must be FROM WATER INGRESS DURING COMPONENT REPLACEMENT. carried out by competent registered engineers, such as British Gas or other IMPORTANT: Refit or replace any components removed from the appliance in the...
  • Page 44 REPLACEMENT PARTS NOTE: A SERVICE TO THE FAN ASSEMBLY AND FLAP VALVE MUST NOT BE ATTEMPTED IF A CO/CO ANALYSER IS NOT AVAILABLE. Fan Assembly: Undo lower pipe union on gas pipe (E). Remove fan lead and earth connector. The earth connector has a positive clip fixing. Remove fixing screws attaching fan (A) to the burner cover (B).
  • Page 45 REPLACEMENT PARTS Sensors: Check that the appliance is electrically isolated. Central heating flow temperature sensor (A): Remove the connector. Release the sensor clip and withdraw the sensor. Apply heat transfer paste to the replacement sensor. Drain the system first: Safety temperature limiter (B): Remove the connectors.
  • Page 46 REPLACEMENT PARTS Domestic hot water heat exchanger: Before removing the heat exchanger, close the inlet valves, drain the hot water circuits and tank. The pipe (A) may be removed between the flow sensor outlet and the plate heat exchanger to improve access to the rear connections. Undo the two screws securing the plastic housing to the heat exchanger.
  • Page 47 REPLACEMENT PARTS Electrode assembly: Switch off the master switch. Isolate appliance from the power supply. Move control panel into service position. Release 4 screws to remove inner case door. Remove the leads from the electrodes. Unscrew the two fixing screws (B) and carefully remove the electrode assembly (A).

  • Page 48: Setting The Gas/Air Ratio

    38, and connect a flue gas combustion analyser. Replace the cap after use. Connect manometer to the inlet pressure Greenstar Highflow 440CDi point (A) on the gas valve. Measure the inlet pressure, it should be setting...

  • Page 49: Short Parts List

    SHORT PARTS LIST 1a Burner skin seal: Part No. 8 711 004 168 0 (GC No. E27 201) 1b Burner: Part No. 8 718 006 658 0 (GC No. E27 200) 2 Fan assembly: 440CDi: Part No. 8 717 204 410 0 (GC No. H66 918) 550CDi: Part No.

  • Page 50: L.p.g. Conversion

    L.P.G. CONVERSION Change code plug: Release three screws (A) to remove cover (B). Remove and dispose of the existing code plug (C). Replace with new conversion code plug. N.G. code plug number: 440CDi 1700 550CDi 1702 L.P.G. code plug number: 440CDi 1701 550CDi 1703 Refit panel (B) and secure with three...

  • Page 51: Electrical Wiring Diagram

    Fuse F2, T 1.6A, L250V 230V/AC Yellow White Fuse F3, T 0.5 A, L250V Pink Yellow WORCESTER 24V CONTROLS Black Green OPTION, PLUG IN POINT Orange (under blanking cover on fascia) Violet EMS BUS contacts Blue...

  • Page 52: Central Heating Function

    CENTRAL HEATING FUNCTION CENTRAL HEATING FUNCTION INSTALLATION & SERVICING INSTRUCTIONS 8 716 115 219c (03.2010)

  • Page 53: Dhw Function

    DHW FUNCTION DHW FUNCTION INSTALLATION & SERVICING INSTRUCTIONS 8 716 115 219c (03.2010)

  • Page 54: Fault Finding

    NOTE ; This fault finding information is for Display code: Fault description Check, repair/replace as necessary guidance only. Worcester Bosch cannot be held responsible for costs incurred by persons not Tank NTC defect Check tank NTC sensor and leads, deemed to be competent.
  • Page 55 GAS BOILER 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. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • Page 56: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 60 Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW Tel. 0844 892 9900 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. worcester-bosch.co.uk 8 716 115 219c (03.2010)

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