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 12/18
Page 1
GREENSTAR CAMRAY EXTERNAL 12/18, 18/25, 25/32 FLOOR STANDING EXTERNAL OIL FIRED CONDENSING BOILER USING BALANCED FLUE SYSTEM FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER CYLINDER THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY INSTRUCTION MANUAL INSTALLATION COMMISSIONING...
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.
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 12/18-18/25-25/32 SAFETY PRECAUTIONS 8 716 112 700a (02.07) & INSTALLATION REGULATIONS...
°C <100 <100 <100 SEDBUK (Band A) 93.1 93.2 94.2 Appliance protection rating Weight (excluding packaging) Emissions class for NOx and CO class INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 TECHNICAL DATA 8 716 112 700a (02.07)
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 EXTERNAL 12/18-18/25-25/32 CLEANING PRIMARY SYSTEMS 8 716 112 700a (02.07)
• Any system connected to the boiler must not have a separate electrical supply. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 MAINS SUPPLY 8 716 112 700a (02.07)
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 12/18-18/25-25/32 OIL SUPPLY 8 716 112 700a (02.07)
1” / 1 ” BSP outlets. • An automatic air vent (N) must be fitted. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 112 700a (02.07)
Page 12
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 EXTERNAL 12/18-18/25-25/32 WATER SYSTEMS & PIPEWORK 8 716 112 700a (02.07)
• **Minimum distance of the flue terminal to a facing wall, fence, building or property boundary is 2500mm. boundary INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 FLUE TERMINAL POSITIONS 8 716 112 700a (02.07)
C - Terminal guard (not included in flue kit) Part No. 7 716 190 050 FRONT LEFT HAND FLUE OUTLET A + B + C Plan view FRONT INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 BALANCED FLUE OPTIONS 8 716 112 700a (02.07)
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 12/18-18/25-25/32 UNPACKING THE BOILER 8 716 112 700a (02.07)
Services Condensate 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 12/18-18/25-25/32 PIPEWORK & FLUE POSITIONS 8 716 112 700a (02.07)
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 12/18-18/25-25/32 BOILER INSTALLATION 8 716 112 700a (02.07)
(J) with one of the longer self tapping screws provided. Measure here here 80mmØ flue pipe INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 FLUE INSTALLATION 8 716 112 700a (02.07)
Page 21
Fit the terminal guard (M, not supplied) and secure with the screws provided. N.B. There will be one screw spare with the left hand outlet position. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 FLUE INSTALLATION 8 716 112 700a (02.07)
Plan sectional view Plan sectional view 25/32 IMPORTANT when refitting Plan sectional view the combustion chamber access door (4) Combustion chamber access door tightening sequence. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 COMBUSTION CHAMBER 8 716 112 700a (02.07)
Rotate the cover plate and seal so it does not cover the capillary, then secure with the screws Return pipe provided. Washer INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 112 700a (02.07)
Page 24
50mm (min.) 500ml IMPORTANT: Insulate all external condensate pipe work or run in 32mm pipe work to prevent freezing. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 PIPEWORK CONNECTIONS 8 716 112 700a (02.07)
Attach air duct pipe and tighten clip (F) to secure to the burner air intake. Plug burner lead (G) into control box (H). INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 REFITTING COMPONENTS 8 716 112 700a (02.07)
230V NOTE: A frost thermostat is fitted as standard to the external appliance to provide frost protection. 1 2 3 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 ELECTRICS 8 716 112 700a (02.07)
Page 28
OFF in service mode. 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 12/18-18/25-25/32 ELECTRICS 8 716 112 700a (02.07)
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 12/18-18/25-25/32 PRE-COMMISSIONING 8 716 112 700a (02.07) CHECKS - APPLIANCE...
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 12/18-18/25-25/32 FILLING THE SYSTEM 8 716 112 700a (02.07)
Remove the oil pump filter, clean with kerosene and refit. 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 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 112 700a (02.07)
Page 33
* 25/32 model for 25kW remove the plastic air guide (see following page ). adjust the air shutter setting (L) to obtain the correct CO level. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 112 700a (02.07)
Page 34
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 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 112 700a (02.07)
3 Check that any other controls that are fitted to the system are operating properly. service flue boiler reset reset GREENSTAR CAMRAY EXTERNAL INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 STARTING THE APPLIANCE 8 716 112 700a (02.07)
Clean or replace all oil filters. Check that the condensate system is not obstructed, clean and refill as necessary. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 112 700a (02.07)
Page 39
(on 12/18 model only) the cabinet. Brass air deflection washer Locating circlip G - Retaining screws - cover H - Cover - oil pump INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 112 700a (02.07)
Page 40
Combustion chamber appliance case. A fire valve sensor clip (Q) is access door tightening provided for this purpose. sequence. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 INSPECTION AND SERVICE 8 716 112 700a (02.07)
20 Brass air restrictor washer Part Number: 8 716 112 729 0 21 Frost thermostat Part Number: 8-716-105-965-0 22 Service lead Part Number: 7-716-192-313-0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 18/25 8 716 112 700a (02.07)
Part Number: 8 716 107 536 0 17 Secondary Heat Exchanger gasket Part Number: 7-747-009-725-0 18 Frost thermostat Part Number: 8-716-105-965-0 19 Service lead Part Number: 7-716-192-313-0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 12/18 8 716 112 700a (02.07)
16 Secondary Heat Exchanger gasket Part Number: 7 747 009 725 0 17 Frost thermostat Part Number: 8-716-105-965-0 18 Service lead Part Number: 7-716-192-313-0 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 SHORT PARTS LIST 18/25 8 716 112 700a (02.07)
U N DE R NO CI RCU M STANCE S M UST A APPLIANCE BE LEFT TO OPERATE WITH CONTR OL LI N K E D OVERRIDDEN. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 FAULT FINDING 8 716 112 700a (02.07)
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.
Page 49
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...
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 EXTERNAL 12/18-18/25-25/32 BAFFLE ARRANGEMENT 8 716 112 700a (02.07) DIAGRAM...
Page 52
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 8 716 112 700a (02.07)
Page 53
These must be fitted. 8 716 113 453a 02/07 SECONDARY HEAT EXCHANGER REPLACEMENT SEAL 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...
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER WATER CYLINDERS For use with the following Greenstar oil fired appliances: Greenstar Camray External 12/18, 18/25, 25/32 THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY USER INSTRUCTIONS &...
Page 55
OFTEC 0845 6585080 SEDBUK Seasonal Efficiency for Domestic www.oftec.org Boilers in the United Kingdom. OFTEC Oil Firing Technical Association for the Petroleum Industry. USER INSTRUCTIONS & GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 8 716 112 711a (02.07) CUSTOMER CARE GUIDE...
Page 56
Controlling central heating Frost protection Fault conditions ENERGY SAVING TIPS ON ENERGY SAVING 10-11 MAINTENANCE MAINTAINING YOUR APPLIANCE FAULT FINDING FAULT OR BREAKDOWN GUARANTEE YOUR GUARANTEE GUARANTEE REGISTRATION GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 CONTENTS 8 716 112 711a (02.07)
SAFETY PRECAUTIONS OIL SMELLS, LEAKS OR FUMES FROM THE FITTING & MODIFICATIONS: APPLIANCE: Fitting the appliance and any associated Extinguish any naked flames. controls may only be carried out by a competent engineer in accordance with the Open windows and doors. relevant Installation Regulations.
To find out more about Worcester, Bosch Group, use the 'Contact Information' shown on the inside front cover. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 EXCELLENCE COMES AS STANDARD 8 716 112 711a (02.07)
Page 59
GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 GENERAL INFORMATION 8 716 112 711a (02.07)
INSTALLATION & SERVICING GENERAL INFORMATION CLEARANCES WARNING: External equipment operating at 230 Volts 600mm must not be serviced or repaired during adverse weather conditions. Do not use pressure washers or steam cleaners on this appliance or cabinet. FUEL: 2500mm This appliance is designed to use 28 second 600mm kerosene, no other fuel must be used.
The Lockout Reset Indicator/ Button (F) is located on the burner control box which situated on the burner at the base of the appliance. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 CONTROLS 8 716 112 711a (02.07)
Turn the room thermostat to the temperature required. Set thermostatic radiator valves to the required temperature for each room. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 OPERATING THE APPLIANCE 8 716 112 711a (02.07)
In the unlikely event that there is no hot water or heating, remove the front panel and check for lockout or other fault conditions. Check page 9 for fault conditions. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 OPERATING THE APPLIANCE 8 716 112 711a (02.07)
Ensure that the Service switch is in Boiler mode. service If there is power supply to the boiler contact flue boiler reset reset GREENSTAR CAMRAY EXTERNAL your service engineer for advice. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 OPERATING THE APPLIANCE 8 716 112 711a (02.07)
Warning: do not block or seal any air vents that are installed to ensure the central heating boiler (or other appliance) operates safely. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 TIPS ON ENERGY SAVING 8 716 112 711a (02.07)
Page 66
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. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 TIPS ON ENERGY SAVING 8 716 112 711a (02.07)
Do not obstruct the flue outlet or the air inlet. Do not pressure wash or steam clean the appliance or its cabinet. To clean the cabinet wipe down with soapy water. MAINTAINING YOUR APPLIANCE GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 8 716 112 711a (02.07)
Hot water temperature too Hot water temperature set Check setting too low Hot water not in timed Check programmer period on the programmer settings GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 FAULT FINDING 8 716 112 711a (02.07)
(see inside front cover for details). Your service administrator will arrange for an Engineer to call with the minimum of delay. Under normal FAULT OR BREAKDOWN GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 8 716 112 711a (02.07)
Great Britain. This guarantee is given in addition to all your normal statutory rights. Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 YOUR GUARANTEE 8 716 112 711a (02.07)
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 Installer details GUARANTEE REGISTRATION GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 8 716 112 711a (02.07)
Page 73
CUSTOMER CARE GUIDE EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 www.worcester-bosch.co.uk Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. 8 716 112 711a (02.07)
Need help?
Do you have a question about the GREENSTAR CAMRAY EXTERNAL 12/18 and is the answer not in the manual?
Questions and answers