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Boulter Camray 5 Installation & Maintenance Manual

Boulter camray 5 oil fired boilers
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Page 1 of 67
Installation & Maintenance Manual
For Camray 5
and Camray Utility 5
Oil Fired Boilers
Manual Part No. PL 47000
Issue No. 4
Date of Issue: November 2001
file://D:\PL47000\PL47000.htm
14/04/2005

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  • Page 1 Page 1 of 67 Installation & Maintenance Manual For Camray 5 and Camray Utility 5 Oil Fired Boilers Manual Part No. PL 47000 Issue No. 4 Date of Issue: November 2001 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 2 Page 2 of 67 HEALTH AND 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.
  • Page 3 7. Under no circumstances should mineral oils be taken internally. OFTEC Code of Practice OCP/1: 1995 For the Safe Installation, Commissioning, Maintenance and Fault Rectification of Oil Firing Equipment should be consulted. BOULTER BOILERS Boulter Boilers Limited Magnet House, White House Road, Ipswich IP1 5JA...
  • Page 4 Page 4 of 67 1:5:7 Shutting Off for Summer 1:5:8 Sealed System Central Heating 1:5:9 Frost Protection 1:5:10 Oil Delivery 1:5:11 Maintenance/Troubleshooting Guide 1:5:12 Option Programmer SECTION 2 - INTRODUCTION 2:1 Introduction 2:2 Flue Options 2:3 Commissioning 2:4 Safety SECTION 3 - TECHNICAL DATA 3:1 Fuels 3:2 Boiler Technical Details 3:3 Burner Details...
  • Page 5 BOULTER BUDERUS CAMRAY 5 PAGE 1 1:1 INTRODUCTION Getting to Know your New Camray 5 Boiler Thank you for choosing the Camray 5 -manufactured in the UK by Boulter Buderus who are renowned oil-firing specialists. Before using your new Boiler, we ask that you carefully read the following information.
  • Page 6 Boiler has been installed it is first commissioned by a competent and preferably an 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 pleased to provide details of commissioning and servicing engineers from their register.
  • Page 7 Page 7 of 67 1:4 BOILER CONTROL PANEL Boiler Control Panel (see fig 1. Boiler Control Thermostat Switch/Mains On Switch. 2. Boiler Overheat/Limit Thermostat Reset Button. 3. ‘Lockout’ Indicator- RED. }These will not be lit until activated 4. Mains Indicator- ORANGE }These will not be lit until activated 5.
  • Page 8 Control Panel Arrangement BOULTER BUDERUS CAMRAY 5 PAGE 3 1:5.4 LOCKOUT INDICATOR (Camray 5 Kitchen Model Only) In the unlikely event of a Burner malfunction, it will automatically shutdown, and the red lockout indicator on the Control Panel will be lit.
  • Page 9 1:5.8 SEALED SYSTEM CENTRAL HEATING If your Camray 5 or UTlLlTY Boiler is used on a SEALED SYSTEM, it is important that the correct operating system pressure is maintained. Your Installer should give guidance on this.
  • Page 10 Flue Terminal Pluming Due to the high efficiency of the Camray 5 range white water vapour from the flue discharge - called pluming may be observed from time to time under certain weather conditions. This is perfectly normal and should be no cause for concern.
  • Page 11 All models are supplied as standard with low level horizontal firing Oil Burner, they are suitable for connection to a conventional chimney or any of the Camray 5/Utility Balanced Flue options. Note: The nozzle on this appliance is only covered by a 1 year guarantee.
  • Page 12 BOULTER BUDERUS CAMRAY 5 PAGE 6 3:1 LIQUID FUELS The Camray 5 and Camray 5 UTILITY Boilers will burn liquid fuels complying with BS2869 Part 2 1988 Class C2 as specified in the Code of Practice for Oil Firing BS5410 Part 1.
  • Page 13 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 separations at least 3mm BOULTER BUDERUS CAMRAY 5 PAGE 7 3:5 DIMENSIONS Output...
  • Page 14 Page 14 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 8 3:6 COMMISSIONING DATA 3:6.1 Class C2, Kerosene Oil RIELLO BURNER Model Output Riello Nozzle Pump Fuel C02% Smoke Flue Exit Boiler Test Camray5 R D B Danfoss Pressure Rate Point Temp Temp Utility &...
  • Page 15 91%) Heat Output (Full Load) kW 26.4 38.1 BOULTER BUDERUS CAMRAY 5 PAGE 9 4:1 STANDARDS & REGULATIONS The installation of the Boiler must comply with the latest edition of : BS 5410 Oil Installations Pt 1 up to 44kW;...
  • Page 16 6. Any kitchen work top above the 100/130 Boiler must be removable for service access. 4:4 THE HEARTH The Camray 5 & Camray 5 Utility have 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.
  • Page 17 Page 17 of 67 The boiler requires a minimum stable draught of 0.1 mbar (0.04w.g.). If the chimney exceeds 6m (20 feet) in length, it may produce a draught exceeding 0.37 mbar (0.15" w.g.) and a draught stabiliser should be fitted. The chimney should comply with the latest edition of the Building Regulations and BS 5410: Part 1.
  • Page 18 When the Boiler is installed in a basement or low level boiler house where air can enter only from high level, the incoming air supply for Combustion and Ventilation should be ducted to low level. A high level outlet should be provided for ventilation. BOULTER BUDERUS CAMRAY 5 PAGE 11 4:7 OIL STORAGE 4:7.1 Oil Tank Consideration to the access by fuel delivery lorries should be given when positioning the oil tank.
  • Page 19 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 3K Oil Loop Deaerator where suction lift is required.
  • Page 20 4:8.7 Flexible Oil Pipes Camray 5 Boilers and 3K Deaerator Fitting Kits are supplied with long life Flexible Oil Pipes. The Flexible Oil Pipes are fitted inside the Boiler casing and are of adequate length to enable the Burner to be removed without disconnecting.
  • Page 21 Page 21 of 67 Flexible Oil Pipes and Fire Check Valve BOULTER BUDERUS CAMRAY 5 PAGE 13 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 22 Page 22 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 14 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 23 Page 23 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 15 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 24 Page 24 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 16 4:9 OIL BURNER The Burner makers’ technical leaflet is supplied with this manual and provides supplementary information not included in this manual. 4:9.1 Burner Pump for Two Pipe and Deaerator System For two pipe oil systems the Burner Oil Pump has to be fitted with the Bypass Screw supplied.
  • Page 25 The Control Panel is pre-wired and fitted to the Boiler ready for connection to the system wiring. 4:10.1 Connecting Control Panel If a Boulter Programmer is to be fitted refer to section 4:11 of this manual for fitting instructions before connecting mains.
  • Page 26 Page 26 of 67 2. Insert Mains Plug into the mating Mains Socket on the underside of the Control Panel. 3. Insert 4 pin Burner Plug on the end of the Burner Cable into its mating Socket on the underside of the Control Panel.
  • Page 27 Page 27 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 18 4:11 PROGRAMMER - CAMRAY 5 ONLY IMPORTANT The Electrical Installation of the programmer must be carried out by a suitably qualified electrical engineer/installer The Programmer kit is available as an optional extra. ( FOR THE WHITE CASED KITCHEN MODEL ONLY) The unit is supplied pre-wired to a 12-way Terminal block as detailed in the wiring diagram and is available as Kit Part No.
  • Page 28 Page 28 of 67 4. Remove the plate and carefully cut through the overlay with a sharp knife. 5. Feed the pre-wired terminal block and wires through the hole now exposed in the Control Panel. Click the Programmer in place from the front. 6.
  • Page 29 PROGRAMMER INSTRUCTIONS 4:11.1 INTRODUCTION The Boulter Programmer is available in kit form as an optional extra for Boulter Buderus. Fitting Instructions for the programmer are included in the Programmer Kit. The Timer/Programmer is supplied pre-programmed with a ‘Standard’ set of times. These may be as required but can be easily changed if not.
  • Page 30 Page 30 of 67 4:11:4 SETTING THE CLOCK 1. Switch ON the Electrical Supply to the Boiler - the Clock Display should come on. 2. Press and release once. Display > 3. Press and release once to answer. The Day on the Display will flash. Display >...
  • Page 31 4:30pm 4:30pm 4.00pm 4.00pm OFF 3 10:30pm 10:30pm 11.00pm 11.00pm BOULTER BUDERUS CAMRAY 5 PAGE 20 Pencil in your own programme below for reference CUSTOM PROGRAMME MON - FRI SAT & SUN PROGRAMME PROGRAMME FIRST PERIOD ON 1 OFF 1...
  • Page 32 4:11.9 TEST The Test facility is a unique feature of the Boulter Programmer. Test enables a quick review of the 7 day programme. TO USE ‘TEST’ With the Timer/Programmer in the operating mode and the Display showing the correct Time and Day.
  • Page 33 4:11.10 HOLIDAY The Holiday Setting is a unique feature of the Boulter Programmer. This enables a period of days to be set (up to 99) during which time the Heating System is OFF. When the Holiday Period is over the Programmer reverts back to the normal programme.
  • Page 34 Page 34 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 22 IMPORTANT ENSURE GOOD EARTH file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 35 4:12.1 Typical External Wiring options IMPORTANT Blue tag must only be fitted to terminal 6 of time clock for gravity hot water only. It must be removed for fully pumped systems. BOULTER BUDERUS CAMRAY 5 PAGE 23 5:1 BALANCED FLUE BOILERS file://D:\PL47000\PL47000.htm...
  • Page 36 Page 36 of 67 A range of Balanced Flue Kits are available as optional extras for Camray 5 & Utility. Balanced Flues permit considerable choice of siting of the Boiler. Boilers may be installed in situations where no chimney exists, where the chimney is unsatisfactory or in outhouses.
  • Page 37 (see BS 5410:1). 3. Care should be taken to ensure that there is clearance between the outer surface of the flue and any combustible material. BOULTER BUDERUS CAMRAY 5 PAGE 24 5:4 POSITIONING THE BOILER Read Sections 5:2 &...
  • Page 38 BOULTER BUDERUS would be pleased to advise on any difficult positioning Fig. 5.4a Balanced Flue Terminal Positions BOULTER BUDERUS CAMRAY 5 PAGE 25...
  • Page 39 LOW LEVEL AND HIGH LEVEL BALANCED FLUES 1. The Terminal must be slightly angled down to ensure correct operation of the boiler. Due to the efficiency levels of Camray 5 pluming from the terminals may occur under certain conditions. Any condensation may be file://D:\PL47000\PL47000.htm...
  • Page 40 3. Ensure that the outlet of the Terminal points downward (TOP upper-most and Boulter correct way up). 4. Ensure that the boiler to offtake gasket is fitted (foil face upwards) and the clamp is made with four nuts and washers securely fixed.
  • Page 41 Page 41 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 28 LOW LEVEL FLUE INSTALLATION Site conditions will dictate to a certain extent the best method of assembling low level balanced flues. The illustration shows a typical rear outlet flue. Assemble the flue generally as follows: 1.
  • Page 42 ‘Boulter’ is upright. 15. Secure the terminal to the flange using the four screws. 16. Fit an approved terminal guard if in an accessible position. Available from Boulter Buderus. 17. Inside: Using the clips supplied fix the flexible air duct to the burner spigot and flue offtake securely.
  • Page 43 Page 43 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 30 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 44 Page 44 of 67 HIGH LEVEL SIDE & REAR INSTALLATION Assemble the flue generally as follows: 1. Position boiler check that all water connections and proposed flue position are according to clearances specified. 2. Mark the flue position on the wall. 3.
  • Page 45 NB. Ensure that TOP is on the upper-most surface of the terminal and BOULTER is upright. 19. Secure the terminal to the flange using the four screws. 20. Fit an approved terminal guard if in accessible position.
  • Page 46 Page 46 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 32 6:4 VERTICAL FLUE FLAT ROOF INSTALLATION file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 47 Page 47 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 33 6:4 VERTICAL FLUE FLAT ROOF INSTALLATION - CONTINUED 6:4.1 Notes on installation file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 48 Page 48 of 67 Site conditions will dictate the best method of assembling the Vertical Balanced Flue. The following illustrations show boilers up against a rear wall as an example. It is not essential for the boiler to be positioned this way; As long as the joists are capable of supporting the flue via the support plate supplied in the kit.
  • Page 49 Keep Cravat as low as possible onto flashing plate to prevent entry of animals, birds or insects. 18. Inside: Using the clips supplied fix the air duct to the burner spigot and vertical flue offtake spigot. Continue with the rest of the installation. BOULTER BUDERUS CAMRAY 5 PAGE 34 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 50 Page 50 of 67 Fig. 6:4b Vertical Flue - Flat Roof Assembly BOULTER BUDERUS CAMRAY 5 PAGE 35 6:5 VERTICAL FLUE PITCHED ROOF INSTALLATION file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 51 Page 51 of 67 BOULTER BOILERS CAMRAY 5 PAGE 36 6:5 VERTICAL FLUE PITCHED ROOF INSTALLATION - CONTINUED 6:5.1 Notes on installation file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 52 Page 52 of 67 Site conditions will dictate the best method of assembling the Vertical Balanced Flue. The following illustrations show boilers up against a rear wall as an example. It is not essential for the boiler to be positioned this way. As long as the joists are capable of supporting the flue via the support plate supplied in the Kit or the Flue support quadrant kit (optional).
  • Page 53 20. Drill the outer air ducts to secure extension to extension by 4 self tapping screws. 21. Using the clips supplied fix the air duct to the burner spigot and vertical flue offtake spigot. Continue with the rest of the installation. BOULTER BOILERS CAMRAY 5 PAGE 37 file://D:\PL47000\PL47000.htm 14/04/2005...
  • Page 54 Page 54 of 67 Fig. 6:5b Vertical Flue - Pitched Roof Assembly BOULTER BUDERUS CAMRAY 5 PAGE 38 6:6 HIGH LEVEL FLUE LENGTH ALTERATION There is a certain amount of adjustment available on the vertical height and horizontal length. This is attained by pushing two telescopic flues together until the desired dimension is obtained. Secure any vertical lengths by using a drill and 4 self tapping screws supplied.
  • Page 55 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 competent engineer, preferably an OFTEC commissioning engineer. If an engineer is not known Boulter Boilers will be pleased to provide details of commissioning and servicing engineers from their register.
  • Page 56 Page 56 of 67 Contents gauges Screw fill and indepentant vent cover or capped fill and vent pipes. Outer valve Filter Sludge cock (Non plastic tanks). HEIGHT OF TANK Is the bottom of the tank above the oil pump if a single pipe system is installed? OIL SUPPLY LINE Ensure that galvanised iron has not been used.
  • Page 57 Is the boiler flueway inspection cover screwed down sufficiently firmly to form a seal? BOULTER BUDERUS CAMRAY 5 PAGE 41 7:4 BOULTER BUDERUS RECOMMENDED COMMISSIONING CHECK LIST - SHEET 2 OF 2 CASING PANELS Have grommets been fitted to relevant oil supply entry points (knockouts)?
  • Page 58 Page 58 of 67 Is the flue adequately sized for the appliance rating? Is the flue free of any obstruction? Has the chimney been adequately lined and insulated? NOTE:- Lining the flue and back filling will help prevent condensate problems BALANCED FLUE APPLIANCES Is the correct flue kit fitted? Is the Flue off take correctly secured to the boiler by four nuts and washers.
  • Page 59 Does the power supply cable enter the casing through a grommet? GENERAL Has the boiler been installed in accorandance with manufacturers instructions? BOULTER BUDERUS CAMRAY 5 PAGE 42 7:5 BOULTER BUDERUS RECOMMENDED COMMISSIONING TESTS Have the manufacturers on-site assembly instructions been followed?
  • Page 60 Check the operation of the limit thermostat Complete commissioning report and enter the details on to the guarantee form which should be returned to BOULTER BOILERS in the envelope provided. Instruct the user on the operation of the appliance and leave this manual with the customer.
  • Page 61 Page 61 of 67 Remove burner and clean thoroughly, the burner draught tube, the electrodes and generally the head assembly. CHANGE the nozzle for one with the specified make, oil rate, spray pattern and angle. Inspect the ignition electrodes for crazing in the porcelain. Replace if there are signs of deterioration. A dirty fan impeller can impair the performance of a burner, inspect and clean if necessary.
  • Page 62 Page 62 of 67 BOULTER BUDERUS CAMRAY 5 PAGE 44 8:2 AIR SHUTTER ADJUSTMENT The Burner has a fixed Air Shutter with manual adjustment. To adjust the CO at the Air Shutter use a 3mm allen key as shown. To increase the setting turn the airshutter clockwise (+) and to decrease turn anticlockwise (-).
  • Page 63 1. All baffles are horizontal 2. All baffle handles are in the forward position. BOULTER BUDERUS CAMRAY 5 PAGE 45 10:1 FAULT FINDING If the Boiler fails to start, make the following checks before calling a service engineer:- 1.

  • Page 64: Fault Finding Chart

    Replace control box. electric cell circuit faulty Flame instability Check combustion setting out and reset if necessary. BOULTER BUDERUS CAMRAY 5 PAGE 53 Burner starts but will not This can be due either to light up absence of oil of ignition.
  • Page 65 Checked and replace with correct size and type nozzle (see Technical Data) Air supply inadequate Check fan operation and cleanliness. BOULTER BUDERUS CAMRAY 5 PAGE 54 Burner pulsates Worn nozzle with Replace with nozzle of correct type and size (see (a) continuously excess throughout or Technical Data).
  • Page 66 Commissioning Check List and Servicing supply Notes. Due to a policy of continual development Boulter Buderus reserves the right to alter or amend the design of its products without prior notice. Indicates changes from previous issue BOULTER BUDERUS CAMRAY 5 PAGE 56 file://D:\PL47000\PL47000.htm...
  • Page 67 Boulter Boilers Limited Magnet House 3 0 White House Road Ipswich IP1 5JA Tel: 01473 241555 Fax: 01473 241321 E-mail: sales@boulter-boilers.com Due to a policy of continual development Boulter Boilers reserves the right to alter or amend the design of its products without prior notlce file://D:\PL47000\PL47000.htm...

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