Floor standing oil fired condensing boiler conventional flue & room sealed flue for fully pumped open vent or sealed central heating systems and domestic hot water cylinders (20 pages)
External oil fired condensing boiler
using balanced flue system
for fully pumped open vent or sealed central heating systems and
domestic hot water water cylinders (20 pages)
Summary of Contents for Worcester GREENSTAR CAMRAY EXTERNAL
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INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING FLOOR STANDING EXTERNAL OIL FIRED CONDENSING BOILER USING BALANCED FLUE SYSTEM GREENSTAR CAMRAY EXTERNAL & EXTERNAL SYSTEM 12/18, 18/25, 25/32 FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEM AND DOMESTIC HOT WATER CYLINDERS...
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LABC will then arrange regular inspection visits during the work to ensure that the installation complies with the regulations. IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL HELPLINE. DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER. PLEASE LEAVE THESE INSTRUCTIONS WITH THE COMPLETED COMMISSIONING FORM AND THE USER MANUAL WITH THE OWNER OR WITH THE APPLIANCE AFTER INSTALLATION OR SERVICING.
The Control of Pollution (Oil) Regulations. OFTEC Standards. Where no specific instruction is given, reference should be made to the relevant codes of practice. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & SAFETY PRECAUTIONS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Weight (excluding packaging) External System Expansion vessel (External System only) litres Emissions class for NOx and CO class Typical NOx emission figures mg/kWhr INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & TECHNICAL DATA EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Drain and thoroughly flush the system to remove the flushing agent and any debris. Refil with clean water and inhibitor to manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & CLEANING PRIMARY SYSTEMS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
• Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & MAINS SUPPLY EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
The table and illustration above is a guide only and does not in any way override the de- as the sole fire protection device. aerator manufacturers instructions. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & OIL SUPPLY EXTERNAL SYSTEM 12/18-18/25-25/32...
• A pressure gauge (G), 3 bar minimum is fitted to the appliance • An automatic air vent (N) must be fitted. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & WATER SYSTEMS & PIPEWORK EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Auto air vent Non return 1000mm above valve the highest point of the system Stop cock Fill Point INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & WATER SYSTEMS & PIPEWORK EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
H - Drainage holes 50mm from base of tube (12mm Ø at 25mm centres) facing away from building. Limestone chippings. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & CONDENSATE PIPEWORK EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
• **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & HIGH LEVEL TERMINAL POSITIONS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
* Rear exit only. ** Horizontal flue runs should be kept as short as possible. Vertical terminal (side outlet) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & BALANCED EXTERNAL OILFIT EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Part No. 7 716 190 050 FRONT RIGHT HAND FLUE OUTLET A + B + C Plan view FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & CABINET MOUNTED BALANCED EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009) HORIZONTAL FLUE OPTIONS...
Lift carton up and away from the boiler. Remove the plastic bag from the boiler and place safely aside. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & UNPACKING THE BOILER EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
105 94 RIGHT HAND SIDE Fire valve capillary & drain access Flue Services Condensate 124 90 LEFT HAND SIDE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & PIPEWORK & FLUE POSITIONS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
100mm sealing ring where the duct enters the casing and seal the joint to the exterior wall and inside the cabinet with a suitable sealant. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & BOILER INSTALLATION EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
(if necessary). Refer to the flue manual supplied with the flue kit for flue installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & FLUE INSTALLATION EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
( J ). Check that all the baffles (K) and baffle retainer (L) are correctly fitted to the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & COMBUSTION CHAMBER EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Rotate the cover plate and seal so it does not cover the capillary, then secure with the screws provided. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & PIPEWORK CONNECTIONS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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IMPORTANT: Insulate all external condensate pipework or run in 32mm pipework to prevent freezing. 50mm (min.) 500ml INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & PIPEWORK CONNECTIONS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
(not supplied) to the oil pump and the return line connection and tighten to secure. (on 12/18 model only) Brass air deflector washer Locating circlip INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & OIL BURNER & PUMP EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Attach air duct and tighten clip (D) to secure to the burner air intake. Plug burner lead (E) into control box (F). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & REFITTING COMPONENTS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
NOTE: A frost thermostat is fitted as standard to the external appliance to provide frost protection. 1 2 3 CAMRAY EXTERNAL SYSTEM SHOWN INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & ELECTRICS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Orange Brown Brown Green/Yellow 1 2 3 4 5 6 1 2 3 4 5 6 Green/Yellow Black Grey Riello Burner INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & ELECTRICS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Orange Brown Brown Green/Yellow 1 2 3 4 5 6 1 2 3 4 5 6 Green/Yellow Black Grey Riello Burner INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & ELECTRICS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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OUTSIDE BOILER should be connected to the remote junction bo. INSIDE BOILER 1 2 3 1 2 3 4 5 6 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & ELECTRICS EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Complete the installation part of the Guarantee Registration Card and complete CD10 or its equivalent, to inform the LABC of the installation. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & PRE-COMMISSIONING EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
The (A) in use and (B) must be bled. Bleed air from the primary heat exchanger air vent (B). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & FILLING THE SYSTEM EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
The internal filter is accessed by removing the oil pump cover. Safely dispose of the container/discharge. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & STARTING THE APPLIANCE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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* 25/32 model for 25kW remove the plastic air guide (see following page ). only, do not over tighten) and refit the burner cover. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & STARTING THE APPLIANCE EXTERNAL SYSTEM 12/18-18/25-25/32...
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Remove the two screws (C) securing the plastic air guide. Remove air guide (D) and reassemble the burner in reverse order. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & STARTING THE APPLIANCE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
The drain points are normally on the lowest points of the system. NOTE: Release drain point (D) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & FINISHING COMMISSIONING - EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
The expansion vessel pressure must be checked and adjusted if necesary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & INSPECTION AND SERVICE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Locating circlip G - Retaining screws - cover H - Cover - oil pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & INSPECTION AND SERVICE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Combustion chamber access door tightening appliance case. A fire valve sensor clip (Q) is sequence. provided for this purpose. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & INSPECTION AND SERVICE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & BAFFLE ARRANGEMENT 12/18 EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & BAFFLE ARRANGEMENT18/25 EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & BAFFLE ARRANGEMENT 25/32 EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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0.85 80 ° EH 2.58 3.27 12 .5 30. 8 30.0 T2 L/H 25/32 guide ( see page 38 ). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & INSPECTION AND SERVICE EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Part Number: 8 716 142 422 0 26 System pressure gauge Part Number: 8 716 107 638 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & SHORT PARTS LIST 12/18 EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
Part Number: 8 716 142 422 0 25 System pressure gauge Part Number: 8 716 107 638 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & SHORT PARTS LIST 18/25 EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009)
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Find symptom list below. correct and complete we cannot guarantee that every eventuality has been covered. the lockout indicator on the Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed burner. to be competent. To reset, wait 2 minutes then press the lockout indicator/reset button.
Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent.
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CIRCUMSTANCES MUST Find symptom in list below. AN APPLIANCE BE LEFT Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed OPERATING WITH ANY to be competent. CONTROL LINKED OUT OR OVER RIDDEN.
FAULT FINDING & DIAGRAMS Replace Replace Boiler not control box nozzle operating with a heating / hot water demand Replace Pipe to Reset Eectrodes & Unblock or Reset air Replace electrodes/ nozzle combustion leads OK? replace pipe setting control box leads holder OK? head...
Service Interval Record overleaf. Service Provider. Before completing the appropriate Service Interval Record overleaf, please ensure you have carried out the service as described in this manual. Always use Worcester, Bosch Group specified spare parts when replacing all controls.
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SERVICE 2 SERVICE 1 DATE DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No. TEL No. OFTEC REG No. OFTEC REG No. PUMP PRESSURE: PUMP PRESSURE: NOZZLE CHANGED? NOZZLE CHANGED? F.G.T. °C FLUE PRESSURE: F.G.T. °C FLUE PRESSURE: COMMENTS COMMENTS SIGNATURE...
EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a brand name of Bosch Thermotechnology Ltd. www.worcester-bosch.co.uk 8 716 115 667a (05.2009)
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