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Boulter Buderus Camray 5 Combi Installation & Maintenance Manual

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Installation & maintenance manual for Camray 5 Combi External Boilers
Page 1 of 57
Installation & maintenance manual for
Camray 5 Combi External
Boilers
Heat is our Element
Health & Safety
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a requirement to
provide information on substances hazardous to health (COSHH Regulations 1988).
The Company takes every reasonable care to ensure that these products are designed and constructed to
meet these general safety requirements, when properly used and installed.
To fulfil this requirement products are comprehensively tested and examined before dispatch.
This appliance may contain some of the materials below.
When working on the appliance it is the Users/Engineers responsibility to ensure that any necessary personal
protective clothing or equipment is worn appropriate to parts that could be considered as being hazardous to
health and safety.
INSULATION &SEALS
file://D:\PL61500\PL61500.htm
14/04/2005

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  • Page 1 Installation & maintenance manual for Camray 5 Combi External Boilers Page 1 of 57 Installation & maintenance manual for Camray 5 Combi External Boilers Heat is our Element Health & Safety INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER. Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a requirement to provide information on substances hazardous to health (COSHH Regulations 1988).
  • Page 2 Installation & maintenance manual for Camray 5 Combi External Boilers Page 2 of 57 Glass Rope, Mineral Wool, Insulation Pads, Ceramic Fibre, Fibre Glass Insulation. May be harmful if inhaled. May be irritating to the skin, eyes, nose or throat. When handling avoid inhalation and contact with the skin or eyes.
  • Page 3 Installation & maintenance manual for Camray 5 Combi External Boilers Page 3 of 57 Introduction Hydraulic Circuits Commissioning Safety SECTION 3 - TECHNICAL DATA Liquid Fuels Boiler Technical Details Burner Details Electrics Dimensions Tundish Position Commissioning Data Performance Data SECTION 4...
  • Page 4 Section 1- Users Guide 1:1 INTRODUCTION Thank you for choosing the Camray Combi manufactured in the UK by Boulter Buderus who are renowned oil-firing specialists. To obtain the best possible performance and trouble free operation from your Boiler, it is important that you read section 1 of this manual carefully.
  • Page 5 Installation & maintenance manual for Camray 5 Combi External Boilers Page 5 of 57 1:3 IMPORTANT SAFETY NOTES To obtain the best possible performance and trouble free operation from your Boiler, it is important that you read these instructions carefully. Your Camray Boiler has built-in safety features, which are detailed in the relevant section of this manual.
  • Page 6 Installation & maintenance manual for Camray 5 Combi External Boilers Page 6 of 57 If an engineer is not known, Boulter Buderus will be pleased to provide details of a commissioning and servicing engineer from their register. *The Oil Firing Technical Association for the Petroleum Industry. Telephone 0845 6585080...
  • Page 7 Installation & maintenance manual for Camray 5 Combi External Boilers Page 7 of 57 1:6 BOILER CONTROL PANEL Fig 1 a Boiler Control Panel (see Fig 1a) 1. Boiler control thermostat 2. Hot water thermostat 3. Boiler overheat/limit thermostat 4. Lockout indicator light - red 5.
  • Page 8 Installation & maintenance manual for Camray 5 Combi External Boilers Page 8 of 57 1:6.2 Hot Water Tank Thermostat This thermostat controls the water temperature in the tank. Guidance on its use is given in Section 1:7 of this manual.
  • Page 9 Installation & maintenance manual for Camray 5 Combi External Boilers Page 9 of 57 Fig 1 b Page 05 1:7 OPERATING FEATURES AND INSTRUCTION 1:7.1 How does your Boiler work? Hot Water If the Programme is set for Hot Water only or Summer/Winter switch is set to Summer: - a) The Boiler will operate until the hot water tank reaches the temperature you have set on the Hot Water Tank Thermostat.
  • Page 10 Control Panel or the programmer switch to the OFF position on the operational programmer. 1:7.3 Sealed System Central Heating Your Camray 5 COMBI Boiler may only be used on a SEALED SYSTEM. It is important that the correct operating system pressure is maintained. If the System Pressure Gauge, in the Control Panel, should indicate low pressure i.e.

  • Page 11: Section 2 - Introduction

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 11 of 57 If the Burner fails to start, adopt the following procedure: - 1) Check that there is oil in the tank and that the supply valve is open.
  • Page 12 Installation & maintenance manual for Camray 5 Combi External Boilers Page 12 of 57 Fig 2a Page 08 2:2 HYDRAULIC CIRCUITS file://D:\PL61500\PL61500.htm 14/04/2005...
  • Page 13 O.F.T.E.C.* registered engineer. It is the responsibility of the installer to ensure that the Boiler is commissioned. If an engineer is not known, Boulter Buderus will be please to provide details of commissioning and servicing engineers from their register.

  • Page 14: Section 3 - Technical Data

    Section 3 - Technical data 3:1 LIQUID FUELS The Camray 5 COMBI Boiler will burn liquid fuels complying with BS2869 Part 2 1998 Class C2 specified in the Code of Practice for Oil Firing BS5410 Part 1. Class C2 (Kerosene) This fuel is suitable for Camray 5 COMBI.
  • Page 15 Installation & maintenance manual for Camray 5 Combi External Boilers Page 15 of 57 This appliance must be effectively earthed and connection to the supply must be through a double pole isolating switch fused 5 amp. The isolating switch must have all pole contact separators at least 3mm.
  • Page 16 Installation & maintenance manual for Camray 5 Combi External Boilers Page 16 of 57 Page 11 3:7 COMMISSIONING DATA 3:7.1 Class C2 Kerosene Oil Nozzle Flue Pump Riello R00 Danfoss fuel rate Smoke exit Model Output C02% type Delevan Kg/h temp.

  • Page 17: Section 4 - Installation

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 17 of 57 Page 12 Section 4 - Installation 4:1 STANDARDS & REGULATIONS file://D:\PL61500\PL61500.htm 14/04/2005...
  • Page 18 1) Noise may be accentuated by the installation in recesses with hard or hollow stud wall surfaces. Due consideration to the siting of Boilers should be given. Further advice from Boulter Buderus should be sought where any doubt exists. 2) Some individuals may be particularly sensitive to even low noise levels and this should be discussed before installation.
  • Page 19 Page 13 4:4 THE HEARTH The Camray 5 Combi has a Hearth Temperature of less than 85°C. The Boiler requires a level hearth on which to stand which should comply with the Building Regulations. Pre-cast concrete slabs satisfies this requirement. If the Boiler is to stand on a base made of combustible material then protection between the Boiler and the floor should be provided by means on non-combustible material.
  • Page 20 Installation & maintenance manual for Camray 5 Combi External Boilers Page 20 of 57 1. 12Ltr expansion vessel 7. Boiler heat exchanger 2. Storage tank 8. 3 port motorised valve 3. Pressure gauge 9. Plate heat exchanger 4. Pressure relief valve 10.

  • Page 21: Circulating Pump

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 21 of 57 The Expansion Vessel is suitable for systems with a static head of up to 5 metres (16.5ft) i.e. the vertical distance between Expansion Vessel and highest point of system, usually the top of bedroom radiators. If the static head is greater than 5 metres, then the charge in the vessel must be increased to equal this higher static pressure.

  • Page 22: Filling Loop

    All combination Boilers suffer performance degradation due to the effects of hard water (limescale build up on heat exchanger surfaces). Boulter Buderus have taken particular care in the design of this Boiler to minimise this (hard water) effect but, strongly recommend that in areas where water temporary hardness (alkalinity) in excess of 150mg/I is likely to be encountered, a water conditioner of the chemical dosing type is fitted.
  • Page 23 Installation & maintenance manual for Camray 5 Combi External Boilers Page 23 of 57 Bidets : Subject to local Water Company regulations the supply of hot and cold mains water direct to a bidet is permitted if it is of 'over-rim flushing' type. The outlets should be shrouded and it should not be possible to temporarily attach a hand held spray.
  • Page 24 Installation & maintenance manual for Camray 5 Combi External Boilers Page 24 of 57 Fig 4.9 4:10 AIR SUPPLY The air supply to the boiler is through the grilles on the casing panel door. 4:11 OIL STORAGE 4:11.1 Oil Tank Consideration to the access by fuel delivery lorries should be given when positioning the oil tank.
  • Page 25 50mm thick garden slabs or a concrete base. As there is only one tapped outlet they are more suited to single pipe feed as gravity supply or with a Boulter Buderus 3K Oil Loop Deaerator where suction lift is required.
  • Page 26 The advantage of this system is gained where a two pipe run from the oil supply tank is long or difficult to achieve. Boulter Buderus 3K Deaerators are available as an optional extra from your merchant (Part NO. BS03060).
  • Page 27 Installation & maintenance manual for Camray 5 Combi External Boilers Page 27 of 57 Fig 4.12 Page 19 Single pipe oil system - Tank outlet above burner Do not fit pump bypass to burner- see 4.9.2 file://D:\PL61500\PL61500.htm 14/04/2005...
  • Page 28 Installation & maintenance manual for Camray 5 Combi External Boilers Page 28 of 57 Table giving maximum pipe length in metres Item H metres 0.5 1.0 1.5 2.0 Kerosene 10mm OD Pipe Burner to supply 20 40 80 100 Single pipe oil system - oil connections...
  • Page 29 Installation & maintenance manual for Camray 5 Combi External Boilers Page 29 of 57 Part 0.5 1.0 1.5 2.0 Kerosene 10mm OD Pipe Burner to supply 100 100 100 90 70 Two pipe oil system - oil connections Items 1-5 supplied with boiler- see fig 4.12d...
  • Page 30 Installation & maintenance manual for Camray 5 Combi External Boilers Page 30 of 57 Schematic diagram fit both hose as shown in Fig 4.12c Page 21 Dearator oil system - Tank outlet below burner Fit pump bypass screw to burner Fig 4.12e...
  • Page 31 Installation & maintenance manual for Camray 5 Combi External Boilers Page 31 of 57 1/4 "x10mm coupling FS00151 Fig 4.12f Page 22 4:13 OIL BURNER The Burner makers' technical leaflet is supplied with this manual and provides supplementary information not included in this manual.
  • Page 32 Installation & maintenance manual for Camray 5 Combi External Boilers Page 32 of 57 Fig 4.13a ONLY USE BYPASS SCREW FOR ALLEN KEY (2.5MM). DO NOT USE SLOTTED SCREW 4:13.2 Burner Pump for Single Pump System The burner is supplied set for single pipe operation. The return port is plugged and the Bypass Screw is not fitted.
  • Page 33 Installation & maintenance manual for Camray 5 Combi External Boilers Page 33 of 57 Fig 4.13b Page 23 4:14 CONTROL PANEL The Control Panel is pre-wired and fitted to the Boiler ready for connection to the system wiring. For operation of the Control Panel see Section 1 - User Guide.
  • Page 34 Installation & maintenance manual for Camray 5 Combi External Boilers Page 34 of 57 4:15 FUNCTIONAL FLOW DIAGRAMS Page 24 4:16 FITTING PROGRAMMER file://D:\PL61500\PL61500.htm 14/04/2005...
  • Page 35 The electrical installation of the programmer must be carried out by a suitably qualified electrical engineer/installer. It is not recommended that a programmer be fitted to the fascia of this boiler. Boulter Buderus recommends that an external programmer is fitted and connected as shown on the next page.
  • Page 36 Installation & maintenance manual for Camray 5 Combi External Boilers Page 36 of 57 1) These instructions are ONLY for suitably qualified personnel. 2) When selecting a Programmer make sure that it is suitable for combi boiler applications. 3) Isolate electric supply.

  • Page 37: 5:1 Positioning The Boiler

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 37 of 57 completely, but the vacated hole must be blanked off. Page 26 Section 5 - Flues 5:1 POSITIONING THE BOILER Read Sections 5:2 & 5:3 Some combustion noise occurs at the Exhaust Terminal of Balanced Flues and care should be exercised to ensure that the position of the exhaust is not near doors or opening windows of the house it serves, or doors or windows of any neighbouring house.

  • Page 38: Terminal Guard

    It is essential in the interest of boiler efficiency and reliable performance that once the Boiler has been installed it is first commissioned by a qualified engineer. If an engineer is not known Boulter Buderus will be please to provide details of a commissioning and servicing engineer from their register.
  • Page 39 Installation & maintenance manual for Camray 5 Combi External Boilers Page 39 of 57 It is recommended that the relevant section of BS 5410 Part 1: latest edition is carefully read. 7:3 REPORTING It is recommended that you use a report sheet and checklist. Make comments on the report where necessary and give a copy to whoever has engaged your services, and retain and file your own copy.

  • Page 40: Oil Supply Line

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 40 of 57 7:7 EXPANSION VESSEL PRESSURE When the system water is heated, the pressure will rise above the Cold Fill setting. If the pressure reaches 2.5 bar when the Boiler is operated at its highest temperature with all radiators in circulation, then an additional expansion vessel must be fitted in the system.
  • Page 41 Installation & maintenance manual for Camray 5 Combi External Boilers Page 41 of 57 Ensure that soldered connections on copper pipes have not been used. Is the size of the pipe adequate for the boiler rating? Are all joints leak proof?
  • Page 42 Installation & maintenance manual for Camray 5 Combi External Boilers Page 42 of 57 Is the flue connected and properly located? VENTILATION Are the air grilles in the casing panel door clear from obstruction? Is the flue adapter fitted correctly to the boiler with all nuts and gaskets?

  • Page 43: Section 8 - Maintenance

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 43 of 57 connection, and replace burner. Set the boiler thermostat to between Summer and Winter positions, see Fig 1. Switch on the electric supply to the boiler, checking that programmes are switched to the 'ON' position, and that room thermostats are calling for heat.

  • Page 44: Combustion Tests

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 44 of 57 A boiler fired with Class C2 Oil should only require attention once a year. 8:1.1 General Inspection With the Boiler operating, inspect for signs of unsatisfactory operation, i.e. leakage of combustion products, leakage of oil, or unusual noises from the pump or motor.

  • Page 45: Final Checks

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 45 of 57 Fit combined air bleed manifold and 0-300psi (0-20 bar) pressure gauge to the appropriate oil pump connection, and replace burner. Switch on the electric supply to the boiler.
  • Page 46 Installation & maintenance manual for Camray 5 Combi External Boilers Page 46 of 57 Fig 8.2a 8:3 BAFFLE ARRANGEMENT file://D:\PL61500\PL61500.htm 14/04/2005...

  • Page 47: System Pressure

    Installation & maintenance manual for Camray 5 Combi External Boilers Page 47 of 57 Fig 8.3a Page 35 8:4 HEATING SYSTEM During routine servicing, the system water should be "topped up" if necessary, using the Filling Loop when the system is cold. Refer to 7:5 Filling the system.

  • Page 48: Section 10 - Fault Finding

    Should be checked to be in accordance with the cold design pressure of the system. The design of the Camray 5 Combi enables the Pressure Vessel to be lifted and laid on to the floor whilst still connected to the Boiler, enabling full access to the Burner and Heat Exchanger.
  • Page 49 Installation & maintenance manual for Camray 5 Combi External Boilers Page 49 of 57 supply switched on? Is the programmer (or Boiler Operating Switch) set to call for heat? Is the Boiler Thermostat set to the desired temperature? Is the Lock-out Reset Button on the Control Box and Control Panel neon illuminated? If so, press to reset Burner.
  • Page 50 Installation & maintenance manual for Camray 5 Combi External Boilers Page 50 of 57 Check combustion setting and re-set if Flame instability. necessary. Burner starts but will not This can be due either to light up. absence of oil or ignition.
  • Page 51 Installation & maintenance manual for Camray 5 Combi External Boilers Page 51 of 57 throughput or uneven and Technical Data). spray pattern. (b) at initial firing. Air in supply line. Purge at pump to remove. Blocked flue ways. Clean boiler and flue.
  • Page 52 Installation & maintenance manual for Camray 5 Combi External Boilers Page 52 of 57 puffing, ignition cuts in improperly adjusted or faulty pressure gauge, smoke pump, C02 indicator nozzle or unsatisfactory and draught gauge, adjust settings as intermittently. draught conditions or faulty necessary, replace nozzle if necessary.
  • Page 53 Installation & maintenance manual for Camray 5 Combi External Boilers Page 53 of 57 Air trapped in boiler heat Bleed air from boiler heat exchanger using manual air vent positioned on top of the boiler exchanger at the rear right hand corner and re- pressurise if required.
  • Page 54 Installation & maintenance manual for Camray 5 Combi External Boilers Page 54 of 57 10.5 PARTS REPLACEMENT INSTRUCTIONS Note. Before attempting any parts replacement always isolate appliance from mains electricity supply. 1) To remove/replace circulating pump a) Isolate pump union valves...
  • Page 55 Installation & maintenance manual for Camray 5 Combi External Boilers Page 55 of 57 g) Remove both elbow fittings (9) h) Unscrew valve body from the storage tank i) Replace with new unit and reassemble in reverse order using jointing tape and paste where...
  • Page 56 Installation & maintenance manual for Camray 5 Combi External Boilers Page 56 of 57 e) Reassemble in reverse order, reinstate cold mains supply and test correct functioning of flow switch Page 47 Buderus is one of the largest heating groups world- To contact us ..
  • Page 57 Installation & maintenance manual for Camray 5 Combi External Boilers Page 57 of 57 Heat is our Element file://D:\PL61500\PL61500.htm 14/04/2005...

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