Worcester greenstar camray 12/18 Instruction Manual
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Worcester greenstar camray 12/18 Instruction Manual

Floor standing oil fired condensing boiler conventional flue & room sealed flue
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See also: Instructions for Using , Instruction Manual
GREENSTAR CAMRAY UTILITY & UTILITY SYSTEM
12/18, 18/25, 25/32
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
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
ONLY
INSTRUCTION MANUAL
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB
GB

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Summary of Contents for Worcester greenstar camray 12/18

  • Page 1 GREENSTAR CAMRAY UTILITY & UTILITY SYSTEM 12/18, 18/25, 25/32 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 THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY ONLY...
  • Page 2 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.

  • Page 3: Table Of Contents

    FAULT FINDING & DIAGNOSIS FAULT FINDING 47-48 FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX COMBUSTION RECORD SERVICE INTERVAL RECORD BAFFLE ARRANGEMENT DIAGRAM BACK PAGE INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 CONTENTS 8 716 113 004b (05.07)

  • Page 4: Safety Precautions

    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 UTILITY 12/18-18/25-25/32 SAFETY PRECAUTIONS 8 716 113 004b (05.07) & INSTALLATION REGULATIONS...

  • Page 5: General Information

    Greenstar Camray Utility & Utility System Installation/Servicing Instructions.......................1 Users Instructions ................... 1 Warranty Return Envelope ................1 Guarantee Registration Card................1 Condensate Trap Kit..................1 Return Pipe Kit....................1 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 GENERAL INFORMATION 8 716 113 004b (05.07)

  • Page 6: Technical Data

    SEDBUK (Band A) 93.1 93.2 94.2 Appliance protection rating Weight (excluding packaging) Utility Weight (excluding packaging) Utility System Emissions class for NOx and CO class INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 TECHNICAL DATA 8 716 113 004b (05.07)

  • Page 7: Layout & Components Utility

    27 OIL SUPPLY ISOLATING VALVE 28 DEFLECTOR PLATE 29 BOILER OVERHEAT RESET BUTTON 30 FLUE OVERHEAT RESET BUTTON 31 TEMPERATURE CONTROL KNOB INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 LAYOUT & COMPONENTS 8 716 113 004b (05.07)

  • Page 8: Layout & Components Utility System

    34 FLUE OVERHEAT RESET BUTTON 35 TEMPERATURE CONTROL KNOB NOTE: OIL SUPPLY ISOLATING VALVE LOCATION IS ILLUSTRATED ON PREVIOUS PAGE ITEM 27. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 LAYOUT & COMPONENTS 8 716 113 004b (05.07)

  • Page 9: Cleaning Primary Systems

    Run the boiler and system at normal operating temperature in accordance with the manufacturer's instructions. Drain and thoroughly flush the system to remove the flushing agent and any debris. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS 8 716 113 004b (05.07)

  • Page 10: Mains Supply

    • Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 MAINS SUPPLY 8 716 113 004b (05.07)

  • Page 11: Oil Supply

    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 UTILITY 12/18-18/25-25/32 OIL SUPPLY 8 716 113 004b (05.07)

  • Page 12: Water Systems & Pipework

    1” / 1 ” BSP outlets. • An automatic air vent (N) must be fitted (all models). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 113 004b (05.07)

  • Page 13: Water Systems & Pipework

    Heating return 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 UTILITY 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 113 004b (05.07)

  • Page 14: Condensate Pipework

    (as shown) to help prevent freezing. Outside wall. Drain pipe. External drain. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 CONDENSATE & PRESSURE 8 716 113 004b (05.07) RELIEF PIPEWORK...

  • Page 15: Boiler Location & Clearances

    (min.10mm clearance) is removable for 25/32 275 25/32 275 maintenance and repair and the front of the boiler is not enclosed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES 8 716 113 004b (05.07)

  • Page 16: Boiler Location & Clearances

    All pipework in bathrooms and shower rooms must be cross bonded. 600mm radius A - Bath or shower cubicle (zone 0) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 BOILER LOCATION & CLEARANCES 8 716 113 004b (05.07)

  • Page 17: Flue Terminal Positions

    2500mm. Flat roof boundary Pitched roof C, D boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FLUE TERMINAL POSITIONS 8 716 113 004b (05.07)

  • Page 18: Conventional Flue

    'Contact Information' on the back cover. A - Boiler B - Flue C - Max. 2 bends at 135° D - Anti down-draught terminal E - Chimney INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 CONVENTIONAL FLUE 8 716 113 004b (05.07)

  • Page 19: Room Sealed Flue Options

    12/18 & 18/25 125mm Ø 125mm Ø 25/32 150mm Ø** INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 ROOM SEALED FLUE OPTIONS 8 716 113 004b (05.07)

  • Page 20: Unpacking The Boiler

    At all times the correct method for handling heavy objects should be strictly observed. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 UNPACKING THE BOILER 8 716 113 004b (05.07)

  • Page 21: Pipework Positions / Flue Opening

    Flue hole size 150 - 240mm Ø180mm 755** 240 - 330mm Ø185mm 330 - 420mm Ø190mm 420 - 500mm Ø195mm INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 PIPEWORK POSITIONS & 8 716 113 004b (05.07) FLUE OPENING...

  • Page 22: Boiler Installation

    In the case of the Utility System take care not to damage the expansion vessel. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 BOILER INSTALLATION 8 716 113 004b (05.07)

  • Page 23: Flue Installation

    The horizontal terminal must be installed at 3° to ensure that the condensate drains back to the boiler whilst also preventing rain ingress down the air duct. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FLUE INSTALLATION 8 716 113 004b (05.07)

  • Page 24: Combustion Chamber

    Plan sectional view Plan sectional view 25/32 IMPORTANT when refitting Plan sectional view the combustion chamber access door (6) Combustion chamber access door tightening sequence. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 COMBUSTION CHAMBER 8 716 113 004b (05.07)

  • Page 25: Pipework Connections

    (L). IMPORTANT: The condensate trap must be correctly filled to prevent the possibility of potentially harmful flue products escaping via the condensate pipework. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 113 004b (05.07)

  • Page 26: Oil Burner And Pump

    (not supplied) to the oil pump and return pipe fixing (D on page 24) and tighten to secure. (on 12/18 model only) Brass air deflector washer Locating circlip INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 OIL BURNER & PUMP 8 716 113 004b (05.07)

  • Page 27: Refitting Components

    (G) in the bottom locations. Plug burner lead (H) into control box. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 REFITTING COMPONENTS 8 716 113 004b (05.07)

  • Page 28: Electrics

    Refit electric control panel cover: Refit front panel (B) to control box (C) and secure with screws (A). 230V 1 2 3 230V 1 2 3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 ELECTRICS 8 716 113 004b (05.07)
  • Page 29 J - BURNER CONTROL BOX. Green/Yellow 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 UTILITY 12/18-18/25-25/32 ELECTRICS 8 716 113 004b (05.07)
  • Page 30 K - CIRCULATING PUMP. Green/Yellow 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 UTILITY 12/18-18/25-25/32 ELECTRICS 8 716 113 004b (05.07)
  • Page 31 A frost thermostat can also be connected to the OUTSIDE BOILER remote junction box if required. INSIDE BOILER 1 2 3 1 2 3 4 5 6 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 ELECTRICS 8 716 113 004b (05.07)
  • Page 32 (M) in place. 1 2 3 4 5 6 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 ELECTRICS 8 716 113 004b (05.07)

  • Page 33: Pre-Commissioning Checks - Appliance

    Secure in place by retightening the expansion vessel clamping screw. Refit the top and front panels. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 PRE-COMMISSIONING CHECKS - 8 716 113 004b (05.07) APPLIANCE...

  • Page 34: Filling The System

    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 UTILITY 12/18-18/25-25/32 FILLING THE SYSTEM 8 716 113 004b (05.07)

  • Page 35: Starting The Appliance

    The internal filter is accessed by removing the oil pump cover. INTEGRAL BURNER LOCKOUT INDICATOR AND Safely dispose of the container/discharge. RESET BUTTON (H) INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 004b (05.07)
  • Page 36 (L) to obtain * 25/32 model for 25kW remove the plastic air guide (see following page ). the correct CO level. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 004b (05.07)
  • Page 37 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 UTILITY 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 113 004b (05.07)
  • Page 38 Burner and circulating pump should be off. Check that any other controls that are fitted to the system are operating properly. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25- STARTING THE APPLIANCE 25/32 8 716 113 004b (05.07)

  • Page 39: Water Treatment

    . INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 WATER TREATMENT 8 716 113 004b (05.07)

  • Page 40: Finishing Commissioning - Appliance

    NOTE: Release drain point (H) to drain the secondary heat exchanger. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FINISHING COMMISSIONING - 8 716 113 004b (05.07) APPLIANCE...

  • Page 41: Inspection And Service

    Clean or replace all oil filters. Check that the condensate system is not obstructed, clean and refill the condensate trap as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 004b (05.07)
  • Page 42 (on 12/18 model only) the room. Brass air deflection washer Locating circlip G - Retaining screws - cover H - Cover - oil pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 004b (05.07)
  • Page 43 A fire valve sensor clip (Q) is sequence. provided for this purpose. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 004b (05.07)

  • Page 44: Inspection And Service

    (see page 36). 0.75 80°EH 2.37 12.0 28.3 T2 L/H 25/32 27.5 0.85 80°EH 2.58 3.27 12.5 30.8 30.0 T2 L/H 25/32 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 113 004b (05.07)

  • Page 45: Short Parts List 12/18

    23 Pressure relief valve Part Number: 8 716 142 422 0 24 System pressure guage Part Number: 8 716 112 729 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25- SHORT PARTS LIST 12/18 25/32 8 716 113 004b (05.07)

  • Page 46: Short Parts List 18/25

    20 Pressure relief valve Part Number: 8 716 142 422 0 21 System pressure guage Part Number: 8 716 112 729 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25- SHORT PARTS LIST 18/25 25/32 8 716 113 004b (05.07)

  • Page 47: Short Parts List 25/32

    19 Pressure relief valve Part Number: 8 716 142 422 0 20 System pressure guage Part Number: 8 716 112 729 0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 SHORT PARTS LIST 25/32 8 716 113 004b (05.07)

  • Page 48: Fault Finding & Diagnosis

    Set up as in installation instructions Oil pressure incorrect Adjust to correct pressure Incorrect components used on Check with installation instructions combustion head Faulty nozzle Replace nozzle INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FAULT FINDING 8 716 113 004b (05.07)

  • Page 49: Fault Finding

    Rectify burner operation and lockouts operation, numerous lockouts Odour in boiler room, oil leaks Rectify oil leaks, replace components if from pipework, flexible hoses necessary connections INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FAULT FINDING 8 716 113 004b (05.07)

  • Page 50: Fault Finding Logic For 535 Se/Ld Rdb Control Box

    FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 FAULT FINDING 8 716 113 004b (05.07)

  • Page 51: Combustion Record

    Service Provider. Before completing the appropriate Service Interval Record below, 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. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 OIL BOILER COMBUSTION 8 716 113 004b (05.07)
  • Page 52 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...
  • Page 53 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 NOTES 8 716 113 004b (05.07)
  • Page 54 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 NOTES 8 716 113 004b (05.07)

  • Page 55: Baffle Arrangement Diagram

    12/18 baffles in tubes 1 & 4. 18/25 baffles in tubes 1, 3 & 4. 25/32 baffles in all 6 tubes. COMBUSTION CHAMBER ACCESS DOOR INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY UTILITY 12/18-18/25-25/32 BAFFLE ARRANGEMENT 8 716 113 004b (05.07) DIAGRAM...
  • Page 56 EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. www.worcester-bosch.co.uk 8 716 113 004b (05.07)

This manual is also suitable for:

Greenstar camray 18/25Greenstar camray 25/32

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