Greenstar Highflow 440
FLOOR STANDING RSF GAS-FIRED COMBINATION BOILER
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
THIS APPLIANCE IS FOR USE WITH
NATURAL GAS OR LPG (Cat II 2H3P TYPE C13 & C33)
NATURAL GAS:
LIQUID PETROLEUM GAS:
GB/IE
47 311 82
47 311 83
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
CONTENTS
INTRODUCTION
EXCELLENCE COMES AS STANDARD
2
3
4
6
SAFETY PRECAUTIONS
GENERAL NOTES
Boiler location and clearances
USING YOUR APPLIANCE
CONTROLS
7
OPERATING THE APPLIANCE
Switching the appliance on/off
Setting the central heating temperature
Controlling central heating
Setting the hot water temperature
Summer mode, hot water only
Frost protection
8
8
8
9
10
10
10
Fault condition
ENERGY SAVING
TIPS ON ENERGY SAVING
11
MAINTENANCE
MAINTAINING YOUR APPLIANCE
FAULT FINDING
14
15
16
FAULT OR BREAKDOWN
GUARANTEE
YOUR GUARANTEE
GUARANTEE REGISTRATION
17
18
1
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
CONTENTS
EXCELLENCE COMES AS STANDARD
Thank you for purchasing a Greenstar Highflow
440 gas-fired condensing boiler manufactured
by Worcester Bosch. The company prides itself
on manufacturing boilers to the strictest quality
control standards throughout every stage of
production. Worcester Bosch has led the field
in innovative appliance 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 converting up to 97% of gas
consumed into heat offering you economical
running costs and value for money. It sits in the
SEBUK Band A – amongst the top energy
rated appliances available
There is also the assurance 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 log
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WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
EXCELLENCE COMES AS STANDARD
SAFETY PRECAUTIONS
IF YOU SMELL GAS:
COMBUSTIBLE AND CORROSIVE MATERIALS
DO NOT operate any electrical switches
Extinguish any naked flame
Do not store or use any combustible materials
(paper, thinners, paints etc.) inside or within the
vicinity of the appliance
Turn off the gas service cock at the meter
Open windows and doors
Chemically aggressive substances, such as
halogenated hydrocarbons containing chlorine
or fluorine compounds can corrode the
appliance and invalidate any warranty.
Telephone your gas company
IF YOU SMELL FUMES FROM THE APPLIANCE:
Switch off the appliance, as shown in Fig. a.
Open windows and doors
FITTING & MODIFICATIONS
Fitting the appliance and any controls to the
appliance may only be carried out by a
competent engineer in accordance with the
Gas Safety (Installation and Use) Regulations.
Fig. a.
Flue systems must not be modified in any way
other than as described in the fitting
instructions and 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. This does not effect your statutory
rights
BENCHMARK STANDARD
‘Benchmark’ is a code of practice for correctly
installing, commissioning and servicing of
domestic water heating appliances
SERVICING
The user is recommended to have the system
regularly serviced by a competent, qualified
engineer (such as British Gas or CORGI
registered personnel) using original spares, to
help maintain the economy, safety and reliability
of the appliance and to have the Service
Record completed in the Benchmark Log Book
A Benchmark Log Book 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
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.
The appliance should be serviced once each
year after installation unless the particular
installation conditions and usage demand more
frequent services
IMPORTANT - ensure that the service engineer
completes the Service Record in the
Benchmark Log Book after each service
HEALTH & SAFETY
The appliance contains no asbestos and no
substances used in the construction process to
contravene the COSHH Regulations (Control
of Substances to Hazardous Health
Regulations 1988)
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WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
SAFETY PRECAUTIONS
GENERAL NOTES
To get the best from your appliance please read
these instructions carefully
CONDENSATE DRAIN
The appliance also produces quantities of
condensate which is discharged regularly by a
pump within the boiler to drain.
SEALED HEATING SYSTEMS
The appliance is fitted to a sealed heating
system which is pressurised. Your installer will
tell you of the minimum and maximum pressure
which must be indicated on the pressure
gauge.
ROOM THERMOSTAT
A room temperature controller (eg. Worcester
TR2 room temperature controller with night
setback module) should be fitted to control the
central heating. Refer to the instructions
supplied with the thermostat for information on
siting and setting.
Check regularly that the pressure is maintained
and contact your installer or maintenance
engineer if there is a permanent significant drop
in pressure. If the system loses pressure it
should be repressurised and the cause of the
fall investigated.
THERMOSTATIC RADIATOR VALVES
It is recommended that this type of valve is
fitted to all but one of the radiators (or at least
those in the sleeping accommodations). The
remaining radiator, which must be where the
room thermostat is located, should be un-
controlled and must be left open. They should
conform to the requirements of BS2767:10.
CENTRAL HEATING SYSTEMS
During the first few hours of operation of the
central heating system, check that all radiators
are being heated at an even rate. 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. Repeated venting will reduce the
quantity of water in the system and this must be
replenished for safe and satisfactory operation
of the appliance.
SHOWERS, BIDETS, TAPS & MIXING VALVES
Standard hot and cold taps and mixing valves
must be suitable for operating at mains
pressure. Thermostatically controlled or
pressure equalising shower valves will guard
against the flow of water at too high a
temperature.
Should water leaks be found in the system or
excessive venting is required then a service
engineer must be contacted to inspect the
installation and rectify any fault.
Hot and cold mains fed water can be supplied
directly to an over-rim flushing bidet subject to
local water company requirements.
Only additives that are compatible with
aluminium may be used in the system. Any
incompatible additive used will invalidate the
guarantee.
With all mains fed systems the flow of water
from individual taps will vary with the number of
outlets operated simultaneously and the cold
water mains supply pressure to the property.
Flow balancing using “ball-o-fix” type valves is
recommended to avoid an excessive reduction
in flow to individual outlets.
FLUE OUTLET
This is a condensing appliance and the terminal
will, at times give out a plume of water vapour.
This is quite normal.
For further information contact Worcester Heat
Systems Ltd. Technical Department.
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WORCESTER BOSCH GREENSTAR HIGHFLOW 440
GENERAL NOTES
6 720 611 731a (08.04)
GENERAL NOTES
HOT AND COLD FLOW
PUMP
The flow of water demanded from both hot and
cold service outlets is dependent on the mains
supply, it may not be possible in some
installations to operate all outlets
simultaneously.
The pump is set by the manufacturer and must
not be adjusted.
PUMP ANTI-SEIZURE
If there has been no heating demand for 24
hours, the pump will run for a few seconds to
reduce the possibility of pump seizure, which is
possible during long periods of inactivity.
WATER MAINS FAILURE
If there is a failure of the mains water supply
then no water will be available at a tap or
shower until the mains supply is restored. The
appliance will still operate in the central heating
mode.
USE IN HARD WATER AREAS
In exceptionally hard water areas a device to
prevent scale formation may be fitted.
Installation of a scale inhibitor assembly should
be in accordance with the requirements of the
local water company. An isolating valve should
be fitted to allow for servicing.
Alternatively the maximum temperature of the
domestic hot water may be reset to about 45°C
which will reduce the risk of scale formation in
these hard water areas.
VENTILATION
This is a room sealed appliance and does not
require any air for combustion from inside the
house. If the appliance is fitted into a cupboard
or a compartment is built around the appliance
after installation then the compartment must be
separated from the boiler space by a perforated
non-combustible partition as described in BS
6798 and BS 5440.
Notwithstanding the requirements of BS 6798,
there is no need for ventilation openings to be
provided in the compartment because of the
low heat loss from the appliance casing if
clearances on the next page are observed.
Do not operate the appliance if the flue terminal
fitted on the outside wall or roof is obstructed
or damaged.
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WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
GENERAL NOTES
GENERAL NOTES
Fig. a.
BOILER LOCATION AND CLEARANCES
This boiler is only suitable for installing internally
within a property at a suitable location onto a
fixed, rigid non-combustable surface at least the
same size of the boiler and capable of
supporting the boiler weight.
Compartments:
Follow the requirements of BS6798 and
BS5440 Part 2 and note:
Fig. b.
Minimum clearances must be maintained.
An access door is required for servicing and
maintenance of the boiler.
If fitting the boiler into an airing cupboard use
a non-combustable perforated material
(maximum hole sizes of 13mm) to separate the
boiler from the air space.
Service clearances. See Fig. a.
The diagram opposite shows the minimum
space required to service the boiler only.
Unvented compartment clearances. See Fig. b.
Fig. c.
The diagram opposite shows the minimum
space required to install and service the boiler
inside an unvented compartment.
*Space required for unvented areas with a
removable door or panel.
**This space can be reduced to 50mm for one
side only as long as both the side clearances
add up to the total of both the side
measurements shown or more.
Airing cupboard clearances. See Fig. c.
The diagram opposite shows the minimum
space required to install and service the boiler
within an airing cupboard.
Fig. d.
Venting compartments. See Fig. d.
If the clearances are less than those stated for
options c & d then ventilation must be provided
as described in BS5440:
A minimum of 2 air vents (C) must be fitted,
one at low level and another at high level onto
the same wall using the same air for circulation.
Minimum free air required for both vents:
2
For air directly from outside: 148cm per vent.
2
For air from internal space/room: 296cm per vent.
6
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
BOILER LOCATION AND CLEARANCES
CONTROLS
1
2
3
4
5
6
7
1.
2.
INDICATOR LAMP FOR “OFF/ON”
“INSTALLER SERVICE FUNCTION” BUTTON
(For use only by service engineer)
3.
4.
5.
6.
7.
RESET BUTTON
DISPLAY
SERVICE BUTTON
“ECO” MODE INDICATOR
INDICATOR LAMP FOR “BURNER ON”
MASTER SWITCH
9
10
8
8.
9.
CENTRAL HEATING
TEMPERATURE CONTROL
10. HOT WATER TEMPERATURE
CONTROL
11. SYSTEM PRESSURE GAUGE
12. FILLING LOOP CONNECTION
L
L
U
2. P
1.
LI
F
T
11
REMOVE THE BOILER CASING FRONT PANEL
TO GAIN ACCESS TO THE SYSTEM PRESSURE
GAUGE & FILLING LOOP CONNECTION
12
7
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
CONTROLS
OPERATING THE APPLIANCE
SWITCHING THE APPLIANCE ON/OFF
Switching on
Switch on the appliance at the master switch (I).
The indicator lamp shows green and the
display will show the central heating flow
temperature, when the appliance is operating
in the central heating mode.
Note: If the display alternates between -II- &
the central heating flow temperature, the
condensate trap filling programme is active. If
the display shows “t” the tank heat up
programme is running.
The condensate trap filling programme ensures
that the condensate trap is filled after the
appliance has been installed or after the appliance
has been out of use for a long period. For that
reason, the appliance remains at minimum heating
output for approximately 15 minutes.
Switching off
Switch off the appliance at the master switch (0).
The green indicator lamp goes out. The
display on the optional timer (if fitted) will
continue to operate until the battery back-up
is exhausted.
SETTING THE CENTRAL HEATING TEMPERATURE
Turn the central heating temperature control
to the desired level:
Control Setting
Anti-clockwise limit
'E'
Water Temperature
approx. 35°C
approx. 75°C
Clockwise limit
approx. 88°C
When the burner is lit, the red indicator lamp is
illuminated.
CONTROLLING CENTRAL HEATING
Set the timer (if fitted) to the correct time.
Set room thermostat to the desired room
temperature.
Set temperature driven control unit, if fitted.
Refer to the instructions with the control.
Set the thermostatic radiator valves to the
desired settings.
8
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
OPERATING THE APPLIANCE
OPERATING THE APPLIANCE
SETTING THE HOT WATER TEMPERATURE
Hot water temperature
The hot water temperature can be set to
between approx. 45°C and 65°C using the
temperature control
The domestic hot water temperature is not
shown on the display.
Control Setting
Anti-clockwise limit
●
Water Temperature
approx. 45°C
approx. 58°C
Clockwise limit
approx. 65°C
“ECO” indicator
ECO
A lit
indicator shows there is no DHW
demand from the integral or external
programmer and indicates a night time setting.
In this state the boiler will not fire when there is
a DHW demand but will produce a limited
amount of warm water depending on store
temperature. During this demand the boiler
pump will be operated.
9
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
OPERATING THE APPLIANCE
OPERATING THE APPLIANCE
SUMMER MODE, HOT WATER ONLY
With room temperature controller fitted
Turn temperature control
on the
appliance anti-clockwise as far as the stop.
The central heating is now turned off. The hot
water function and the power supply for the
programmer and thermostat remain switched on.
FROST PROTECTION
Leave master switch switched on.
If the temperature falls to 5°C the boiler will fire
to avoid the possibility of freezing.
Add a suitable anti-freeze fluid to the water in
the central heating system.
FAULT CONDITION
In the unlikely event of a fault occurring while
the appliance is in operation:
The display shows a fault code and the button
may also flash.
If the button
flashes:
Press and hold the button
until the display
shows “— —”. The appliance will then start up
again and the display will show the central
heating flow temperature.
If the button
does not flash:
Switch the appliance off and then on again at
the master switch.
The appliance will start up again and the
central heating flow temperature will be
displayed.
If the fault remains and cannot be cleared:
Call Worcester Heat Systems Ltd. for
assistance, giving a description of the fault
and, if possible the fault code from the fascia
display.
10
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
OPERATING THE APPLIANCE
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 an
appliance that continually switches on and off.
Central heating systems with room
thermostats/thermostatic radiator valves
The central heating control on the boiler should
be set to the maximum rated temperature of the
central heating system or to position “E”, when
the maximum central heating water temperature
obtained is 75°C.
The temperature of each room can be set
individually (except primary room with the room
thermostat) using the thermostatic radiator
valves. If you wish to have a lower temperature
in the primary room than in the other rooms,
leave the room thermostat at the set
temperature and turn down the radiator using
the radiator valve.
11
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
TIPS ON ENERGY SAVING
TIPS ON ENERGY SAVING
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.
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 with the
latest equipment available. The minimum level of
control for a combi boiler or fully pumped
system is a programmer, interlocking room
thermostat and thermostatic radiator valves.
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WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
TIPS ON ENERGY SAVING
TIPS ON ENERGY SAVING
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
valves every 2-3 months to prevent them from
sticking. It is also important that the plastic tops
of all valves are always in position and not
cracked or damaged so as to prevent
accidents. Care should be taken when vacuum
cleaning carpets so as 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.
13
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
TIPS ON ENERGY SAVING
MAINTAINING YOUR APPLIANCE
Your new Greenstar Highflow 440 gas-fired
appliance 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 service contract, please tick
the appropriate box on your warranty
registration card.
If your Greenstar Highflow 440 should fail to
operate correctly or requires servicing please
contact the Worcester Bosch Service
Department, see inside front cover for details.
14
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
MAINTAINING YOUR APPLIANCE
FAULT FINDING
Problem
Cause
Remedy
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
Radiators are too hot
Clock is incorrectly set
Momentary power failure
Turn down thermostatic
radiator valves / room stat
temperature exceeded by
large amount
Temperature rises
instead of falling
Check setting
Switch off appliance at
master switch, wait a few
seconds then switch on
again
No display or display unit
does not respond
Check setting
Hot water temperature
too low
Hot water temperature
dial set too low
15
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
FAULT FINDING
FAULT OR BREAKDOWN
This appliance is supported in the UK by
Worcester Heat Systems Ltd. - part of the
Bosch Group.
Specialist factory trained Service Engineers are
available to attend a breakdown occurring on
this appliance.
No charge will be made for parts and/or
labour providing:
An appliance fault is found and the appliance
has been installed within the past 24 months.
Reasonable evidence of this must be
supplied on request.
A call-out charge will be made where:
The appliance has been installed for over 24
months
OR
Our Field Service Engineer finds no fault with
the appliance (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
Heat Systems Ltd.
Note. NO APPLIANCE FAULT IS FOUND ON
OVER 30% OF ALL SERVICE CALL OUTS.
Please read this guide carefully to gain a good
understanding of the operation of your
appliance. In the case of a suspected fault,
refer to the fault finding section of this guide.
If in doubt contact our Technical Helpline
In the event of an appliance 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
to 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 appliance by any third party will not
be accepted.
16
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
FAULT OR BREAKDOWN
YOUR GUARANTEE
This appliance is guaranteed against faulty
material or workmanship for a period of 24
calendar months from the date of installation
subject to the following terms and conditions.
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
Worcester Heat Systems Ltd.
The householder may be asked to prove the
date of installation, that the appliance was
correctly commissioned and, where
appropriate, the first years service has been
carried out to the satisfaction of Worcester
Heat Systems Ltd. when requested.
Any product or part returned for servicing
under the guarantee must be accompanied
by a claim stating the model, serial number,
date of installation.
Worcester Heat Systems 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 and
servicing manual and users instructions.
The appliance has been used only for normal
domestic purposes for which it was
designed.
This guarantee applies only to equipment
purchased and used in the United Kingdom.
This guarantee does not affect your statutory
rights.
17
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
YOUR GUARANTEE
GUARANTEE REGISTRATION
You should complete and return the postpaid
Guarantee Registration Card within 14 days of
purchase.
Returning the card will register you as the
owner of your new Greenstar Highflow 440
appliance 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.
For your own record:
Model
Serial No.
(See identity label inside appliance casing)
Type / size
Date of installation
Check that the Benchmark “Log Book” has
been completed by your installer or service
engineer.
18
WORCESTER BOSCH GREENSTAR HIGHFLOW 440
6 720 611 731a (08.04)
GUARANTEE REGISTRATION
USER INSTRUCTIONS &
CUSTOMER CARE GUIDE
EXCELLENCE COMES AS STANDARD
Worcester Heat Systems Ltd (Bosch Group)
Cotswold Way, Warndon, Worcester WR4 9SW.
Tel. 01905 754624 Fax. 01905 754619
6 720 611 731a (08.04)
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