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Worcester Greenstar Highflow 440

Worcester Greenstar Highflow 440
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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 TYPE 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 SYSTEMS AND MAINS FED DOMESTIC HOT WATER

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Worcester Greenstar Highflow 440 Specifications

General IconGeneral
TypeCombi
Output40kW
ErP Efficiency RatingA
Max. Central Heating Output40kW
Fuel TypeNatural Gas
MountingFloor Standing
Central Heating Flow Temperature Range30 - 80°C
Warranty5 years

Summary

Greenstar Highflow 440 Boiler

Floor Standing RSF Gas-Fired Combination Boiler

Specifies the boiler type: floor standing, RSF gas-fired combination.

Instruction Manual: Installation, Commissioning & Servicing

Covers the essential procedures for installing, commissioning, and servicing the boiler.

Safety Precautions and Regulations

Installation Regulations and Standards

Compliance with relevant installation regulations and standards.

Mains Supplies Requirements

Electric Supply Specifications

Details on required voltage, frequency, cable type, and earthing.

Water Supply and Pressure

Requirements for water supply connections and pressure.

Gas Supply Regulations

Requirements for gas supply connection and checks.

Condensate & Pressure Relief Pipework

Condensate Pipework Installation

Guidelines for installing the condensate discharge pipe.

Pressure Relief Pipework Safety

Safe installation and positioning of the pressure relief pipe.

Boiler Location and Clearances

General Installation Clearances

Minimum space required for boiler installation.

Service Clearances

Minimum space required for servicing the boiler.

Mounting Frame Connections

Gas Supply Isolation Safety

Safety warning to isolate gas supply before work.

Gas and Water Pipe Connections

Steps for connecting the gas and water pipes to the frame.

Flue Outlet Positions

Minimum Flue Terminal Dimensions

Table of minimum distances for flue terminals.

Room Sealed Flue Options

Horizontal Flue Installation Angle

Crucial instruction for horizontal flues: rise away from boiler.

Unpacking the Boiler

Boiler Unpacking Steps

Step-by-step instructions for safely unpacking the boiler.

Mounting Frame Fixing & Flue Opening

Drilling Safety Precautions

Warning about hazards before drilling into walls.

General Installation Safety

Essential safety measures to undertake during installation.

Mounting Frame Installation

Procedure for correctly fixing the mounting frame.

Flue Opening Creation

Instructions for marking and creating the flue opening.

Horizontal Flue Opening Height Adjustment

Adjustment for horizontal flue openings based on length.

Flue Installation Procedures

Fitting the Flue Through the Wall

Steps for inserting and securing the flue through wall opening.

Flue Installation: Outlet Conversion

Condensate, Gas & Water Connections

Condensate Pipe Connection

Instructions for connecting the condensate waste pipe.

Gas and Water Supply Safety

Safety warning to isolate supplies before making connections.

Making Gas and Water Connections

Step-by-step guide for connecting gas and water pipework.

Flue Connections

Pressure Relief Valve Outlet

Fitting the Relief Valve Drain Pipe

Instructions for connecting the drain pipe to the relief valve.

Pressure Relief Valve Safety Warning

Important safety notice about the pressure relief valve discharge.

Pre-Commissioning Checks

Pre-Commissioning Safety Warning

Safety precautions before starting pre-commissioning checks.

Gas Type and Supply Check

Verify gas type matches supply and check for leaks.

Filling the System

Starting the Appliance

Critical Start-up Warning

Warning against starting an unpressurised or empty system.

Checking Gas Inlet Pressure

Procedure to verify correct gas inlet pressure.

Gas Pressure Achievement Warning

Crucial step to ensure correct gas pressure before proceeding.

Initiating Central Heating

How to turn on and control central heating.

Setting Hot Water Temperatures

How to adjust domestic hot water and tank temperatures.

Water Treatment Procedures

System Debris and Warranty Warning

Warning on impact of debris and water treatment on warranty.

Central Heating Flushing Process

Step-by-step guide for flushing the central heating system.

Central Heating Inhibitor Addition

Procedure for adding inhibitor to the heating system.

Finishing Commissioning and Handover

Handover Procedures

Steps for completing handover to the user.

Inspection and Service Procedures

Pre-Service Safety Precautions

Safety warnings before performing any inspection or service.

Post-Component Replacement Checks

Checks required after replacing components.

Requirement for Qualified Engineers

Mandate for service work to be done by competent personnel.

Routine Inspection Checklist

List of checks to perform during a routine inspection.

Using Service Functions

How to access and use the appliance's service functions.

Component Access for InspectionService

Accessing Internal Boiler Components

Steps required to open the boiler for access.

Detailed Inspection and Service Tasks

Checking Ionisation Current

Procedure to check the boiler's ionisation current.

Primary Heat Exchanger Cleaning

Instructions for cleaning the primary heat exchanger.

Service Procedures: Burner and Pressure

Burner Inspection and Cleaning

Steps for inspecting and cleaning the burner.

Replacement Parts: Safety and Preparation

Safety Precautions for Component Replacement

Essential safety steps before replacing parts.

Component Refitting Guidelines

Instructions for refitting components using new seals.

Appliance Draining Procedure

Steps for safely draining the boiler.

PCB and Transformer Replacement

Steps for accessing and replacing the PCB and transformer.

Replacement Parts: Specific Components

Condensate Pump Replacement

Steps for removing and replacing the condensate pump.

Circulating Pump Replacement

Procedure for replacing the circulating pump.

Diverter Valve Replacement

Steps for replacing the diverter valve.

Replacement Parts: Sensors and Limits

Replacing Various Sensors

General steps for replacing sensors.

Central Heating Flow Temperature Sensor

Procedure for replacing the CH flow temperature sensor.

Safety Temperature Limiter Replacement

Steps for replacing the safety temperature limiter.

Tank Sensor and Overheat Thermostat Replacement

Procedures for replacing tank sensors and overheat thermostat.

Flow SensorRegulator Replacement

Steps for replacing the flow sensor or regulator assembly.

Flue and DHW Temperature Sensor Replacement

Procedures for replacing flue and DHW temperature sensors.

Replacement Parts: Major Components

Domestic Hot Water Heat Exchanger Replacement

Steps for replacing the DHW heat exchanger.

Expansion Vessel Replacement

Steps for replacing the expansion vessel.

Pressure Relief Valve Replacement

Procedure for replacing the pressure relief valve.

Condensate Trap Replacement

Steps for replacing the condensate trap.

Gas Valve Replacement

Procedure for replacing the gas valve.

Replacement Parts: Electrodes, Burner, Heat Exchanger

Electrode Assembly Replacement

Steps for replacing the electrode assembly.

Burner Replacement

Procedure for replacing the burner.

Primary Heat Exchanger Replacement

Steps for replacing the primary heat exchanger.

Setting the GasAir Ratio

When GasAir Ratio Adjustment is Needed

Conditions requiring adjustment of CO2 settings.

Method for GasAir Ratio Adjustment

Using an electronic tester for CO2 measurement and adjustment.

Competency and Equipment Requirements

Mandatory requirements for qualified personnel and tools.

GasAir Ratio Adjustment Steps

Step 5: Measuring CO2 Level

Procedure for measuring the CO2 level.

Step 7: Adjusting CO2 for Min Output

Adjusting CO2 level using gas valve screw for minimum output.

LPG Conversion Procedure

Changing the Code Plug

Steps to replace the code plug for LPG conversion.

Changing the Gas Pipe

Procedure to swap the gas pipe for LPG usage.

Adjusting CO2 Level Post-Conversion

Guidance on adjusting CO2 level after LPG conversion.

Electrical Wiring Diagram and Component Identification

Fault Finding Guide

Fault Finding Information Disclaimer

Disclaimer on the scope and responsibility for fault finding.

Understanding Fault Codes and Display

Explanation of the boiler's fault code system.

Further Fault Finding

Fault Finding Tables

Fault Finding Tables (Continued)

User Instructions & Customer Care Guide

Product Name and Type

Identifies the product as Greenstar Highflow 440.

Contact Information and Abbreviations

User Guide and Appliance Operation

Instructions for operating and caring for the appliance.

Introduction to the Manual

Key Safety Precautions

Highlights important safety measures.

Safety Precautions (User Guide)

Boiler Location and Clearances (User Guide)

General Boiler Siting Guidelines

Guidelines for installing the boiler on a suitable surface.

Service Clearance Requirements

Minimum space needed for servicing the boiler.

Appliance Controls Overview

Temperature Controls

Controls for central heating and hot water temperatures.

Operating the Appliance: Central Heating

Switching Appliance On and Off

Procedure for powering the appliance on and off.

Setting Central Heating Temperature

How to adjust the central heating water temperature.

Operating the Appliance: Hot Water

Setting Hot Water Temperature

How to adjust the domestic hot water temperature.

Appliance Operation Modes

Fault Condition Handling

What to do if a fault occurs during operation.

Maintaining Your Appliance

Importance of Regular Servicing

Essential need for regular servicing beyond the guarantee period.

Fault Finding: Temperature Issues

Fault or Breakdown Procedures

Appliance Guarantee Terms and Conditions

Guarantee Registration Process

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