Bosch GREENSTAR CAMRAY KITCHEN Instruction manual

GREENSTAR CAMRAY KITCHEN
& KITCHEN 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 KEROSENE (28 SECOND
OIL) ONLY
GB
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
INSTALLATION & SERVICING INSTRUCTIONS
SYMBOLS USED IN THIS MANUAL:
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE WORCESTER APPLIANCE MODEL(S)
STATED ON THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH
ANY OTHER MAKE OR MODEL OF APPLIANCE.
Domestic hot water
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
Central heating
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT PERSON. FAILURE TO INSTALL
CORRECTLY COULD LEAD TO PROSECUTION.
COMPLYING WITH THE BUILDING REGULATIONS:
This heating appliance forms part of the controlled services for the building. It is law that all controlled
services for buildings must comply with building regulations. You must be able to satisfy your Local
Authority Building Control Body (LABC) that the work carried out concerning the installation and
commissioning of this heating appliance has been carried out to a satisfactory standard.
Room thermostat
Frost thermostat
OFTEC operate a competent persons scheme and registered installers are able to certify that their
work complies with building regulations. Under the scheme;
OFTEC must be informed about every installation.
OFTEC will issue a building regulations compliance certificate to the householder and will
notify the LABC.
Wait time period
OFTEC provide controlled document forms CD10 and CD11 for use during installation and
commissioning respectively.
Programmer/timer OFF
Cold water main supply
Other organisations operate self-certification schemes e.g. NAPIT and BESCA Ltd. and it may be
possible for installers who are members of these organisations to self certify their work.
Alternatively you must submit a building control notice to the LABC before installing any boiler. The
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.
Electricity supply
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 SERVICE INTERVAL RECORD CAN BE FOUND ON
THE BACK PAGE OF THIS MANUAL.
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that more than one person is
involved in the transfer of the packaged
appliance from the van to the point of installation.
It is advised that no attempt should be made to
move the packaged appliance without the use of
a suitable truck.
At all times the correct method for handling
heavy objects should be strictly observed.
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for
help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body.
• Wear protective clothing and gloves to
protect from any sharp edges.
ABBREVIATIONS USED IN THIS MANUAL:
Ø
Diameter
CH
Central Heating
DHW
Domestic Hot Water
TRV
Thermostatic Radiator Valve
IP
Ingress Protection
CF
Conventional flue
BF
Balanced flue
N/A
Not allowed
SEDBUK
Seasonal Efficiency of Domestic Boilers in the United Kingdom
OFTEC
Oil Firing Technical Association for the Petroleum Industry
IEE
Institute of Electrical Engineers
LABC
Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
Check List
Item
Qty
Greenstar Camray Kitchen & Kitchen System Installation/Servicing Instructions. 1
Users Instructions.................................................................................................1
Fascia Information Card......................................................................................1
Warranty Return Envelope..................................................................................1
Guarantee Registration Card............................................................................1
Condensate Trap Kit............................................................................................1
Return Pipe Kit......................................................................................................1
1
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
INSTALLATION &
SERVICING INSTRUCTIONS
SAFETY &
REGULATIONS
CONTENTS
IMPORTANT INFORMATION AND SYMBOLS
1
SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS
3
APPLIANCE
INFORMATION
SAFETY & REGULATIONS
APPLIANCE INFORMATION
GENERAL INFORMATION
4
TECHNICAL DATA
5
LAYOUT & COMPONENTS KITCHEN
6
LAYOUT & COMPONENTS KITCHEN SYSTEM
7
CLEANING PRIMARY SYSTEMS
MAINS SUPPLY
PRE INSTALLATION
PRE-INSTALLATION
8
9
10
WATER SYSTEMS & PIPEWORK
CONDENSATE & PRESSURE RELIEF PIPEWORK
BOILER LOCATION & CLEARANCES
11-12
13
14-15
FLUE TERMINAL POSITIONS
16
CONVENTIONAL FLUE
17
ROOM SEALED FLUE OPTIONS
18
INSTALLATION
OIL SUPPLY
UNPACKING THE BOILER
19
PIPEWORK POSITIONS / FLUE OPENING
20
BOILER INSTALLATION
21
FLUE INSTALLATION
22
COMBUSTION CHAMBER
23
PIPEWORK CONNECTIONS
24
OIL BURNER AND PUMP
25
REFITTING COMPONENTS
26
ELECTRICS
COMMISSIONING
INSTALLATION
27-32
FILLING THE SYSTEM
STARTING THE APPLIANCE
33
34
35-38
WATER TREATMENT
39
FINISHING COMMISSIONING - APPLIANCE
40
FAULT FINDING
& DIAGRAMS
PRE-COMMISSIONING CHECKS - APPLIANCE
SERVICING
& SPARES
COMMISSIONING
SERVICING & SPARES
INSPECTION AND SERVICE
41-47
SHORT PARTS LIST 12/18
48
SHORT PARTS LIST 18/25
49
SHORT PARTS LIST 25/32
50
FAULT FINDING
NOTES
FAULT FINDING & DIAGNOSIS
51-53
FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX
54
COMBUSTION RECORD
55
SERVICE INTERVAL RECORD
55
2
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
CONTENTS
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS
INSTALLATION REGULATIONS
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
Extinguish any naked flames.
Open windows and doors.
Isolate the electrical supply.
Isolate the fuel supply to the boiler.
Rectify fault.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the construction
process that contravene the COSHH Regulations (Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the
vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances which can corrode
the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer in accordance with these instructions and the relevant Installation Regulations.
Flue systems must not be modified in any way other than as described in the fitting instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated components and
systems could invalidate the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified engineer (such
as OFTEC registered personnel) using approved spares, to help maintain the economy, safety
and reliability of the appliance.
Failure to install appliances correctly could lead to
prosecution.
The appliance should be installed by a competent
person. The person installing the appliance should
be aware of the Health and Safety at Work Act and
take appropriate action to ensure that the
regulations are adhered to. In order to give
optimum efficiency and trouble free operation the
appliance must be commissioned by a qualified
OFTEC engineer.
The compliance with a British Standard does not,
in itself, confer immunity from legal obligations. In
particular the installation of this appliance must be
in accordance with the relevant requirements of the
following British Standards and regulations in
respect of the safe installation of equipment:
BS 5410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part 5: Specification for Oil Storage
Tanks.
BS 7593: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 5449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 5955: part 8: Specification for the installation
of thermoplastic pipes and associated fittings for
use in domestic hot and cold water services and
heating systems.
BS 7291: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations in buildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 7671: IEE Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse
links for domestic and similar purposes.
The Building Regulations Part J and L1 England
and Wales; Part F and Part J Section III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.
3
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler.
B - Literature pack.
C - Condensate trap kit.
600mm
370mm
D - Return pipe.
APPLIANCE
INFORMATION
A
855mm
B
C
D
Check List
Item
Qty
Greenstar Camray Kitchen & Kitchen System Installation/Servicing Instructions. 1
Users Instructions ................................................................................................................ 1
Fascia Information Card....................................................................................................... 1
Warranty Return Envelope ................................................................................................. 1
Guarantee Registration Card............................................................................................. 1
Condensate Trap Kit............................................................................................................. 1
Return Pipe Kit....................................................................................................................... 1
4
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
GENERAL INFORMATION
TECHNICAL DATA
DESCRIPTION
UNITS
12/18
18/25
25/32
Primary water capacity (total) Kitchen
litres
23
23
21
Primary water capacity (total) Kitchen System
litres
30
30
28
Maximum static head
metres
30
30
30
Minimum static head
metres
1
1
1
mbar
26
52
69
mH2O
5.7
4.9
4.1
bar
2.5
2.5
2.5
kg/hr
29
40
51
Fuel line (compression)
mm
10
10
10
Kitchen System flow
mm
22
22
28
Kitchen flow and optional vent/air vent
BSP
1
1
11/4
Primary drain
BSP
3/
3/
Condensate (polypropylene)
mm
21.5
21.5
21.5
Pressure relief valve outlet - Kitchen System
mm
15
15
15
AC...V
230
230
230
Frequency
Hz
50
50
50
Max. power consumption Kitchen
W
150
160
160
Max. power consumption Kitchen System
W
255
265
265
Boiler flow temperature range (cut in/cut out)
°C
55/81
55/81
55/81
Control thermostat differential
°C
5
5
5
Boiler high limit thermostat set point
°C
95
95
95
Boiler manual reset overheat thermostat set point
°C
105
105
105
Flue manual reset overheat thermostat set point
°C
110
110
110
Maximum hearth temperature
°C
<100
<100
<100
SEDBUK (Band A)
%
93.1
93.2
94.2
Appliance protection rating
IP
20
20
20
Weight (excluding packaging) Kitchen
kg
101
102
109
Weight (excluding packaging) Kitchen System
kg
108
110
117
class
3
3
3
mg/kWhr
80
50
50
APPLIANCE
INFORMATION
Central Heating
Water side resistance (20°C difference) Kitchen
Max. available pumphead (20° difference) Kitchen System
Max. permissible sealed system operating pressure
in accordance with WRAS guidelines
Flue
Exit flue gas mass flow
Pipework connections
4
4
3/
4
Electrical
Electrical power supply voltage
Thermostats
General Data
Emissions class for NOx and CO
Typical NOx emission figures
5
TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
LAYOUT & COMPONENTS
3 4
2
5
6
7
1
8
9
10
34
33
11
32
12
31
13
30
14
15
29
16
17
a
27
25
18
26
19
The diagram opposite excludes the top, front
and RH side casing panels.
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 FLUE GAS SAMPLING POINT
4 FLUE MANIFOLD ACCESS COVER
5 FLUE OVERHEAT THERMOSTAT PHIAL
6 POWER CABLE CLIP
7 FIRE VALVE SENSOR CLIP
8 AIR INLET CASING
9 FLEXIBLE AIR DUCT (CONNECTING TO
AIR INTAKE ON BURNER)
10 SECONDARY HEAT EXCHANGER
BLEED POINT (ONE ON EITHER SIDE)
11 SECONDARY HEAT EXCHANGER
12 SECONDARY HEAT EXCHANGER
DRAIN
13 CONDENSATE OUTLET
14 BAFFLE RETAINER ACCESS DOOR
15 HEAT EXCHANGER FLOW PIPE
16 CONTROL & MANUAL RESET
OVERHEAT THERMOSTAT PHIAL
17 AUTO-RESET HIGH LIMIT
THERMOSTAT PHIAL
18 PRIMARY HEAT EXCHANGER
19 COMBUSTION CHAMBER ACCESS
DOOR
20 BASE PLATE AND OIL DRIP TRAY
21 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (9) TO AIR
INLET CASING (8) )
22 BURNER MOTOR (BEHIND PLASTIC
COVER)
23 OIL PUMP (BEHIND PLASTIC COVER)
24 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
25 BURNER CONTROL BOX (BEHIND
PLASTIC COVER)
26 RIELLO RDB BURNER
27 OIL ISOLATING VALVE
28 DEFLECTOR PLATE
29 BOILER OVERHEAT RESET BUTTON
30 QUICK REFERENCE GUIDE SLOT
31 FLUE OVERHEAT RESET BUTTON
32 LOCKOUT INDICATOR
33 TEMPERATURE CONTROL KNOB
34 DEMAND INDICATOR
APPLIANCE
INFORMATION
KITCHEN
28
24
20
23
22
21
OPTIONAL ACCESSORIES (not supplied)
a7 day TWIN CHANNEL DIGITAL
PROGRAMMER
Part No. 7 716 192 033
6
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
LAYOUT &
COMPONENTS
LAYOUT & COMPONENTS
KITCHEN SYSTEM
The diagram opposite excludes the top, front
and RH side casing panels.
5
PRE INSTALLATION
2
3
4
6
7
1
8
9
38
10
37
11
36
12
35
34
13
33
32
14
15
16
31
17
a
18
30
19
20
29
28
27
21
26
25 24
23
22
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 FLUE GAS SAMPLING POINT
4 FLUE MANIFOLD ACCESS COVER
5 FLUE OVERHEAT THERMOSTAT PHIAL
6 POWER CABLE CLIP
7 FIRE VALVE SENSOR CLIP
8 AIR INLET CASING
9 FLEXIBLE AIR DUCT (CONNECTING TO
AIR INTAKE ON BURNER)
10 SECONDARY HEAT EXCHANGER
BLEED POINT (ONE ON EITHER SIDE)
11 SECONDARY HEAT EXCHANGER
12 SECONDARY HEAT EXCHANGER
DRAIN
13 CONDENSATE OUTLET
14 BAFFLE RETAINER ACCESS DOOR
15 AUTO-RESET HIGH LIMIT
THERMOSTAT PHIAL
16 HEAT EXCHANGER FLOW PIPE
17 CONTROL & MANUAL RESET
OVERHEAT THERMOSTAT PHIAL
18 CIRCULATING PUMP
19 PRIMARY HEAT EXCHANGER
20 COMBUSTION CHAMBER ACCESS
DOOR
21 BASE PLATE AND OIL DRIP TRAY
22 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (9) TO AIR
INLET CASING (8) )
23 BURNER MOTOR (BEHIND PLASTIC
COVER)
24 OIL PUMP (BEHIND PLASTIC COVER)
25 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
26 EXPANSION VESSEL BRACKET
27 BURNER CONTROL BOX (BEHIND
PLASTIC COVER)
28 DEFLECTOR PLATE
29 RIELLO RDB BURNER
30 EXPANSION VESSEL
31 PRESSURE RELIEF VALVE
32 BOILER OVERHEAT RESET BUTTON
33 QUICK REFERENCE GUIDE SLOT
34 FLUE OVERHEAT RESET BUTTON
35 LOCKOUT INDICATOR
36 TEMPERATURE CONTROL KNOB
37 DEMAND INDICATOR
38 SYSTEM PRESSURE GAUGE
OPTIONAL ACCESSORIES (not supplied)
a7 day TWIN CHANNEL DIGITAL
PROGRAMMER
Part No. 7 716 192 033
NOTE: OIL ISOLATING VALVE LOCATION
IS ILLUSTRATED ON PREVIOUS PAGE
ITEM 27.
7
LAYOUT &
COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
CLEANING PRIMARY SYSTEMS
IMPORTANT: All the following Pre-Installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT: Debris from the system can
damage the boiler and reduce efficiency.
Failure to comply with the guidelines for
t he use of wat er treatment with the
appliance will invalidate the appliance
warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER.
CLEANING THE PRIMARY SYSTEM:
Cleanse the system in accordance with
BS 7593.
Fill the system with cold mains water to the
recommended pressure and check for leaks.
Open all drain cocks and drain the system.
PRE INSTALLATION
FLUSH THE EXISTING SYSTEM WITH A
POWER FLUSHING MACHINE OR WITH A
CHEMICAL CLEANER BEFORE
INSTALLING NEW COMPONENTS.
Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
Circulate the flushing agent before the boiler
is fired up.
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.
8
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
CLEANING PRIMARY
SYSTEMS
MAINS SUPPLY
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2 (24 x
0.2mm) temperature rated to 90°C.
• Protection IP20.
• External 5A fuse to BS1362.
• The appliance must be earthed.
• All pipes to the boiler must be
cross-bonded.
PRE INSTALLATION
• It must be possible to isolate the appliance
from the electric supply with at least a 3mm
contact separation in both poles supplying
the appliance.
• Wiring between the appliance and the
electrical supply must comply with IEE wiring
regulations and any local regulations which
may apply for fixed wiring to a stationary
appliance.
• Any system connected to the boiler must not
have a separate electrical supply.
9
MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
H
J
K
L
M
N
- Oil storage tank.
- Isolating valve.
- Oil strainer & water seperator.
- Fire valve to BS 5410.
- External wall.
- Fire valve sensor.
- Oil burner.
OIL SUPPLY
- Oil supply pipe.
- Oil pump.
- Full base (plastic tanks).
- Non-return valve.
- De-aerator.
- Oil filter (16µm max filtration size)
OIL SUPPLY :
• This appliance is suitable for kerosene (28
second oil) only, no other fuel must be used.
• Plastic or steel tanks should be installed to
BS 5410. A steel tank should conform to
BS 799: part 5 and have a slope of 1 in 24
away from the outlet valve with a sludge cock
at its lower end.
• Do not use galvanised steel tanks or
pipework for the oil supply system.
• Do not use soldered joints on the oil
supply pipework.
NOTE: All dimensions are in metres unless stated otherwise.
The maximum pipe run figures are based on using copper pipe with an inside diameter of
2mm less than the Ø.
E
F
BD
BN G
K
B C
H
4m (13ft) max.
A
300mm
min.
a)
J
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
HEAD 10mmØ
12mmØ
HEAD 10mmØ
12mmØ
0.5
12
30
2.5
62
100
1.0
25
69
3.0
74
100
1.5
37
91
3.5
87
100
2.0
49
100
4.0
99
100
b) Double pipe sub-gravity feed system:
Maximum suction height 3.5 metres. Non-return
valves must be fitted to the inlet and return oil line
between the oil pump (J) and oil storage tank (A).
c) Single pipe suction lift with de-aerator
Maximum suction height 3.5 metres. The oil
tank (A) must be positioned below the oil pump
(J). Create an inlet and return loop between the
de-aerator (M) and oil pump (J).
F G
B
D
L
A
B C
L
150mm
B
H
K
N
J
E
3.5m (11.5ft) max.
b)
A
J
D
3.5m (11.5ft) max.
c)
B
A top feed oil tank fitted with a de-aerator
using an internal non-return valve should have
any non-return valves fitted in the base of the
tank to the suction line removed to assist
purging air from the oil line.
Lay the oil supply pipe (H) as straight and
level as possible to avoid air pockets and
unnecessary friction losses. Route away
from the boiler access door or other hot
surfaces.
F
G
M
H
A non-return valve must be incorporated within
the de-aerator or fitted to the oil line between
the oil storage tank (A) and the de-aerator (M).
Pipework
Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump (J).
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
HEAD 10mmØ
12mmØ
HEAD 10mmØ
12mmØ
0
50
100
2.0
26
66
0.5
44
100
2.5
20
50
1.0
38
95
3.0
14
37
1.5
32
80
3.5
8
22
B C
a) Single pipe gravity feed system:
The oil storage tank (A) must be positioned so
that the oil level does not exceed 4 metres above
the level of the burner oil pump (J) and in addition the oil level must be at least 300mm above
the oil pump (J). Where the maximum oil level in
the oil storage tank exceeds 4 metres, a head
breaking device must be installed between the
tank (A) and the burner oil pump (J).
PRE INSTALLATION
A
B
C
D
E
F
G
Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
Fit an oil strainer and water seperator (C) to
the oil supply pipe, near the oil storage tank.
Fit an additional oil filter (N, 16µm max
filtration size) close to the boiler, but not
inside the boiler casing.
Fit a fire valve in accordance with BS 5410.
The fire valve (D) should be fitted externally
to the building with the fire valve sensor (F)
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
located within the appliance case.
FUEL FLOW RATE
FUEL FLOW RATE
A fire valve with a shut off temperature of
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
85°C or higher is recommended to avoid
8mmØ 8mmØ 8mmØ 10mmØ
8mmØ 8mmØ 8mmØ 10mmØ
the possibility of nuisance shut offs.
2.0
60
30
14
65
0
100
55
26
100
2.5
45
25
11
50
0.5
95
45
23
100
A capillary type valve provides a neat and
3.0
35
15
8
35
1.0
80
40
20
90
simple installation. Alternatively, a fusible
3.5
25
10
5
20
1.5
70
35
17
75
link or electrical system may be used.
K
E
The table and illustration above is a guide only and does not in any way override the deaerator manufacturers instructions.
Under no circumstances should a
combination isolating/fire valve be used
as the sole fire protection device.
10
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
OIL SUPPLY
WATER SYSTEMS & PIPEWORK
IMPORTANT: The boiler should not be
allowed t o operat e wit h a ret urn
temperature of less than 40°C when the
system is up to operating temperature.
TYPICAL OPEN VENT SYSTEM:
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework used must have a
polymeric barrier, comply with BS 7921and
be installed to BS 5955 with 1000mm
(minimum) length of copper or steel pipe
connected to the boiler.
E
• Plastic pipework used for underfloor heating
must be correctly controlled with a
thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C
with 1000mm (minimum) length of copper or
steel pipe connected to the boiler.
S
1000mm min.
150mm max.
H
F
M
PRE INSTALLATION
R
T
A
R
L
T
R
L
R
K
L
L
T
L
C
K
J
D
D
A - Appliance.
G - Pressure gauge.
B - Expansion vessel.
H - Open vent 22mmØ min.
P - Pressure relief
discharge.
C - Automatic bypass valve.
J - Circulating pump.
R - Radiators.
D - Drain cock.
K - Zone valve.
S - Static head.
E - Feed and expansion cistern.
L - Lockshield valve.
F - Feed and expansion
15mmØ min.
M - Hot water cylinder.
N - Automatic air vent.
T - Thermostatic radiator
valve (TRV).
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on the
system.
OPEN VENT PRIMARY SYSTEM:
• The open vent pipe (H) and feed and
expansion pipe (F) must rise continuously
from the appliance.
• The feed and expansion cistern (E) must be
positioned to provide a static head (S) of at
least 1 metre above the highest point in the
heating system to the water level in the feed
and expansion cistern (E).
• Ensure adequate space is left in the expansion
cistern for expansion of the system water.
• No valve shall be fitted in the open vent pipe
(H) or the feed and expansion pipe (F).
• The open vent pipe (H) must be at least
22mmØ.
U - To filling system.
TYPICAL SEALED SYSTEM:
N
M
R
T
R
L
T
PRIMARY SYSTEM/CONNECTIONS/VALVES:
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS 2767:10.
• All other valves should conform to BS 1010.
• On new installations TRVs must be used on
all radiators except the radiator where the
room thermostat is sited, this must be fitted
with lockshield valves and left open. All
installations should have TRVs fitted to
radiators within the sleeping accommodation.
• An automatic bypass valve must be connected
between the heating flow and return where
TRVs are used on all radiators, fitted to give
at least a 3 metre circuit when activated.
L
P
A
R
R
B
L
G
L
T
L
U
C
J
K
D
D
FULLY PUMPED SEALED PRIMARY SYSTEM:
• A pressure relief valve (P), spring loaded
safety valve set to operate at 3bar, must be
fitted to the heating flow pipe as close as
possible to the boiler or onto one of the boiler
top 1” / 11/4” BSP outlets.
• An expansion vessel (B) must be fitted to the
heating return pipe as close as possible to
the boiler and pressurised for the system
volume according to the instructions supplied
with the vessel.
• A pressure gauge (G), 3 bar minimum, must
be fitted to the heating flow pipe or one of the
boiler 1” / 11/4” BSP outlets.
• An automatic air vent (N) must be fitted.
11
WATER SYSTEMS &
PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
WATER SYSTEMS & PIPEWORK
Water main
supply
Heating return
Stop
cock
Temporary hose
Heating return
Auto air
vent
Test cock
Stop
cock
FILLING PRIMARY SEALED SYSTEMS:
• Filling the system must comply with one of
the methods shown opposite.
• The filling point must be at low level and must
never be a permanent direct fixing to the
mains water supply.
• Filling loops must be WRAS approved.
Make up
vessel
Non return
valve
1000mm above
the highest point
of the system
PRE INSTALLATION
Hose
return
Non return Non return
valve
valve
Stop
cock
COMMISSIONING
INSTALLATION
Fill Point
12
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
WATER SYSTEMS &
PIPEWORK
CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE PIPEWORK:
a
C
B
A
D
75mm
min.
b
• The condensate pipework must fall at least
50mm per metre towards the outlet and
should take the shortest practicable route
and not exceed 3 metres outside the building.
If a run greater than 3m is required, 32mmØ
polypropylene pipe must be used.
c
C
E
C
A
• The pipework must follow one of the options
shown opposite:
A
450 min.
PRE INSTALLATION
• All national and, where appropriate, local
regulations for the discharge and
neutralisation of condensate should be
followed.
• The condensate pipe must be a minimum of
21.5mmØ polypropylene pipe.
a - Internal waste drainage system
D
b - Soil/vent stack
Invert
c - External drainage system
d
d - External condensate absorption point
• Condensate pipework must not be connected
to rainwater downpipes.
Unsuitable for clay soil types
C
500mm min.
• Use waterproof pipe insulation in exposed
positions and for external pipework
F
A
25mm
min.
G
I
H
200mm min.
400mm
min.
IMPORTANT: Condensate pipework must not
leak and the condensate trap must be filled
with water before the boiler is started to
prevent the possibility of potentially harmful flue
products escaping via the condensate route.
A - Condensate from the boiler condensate
trap (supplied) which has a 75mm
minimum water seal.
B - Sink.
C - 21.5mm Ø polypropylene condensate pipe.
D - Gully.
E - Internal soil and vent stack.
F - 300mm x 100mm Ø sealed plastic tube.
G - Ground level.
H - Drainage holes 50mm from base of tube
(12mm Ø at 25mm centres) facing away
from building.
I-
Limestone chippings.
K
PRESSURE RELIEF PIPEWORK:
J
K
IMPORTANT: The pressure relief valve is a
safety device for the boiler and if activated may
discharge boiling water or steam through the
relief valve drain pipe.
Care should be taken when siting the outlet
pipe so that it does not cause an obstruction or
discharge above a window, entrance or other
public access where it could cause a hazard.
• The pressure relief drain pipe (K) should be
at least 15mm diameter copper pipe and run
downwards away from the boiler and discharge
away from any electrics or other hazard,
preferably to an external drain or soakaway.
• Pipe (K) should be finished with a partial
bend, near the outlet to face the external wall
(as shown) to help prevent freezing.
J -
Outside wall.
K-
Drain pipe.
13
CONDENSATE &
PRESSURE RELIEF
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
a: RECOMMENDED
INSTALLATION CLEARANCES
BOILER LOCATION &
CLEARANCES
570mm
1200mm
• This boiler is only suitable for installing
internally within a property at a suitable
location onto a fixed rigid surface of the same
size as the boiler and capable of supporting
the boiler weight.
1155mm
300mm
• The boiler must be installed on a flat level
surface to ensure condensate does not enter
the primary heat exchanger.
100mm
• The boiler is not suitable for external
installation unless a suitable enclosure is
provided.
100mm
600mm
• Roof space installations must fully conform to
BS 5410 part 1 section 4.6.9.
• In order to ensure clean and efficient
combustion an adequate supply of air must
be delivered to the combustion chamber.
b: ANNUAL SERVICE CLEARANCES
380mm
1200mm
• To provide sufficient air a suitable inlet must
be provided into the room or space in which
the boiler is situated.
10mm
PRE INSTALLATION
Open flue model (CF):
865mm
CF minimum air inlet sizes**
5mm*
Output
12/18
18/25
25/32
Size cm2
99
138
165
An air brick or other form of continuous air
supply may have to be built into the installation
in order to ensure an adequate supply of air.
5mm*
600mm
• If the appliance is to be installed in a confined
space or compartment two air vents are
required, one at high level and one at low level.
The minimum free area of each vent is
shown opposite and depends whether the
air is taken from another room or from
outside the building.
c: MAINTENANCE & REPAIR
CLEARANCES
380mm
1200mm
• Where the air is taken from another room that
room must contain an air inlet as described
above.
300mm
865mm
Room sealed balanced flue model (RS):
The appliance does not require a separate vent
for combustion air.
5mm*
• Installation in cupboards or compartments
require permanent vents for cooling purposes,
one at high level and one at low level, either
direct to outside air or to a room.
5mm*
600mm
• Both vents must pass to the same room or be
on the same wall to the outside air.
The minimum air vent free area is given in the
table opposite.
2
MINIMUM AIR VENT AREA (cm ) FOR APPLIANCES INSTALLED IN A COMPARTMENT:
1Internal air to and from a space/room inside the building. 2External air to and from directly outside the building.
Conventional flue:**
Internal1ventilation
High
Model Level
12/18 198
18/25
Low
Level
297
Room Sealed flue:**
2
External ventilation
Internal1ventilation
High
Low
High
Low
Level Level
Model Level Level
99
198
12/18 198
198
External 2 ventilation
High
Low
Level Level
99
99
275
413
138
275
18/25
275
275
138
138
25/32 330
495
165
330
25/32 330
330
165
165
a: INSTALLATION CLEARANCES:
Diagram ( a ) shows the minimum space
recommended to install the boiler only.
b: SERVICE CLEARANCES:
Diagram ( b ) shows the minimum space
required to carry out an annual service.
* Remove the flue 'knock-out' panel sections if
this clearance is less than 75mm.
The appliance is suitable for an under worktop
installation providing that the worktop above the
boiler (min 10mm clearance) is removable for
maintenance and repair and the front of the
boiler is not enclosed.
** Due to changes to BS 5410 and modern
building design, these figures no longer incorporate the adventitious ventilation allowance.
14
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
BOILER LOCATION &
CLEARANCES
BOILER LOCATION &
CLEARANCES
COMPARTMENTS:
Follow the requirements of BS 5410 and note:
•
Minimum clearances must be maintained.
•
An access door is required to install, service
and maintain the boiler and any ancillary
equipment.
•
If fitting the boiler into an airing cupboard
use a non-combustible material (if perforated,
maximum hole sizes of 13mm) to separate
the boiler from the airing space.
Venting compartments:
PRE INSTALLATION
There must be sufficient clearance around the
appliance to allow proper circulation of
ventilation air. The clearances required for
installation and servicing will normally be
adequate for ventilation.
600mm
•
Ventilation must be provided for boilers
fitted into compartments as described in
BS 5410.
•
Combustion air must not be taken from a
room or internal space containing a bath or
shower and must not communicate with a
protected area such as a hall, stairway,
landing, corridor, lobby, shaft etc.
•
Air vents must allow access for clean free
air and must be sited to comply with the flue
terminal position requirements.
•
Air ducting runs must not exceed 3m.
•
Low level air vents must be less than
450mm from the floor.
•
A warning label must be added to the vents
with a statement to the effect: ''Do not block
this vent. Do not use for storage.”
600mm
750mm
2
3
1
2
1
3
2250mm
0
SHOWER / BATHROOMS:
The boiler must not be installed in zones 0, 1
or 2 (the shaded areas shown on the diagrams opposite).
A
IMPORTANT: conventional flued boilers must
not be fitted in a bathroom.
600mm
750mm
3
2
1
1
2
3
2250mm
0
I M PORTANT: any appliance control using
mains electricity must not be able to be
touched by a person using the bath or shower.
Electrical switches, fused spur and socket
outlets must not be fitted in the bathroom.
In all cases the IEE wiring regulations must be
consulted.
All pipework in bathrooms and shower rooms
must be cross bonded.
A
600mm radius
A - Bath or shower cubicle (zone 0)
15
BOILER LOCATION &
CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
Minimum dimensions of flue terminal positions for oil fired appliances:
FLUE TERMINAL POSITIONS
TERMINAL POSITION
CF
RS(H) RS(V)
A1 2
Directly below an opening, air brick, opening window, etc
N/A
600mm
N/A
B1 2
Horizontally to an opening, air brick, opening window, etc
N/A
600mm
N/A
C
Below a plastic/painted gutter, drainage pipe or eaves if
combustible material protected
N/A
75mm
N/A
D3
Below a plastic/painted gutter, drainage pipe or eaves without
protection to combustible material
N/A
600mm
N/A
E
From vertical sanitary pipework
N/A
300mm
N/A
F
From an external or internal corner or from a surface or boundry
alongside the terminal
N/A
300mm
N/A
G
Above ground or balcony level
N/A
300mm*
N/A
H
From a surface or boundary facing the terminal
N/A
600mm** N/A
J
From a terminal facing the terminal
K
Vertically from a terminal on the same wall
L
Horizontally from a terminal on the same wall
M
1200**mm
• The flue must be fitted and terminated in
accordance with the recommendations of
BS5410.
• The flue must not cause an obstruction.
• Discharge from the flue outlet must not be a
nuisance.
• Flue gases have a tendency to plume and in
certain weather conditions a white plume of
condensation will be discharged from the flue
outlet which could be regarded as a
nuisance, for example, near security lighting.
• There should be no restriction preventing the
clearance of combustion products from the
terminal.
—
N/A
1500mm
N/A
—
750mm
—
Above the point of highest intersection with the roof
600mm
—
600mm
N
From a vertical structure on the side of the terminal
750mm
—
750mm
O
Above a vertical structure less than 750mm from the side of the terminal 600mm
—
600mm
P
From a ridge terminal to a vertical structure on the roof
1500mm
—
N/A
Q
Above or to the side of any opening on a flat or sloping roof
300mm
—
300mm
R
Below any opening on a sloping roof
1000mm
—
1000mm
Key: — Not applicable, N/A Not allowed, CF Conventional flue, RS(H) Room Sealed Horizontal flue, RS(V) Room Sealed Vertical
flue.
Notes:
1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or
entering into buildings.
2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.
3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and
extending 300mm higher and wider than the tank is provided between the tank and the terminating position.
4. Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a
combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.
5. If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has
access, the terminal should be protected by a guard.
6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the
case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire
retardant material and close wire in the vicinity of the flue.
7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.
8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the
manufacturer of the plastic components.
• The air inlet/outlet duct and the terminal of
the boiler must not be closer than 25mm to
any combustible material. Detailed
recommendations on protection of
combustible materials are given in BS 5410:1
PRE INSTALLATION
—
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
• A protective stainless steel terminal guard,
Part No: 7 716 190 050, must be fitted if
the terminal is 2m or less above a surface
where people have access.
See 'Contact Information' on the back cover
for flue guard information.
• The following additional guidelines (from part
L Exceptions Guidance Document) are
recommended when determining the flue
outlet position:
• Avoid discharging flue gases into car ports
or narrow passageways.
• *Minimum distance of the flue terminal from
above ground is 2100mm where directed to a
public footpath, private access route or a
frequently used area and 2500mm from a
car parking area.
• **Minimum distance of the flue terminal to a
facing wall, fence, building or property
boundary is 2500mm.
P
Q
O
Q
Q
Q
Q
Q
Q
M
boundary
R
F
Pitched roof
C, D
J
A
H
Flat roof
N
B
F
E
K
F
G
L
boundary
16
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
FLUE TERMINAL
POSITIONS
CONVENTIONAL FLUE
• Open (conventional) flued appliances must
not be installed in a bedroom, bathroom or
bedsitting room.
• The flue system must be in accordance with
BS 5410 : Part 1 and the current Building
Regulations.
D
E
• The flue must be constructed of materials
suitable for use with condensing combustion
products.
• External flue systems must be of the insulated
type.
PRE INSTALLATION
• Brick and masonry chimneys must be lined
with a suitable non-combustible material and
properly jointed to withstand the effects of
the working temperature (minimum rating of
material 120°C) of the appliance and any
condensate which may form.
• All flue joints must be sealed to prevent the
leakage of condensate and combustion
products.
• Ensure that joints are made so that the
condensate runs away and is not collected
within the joint.
NOTE: The flue can be increased in size from
the boiler take off point providing the joint is
correctly sealed. Never reduce the flue diameter
from the boiler take off point.
CF Sizing:
• 12/18 and 18/25 = 100/103mmØ
25/32
= 130mmØ
• Because the flue operates at a lower
temperature on a condensing boiler
compaired to that of a conventional
appliance, the flue draught will be lower.
Typically the draught will be between
0.5mmwg and 4.4mmwg, measured with the
flue warm but the burner not firing. The actual
figure will vary depending on weather
conditions, flue height and position.
C
B
• The flue should be vertical and contain as few
bends as possible, a maximum of two 135°
bends should be used.
A
• The flue outlet must be extended beyond the
eaves of the building and where possible,
above the apex.
• Fit a suitable anti down-draught terminal
where down draughts are experienced.
Manufacturers of conventional flue systems
suitable for this appliance are listed under
'Contact Information' on the back cover.
A - Boiler
B - Flue
C - Max. 2 bends at 135°
D - Anti down-draught terminal
E - Chimney
17
CONVENTIONAL FLUE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
L = 140 - 335mm
L
ROOM SEALED FLUE OPTIONS
L
L = 2000mm
A
The diagrams (opposite) show the components
used and the maximum flue length (L) for
each flue configuration.
A
C
2x
C
In all cases L is measured from the outside of
the boiler casing.
B
125mm Ø
• To achieve the maximum flue length (L), a flue
section will have to be reduced in length.
• Only the flue terminal or straight flue
extensions can be reduced in length by
cutting.
L = 4000mm
L
IMPORTANT:
All horizontal sections must rise away
from the boiler by 52mm per metre (3°) to
allow the condensate to drain back to the
boiler.
A
4x
L = 8000mm
B
125mm Ø
L
A
C
E
D
E
B
PRE INSTALLATION
• The flue terminal end can be fitted from the
inside or outside of the building.
8x
B
12/18 & 18/25
125mm Ø
25/32
150mm Ø**
A - Horizontal terminal
B - Straight flue extension
C - Flue bend 90°
D - Flue bend 45°
E - Vertical Terminal Kit (incl. 90° elbow)
L = 3000mm
Calculating the flue length:
L
A
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
Horizontal 80/125mm Ø: 4000mm (excluding
120mm of terminal extending outside the building)
C
3x
B
125mm Ø
Vertical 80/125mm Ø & 100/150mm Ø:
8000mm (measured from the boiler top panel).
L = 7000mm
Then reduce the total straight flue length for
each extra flue bend (excluding the vertical flue
kit 90° elbow) by:
L
E
D
1000mm for 90°
D
500mm for 45°
L = 3000mm
L
A
D
3x
7x
B
Flue Extension lengths:
12/18 & 18/25
125mm Ø
25/32
150mm Ø**
D
B
125mm Ø
Horizontal & Vertical 80/125mm Ø: 1000mm
overall length.
Effective length when engaged into sockets
within the flue run is 950mm.
Flue Terminal lengths:
Horizontal 80/125mm Ø: 720mm
Vertical 80/125mm Ø: 1080mm + cage
Vertical 100/150mm Ø: 1290mm + cage
* to outside wall.
L = 7000mm
L = 3000mm
C
3x
B
125mm Ø
L
E
A
L
7x
B
** The 80/125 to 100/150mmØ vertical
adaptor must be fitted vertically at the lowest
point of the vertical section of the flue.
Failure to fit the adaptor vertically will cause
the condensate to pool within the flue and
will adversely affect the flue’s performance.
12/18 & 18/25
125mm Ø
25/32
150mm Ø**
18
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ROOM SEALED FLUE
OPTIONS
IIMPORTANT: All the previous Pre-Installation sections must be read
and requirements met before starting boiler or flue installation.
UNPACKING THE BOILER
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
1
•
When lifting or putting things down, bend
the knees, and keep the back straight
and feet apart.
•
Do not lift and twist at the same time.
•
Lift and carry objects close to the body.
•
Wear protective clothing and gloves to
protect from any sharp edges.
Unpacking:
It is advised that at least two or more persons are
involved in the transfer of the packaged boiler from
the van to the point of delivery.
INSTALLATION
1 Once the packaged boiler has been
delivered, the outer carton is removed first.
Care should be taken when releasing the
straps. If a sharp implement is used make
sure the outer carton is not pierced and that
the implement is used in such a way so that it
may not cause personal injury. All sharp
objects must be covered or the blade
retracted after use and put away in a safe
place.
2 Lift carton up and away from the boiler.
Remove the plastic bag and upper front
protection cover from the boiler and place
safely aside.
Two or more persons are required
to move the boiler taking care not to damage
the boiler, panels or the floor.
At all times the correct method for handling
heavy objects should be strictly observed.
2
19
UNPACKING THE BOILER
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
All dimensions in mm
PIPEWORK POSITIONS &
FLUE OPENING
CAUTION: Ensure there are no pipes,
electric cables, damp proof courses or
other hazards before drilling.
RS -155
CF - 170
185
25
C
*F
A
C
*F
A
A
*G
755
PIPEWORK POSITIONS:
A - Flow (Kitchen models only) /open vent 1” BSP
12/18, 18/25.
11/4” BSP 25/32.
B - Primary drain/feed 3/4” BSP.
*G
D
D
550
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
E
C - Return 22mm Ø copper 12/18, 18/25.
28mm Ø copper on 25/32 model.
532
459
D - Condensate outlet 21.5mm Ø.
E - Flue outlet.
*Extra pipe outlets, (Kitchen System only):
F - Flow 22mm Ø copper 12/18, 18/25 and
28mm Ø copper for 25/32.
282
284
B
B
B
60
FRONT VIEW
SIDE VIEW
G - Pressure relief pipe 15mm Ø copper.
NOTE: For servicing purposes, keep
condensate and pressure relief discharge
pipes away from components and pipework
connections.
IMPORTANT: The flue and pipework
openings are covered with tabbed blanks.
F
G
H
INSTALLATION
E
Remove carefully as necessary.
FLUE OPENING:
Follow the diagram opposite to mark the
centre of the flue (1, & 2) for rear opening,
(2 & 3) for side opening or
(1 & 4) for top opening.
** IMPORTANT: for horizontal flues, increase
this height by 52mm for every 1000mm of
horizontal length that the flue opening is
away from the boiler.
NOTE: all horizontal flue sections must rise away
from the boiler by 52mm per metre to ensure that
condensate flows back into the boiler for safe
discharge via the condensate waste pipe.
4
RS 155
CF 170
G
Make an opening (F, G or H) through the wall
using a core drill or similar at a size relative to
the wall thickness as shown below:
125mm Ø flue:
3
F
1
155
190
H
2
Wall thickness
150 - 240mm
240 - 330mm
330 - 420mm
420 - 500mm
Flue hole size
Ø155mm
Ø160mm
Ø165mm
Ø170mm
150mm Ø flue:
Wall thickness
150 - 240mm
240 - 330mm
330 - 420mm
420 - 500mm
Flue hole size
Ø180mm
Ø185mm
Ø190mm
Ø195mm
+5
755**
20
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
PIPEWORK POSITIONS &
FLUE OPENING
KITCHEN SHOWN
2
1
A
(All models):
1 Lift the top panel (A) upwards to
disengage the ball stud connections (B)
and remove. Pull front panel (C) forward
from the bottom and near the top
disengaging the ball studs from their
connections ( D) and lift off the ledge (E)
that runs along the bottom of the fascia
to remove.
B
E
BOILER INSTALLATION
J
D
(Kitchen system only):
In the case of the Kitchen System boiler,
remove the retaining tie at the base of
the expansion vessel (F ).
Loosen the expansion vessel clamping
screw (G) and move the vessel to the
right to clear the top support.
Lift the expansion vessel (H) up and
move the base out and slide down to
remove.
Place the expansion vessel out side of
the boiler taking care not to kink or
stretch the flexible hose.
Remove the securing screws ( I ) from
each side and remove the expansion
vessel securing bracket.
L
C
INSTALLATION
L
(All models):
2 Depress locking ears to unplug burner
lead ( J ) from control box.
D
3 Unscrew to loosen the retaining ring
(K) that secures the flexible air supply
tube to the burner (L) and pull the
flexible air supply tube free from the
burner.
Undo the two screws securing the
deflector plate (M) and remove the
plate.
L
KITCHEN SYSTEM ONLY
Undo and remove the retaining nut (N)
on top of the burner. The burner
mounting (O) can now be eased
off the lug (P) on the burner collar to
remove the burner from the heat
exchanger. Store the burner and
retaining nut safely away from the boiler.
1
H
4 Carefully move the boiler into position
observing at all times the correct
method for handling heavy objects. In
the case of the Kitchen System take care
not to damage the expansion vessel.
G
F
I
P
3
K
N
O
M
21
BOILER INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
A
FLUE INSTALLATION
B
D
The flue can exit the boiler from outlets A, B, C
or D allowing vertical (RS) and horizontal (RS
low or high level) flues to be fitted. (CF position
'A' only).
Refer to the separate flue installation
instructions supplied with the flue kits available
for this boiler:
C
RS FLUE KITS & COMPONENTS
80/125mm Ø (not supplied):
600mm
(min)
E - Boiler outer casing
H
H - Outside wall/roof
K - CF adaptor
Inline adaptor 80/125 to 100/150mm Ø:
Part No. 7 716 190 063
CF FLUE KIT all models (not supplied):
For Greenstar Camray 12/18 and 18/25
models use
K
L
120mm
INSTALLATION
100/150mmØ (not supplied) for 25/32
vertical terminal:
Vertical flue kit: Part No. 7 716 190 059
Extension kit (1 metre) x1: Part No. 7 716 190 045
Inline elbow 90° x1: Part No. 7 716 190 046
Inline elbow 45° x2: Part No. 7 716 190 047
F - Outer flue tube
G - Outlet/elbow connection
Horizontal flue kit: Part No. 7 716 190 031
Vertical flue kit: Part No. 7 716 190 032
Extension kit (1 metre) x1: Part No. 7 716 190 033
Inline elbow 90° x1: Part No. 7 716 190 034
Inline elbow 45° x2: Part No. 7 716 190 035
Stainless steel horizontal terminal guard:
Part No. 7 716 190 050
CF Adaptor kit: Part No. 7 716 190 036.
E
For Greenstar Camray 25/32 models use
CF Adaptor kit: Part No. 7 716 190 036 and
CF Adaptor 100/130mm: Part No. 7 716 190 065.
INSTALLATION NOTES:
When connecting a flue elbow directly to
the boiler flue outlet, loosen the flue elbow
retaining bracket screws (N) before fitting
the flue elbow. Insert the flue elbow with its
clamp loosely fitted, then tighten the bracket
screws (N). Clamp the elbow when
adjusted to its required orientation.
If using an extension or horizontal terminal
onto the boiler flue outlet, remove the flue
elbow retaining bracket (M).
G
F
G
H
E
2m
1m
3°
52mm
Ensure all flue seals are in good condition
and seated properly.
104mm
To ease assembly of flue components,
grease seals lightly with the solvent-free
grease supplied.
The retaining bracket (M) must be fitted if a flue
elbow is used on the boiler flue outlet.
Bracket (M)
Screw (N)
Use flue clamps to support the flue system.
Bracket (M)
IMPORTANT: The boiler is not designed to
take the weight of the flue system, this
must be supported externally to the boiler.
Screw (N)
All horizontal flue sections must rise by at
least 52mm for each metre away from the
boiler to ensure that condensate flows back
into the boiler for safe discharge via the
condensate waste pipe.
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.
22
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
FLUE INSTALLATION
KITCHEN SHOWN
1
2
COMBUSTION CHAMBER
Combustion chamber:
1 Remove the control box securing screws
(A, bottom screw both sides) and loosen
the pivot screws (B, top screw both sides).
B
2 Pivot down control box.
A
4
3 Release retaining nuts and washers (C).
Remove combustion chamber access door (D).
K
4 Release screws (E) on either side and
remove upper access door (F).
7
5 Ensure baffles (G) and baffle retainers (H),
restrictor plates ( I ) and acoustic insulation
insert ( J ) are correctly fitted for the boiler
model as shown in the plan view opposite.
4
F
L
C
Ex2
Refit the upper access door (F ) and
secure with screws (E).
D
6 Secure combustion chamber access door
with nuts and washers (C). Tighten until
door is firmly secured using the sequence
below. Do not overtighten the nuts.
5
3
7 Unscrew screws (K) and remove flue
manifold access cover (L).
INSTALLATION
6
8 Check that all the baffles (M) and baffle
retainer (N) are correctly fitted to the
secondary heat exchanger.
8
N
M
5
12/18
18/25
Plan sectional view
Plan sectional view
J
J
G
G
I
I
H
25/32
Hook the
retainer (N)
over the
end two
baffles
H
IMPORTANT when refitting
the combustion chamber
access door (6)
Plan sectional view
J
G
H
23
COMBUSTION
CHAMBER
Combustion chamber
access door tightening
sequence.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
KITCHEN SYSTEM SHOWN
CAUTION: I SOLATE TH E OI L & WATE R
MAINS SUPPLY BEFORE STARTING ANY
W OR K AN D OB S E RVE ALL R E LE VANT
SAFETY PRECAUTIONS.
G
A -
A
Kitchen
model
only
H
A1
Flow Kitchen
System only
(behind
boiler)
A1 I
Pressure
relief outlet
(behind
boiler)
E
B -
J
D
Flow & optional open vent/air vent
1” BSP on 12/18, 18/25 and (11/4” BSP
on 25/32 models)
Flow Kitchen System models only
22mmØ copper (28mmØ copper for
25/32 models)
Primary drain & optional feed and
expansion/feed 3/4” BSP
C -
Return 22mm Ø copper (28mm Ø on
25/32 models)
D -
Fixing point for optional return oil pipe.
E -
Oil isolating valve (10mmØ)
F -
Flexible oil fuse
G -
Flue manifold condensate outlet
H -
Condensate outlet (21.5mmØ) - supplied
I -
Condensate pipe - not supplied
J
Condensate trap with wall clamp - supplied
-
WATER CONNECTIONS:
Remove the transit bungs from the pipework
connections on the boiler.
B
NOTE: Surplus water may be present due to
factory testing.
Ensure all pipework is clean.
Fit the return pipe (C) to the secondary heat
exchanger using the sealing washer supplied.
Align water pipework and connect.
Check that all unused sockets have been capped.
F
INSTALLATION
C (return pipe)
located at the side
of the secondary
heat exchanger
PIPEWORK CONNECTIONS
OIL SUPPLY CONNECTIONS:
1m
50mm (min.)
I
Return
pipe (C) Washer
500ml
L
M
K
Route the oil supply pipe along the left
side of the boiler and connect to the isolating
valve (E) and ensure the valve is closed.
Connect the flexible oil hose (F) to the isolating
valve (E).
CONDENSATE CONNECTION:
Fit the elbow (supplied) onto the
condensate pipe (H) (supplied).
Fit the sealing washer to the condensate
pipe (H) and connect it to the flue manifold
outlet (G).
Fit the condensate trap in a serviceable
position using the clamp supplied.
Connect 21.5mm polypropylene pipe ( I ) (not
supplied) to the condensate pipe (H) and
condensate trap (J) before terminating to
waste.
Ensure that the condensate pipe runs away
from the boiler at a constant fall of 50mm
(min.) for every metre.
Carefully pour 500ml of water into the
condensate collection (K) to fill condensate
trap.
Check the water is running away and the
condensate pipework joints are water tight.
Check the flue manifold seal is undamaged
and seated correctly.
Refit flue manifold access cover (M) and
secure with screws (L).
IMPORTANT: The condensate trap must be
correctly filled to prevent the possibility of
potentially harmful flue products escaping
via the condensate pipework.
24
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
PIPEWORK
CONNECTIONS
OIL BURNER & PUMP
CAUTION: ISOLATE THE OIL & WATER
MAINS SUPPLY BEFORE STARTING ANY
W OR K AN D OB S E RVE ALL R E LE VANT
SAFETY PRECAUTIONS.
OIL BURNER:
1 Check the nozzle (A) and electrode (B)
settings are correct as shown opposite.
Ensure nozzle (A) is aligned centrally within
the combustion head (C).
Inspect for any visible defects.
2 IMPORTANT: Before removing or fitting a
nozzle (A), loosen screw (D) and move
the electrodes (B) forward.
Electrode gap
After refitting check that the electrode
gaps are correct, as shown opposite.
1
3.5 - 4.0mm
B
A
5mm
NOTE: the 12/18 model has a brass deflection
washer and locating circlip behind the nozzel.
These must be in place for the correct
operation of the burner.
INSTALLATION
B
A
A
2.0 - 2.5mm
D
B
5mm
2
IMPORTANT: Whenever replacing the
combustion head, ensure that the
photocell is lined up with the sight hole.
C
OIL PUMP:
A
B
D (on 12/18 and 18/25 models only)
RIELLO RDB OIL PUMP
Connecting the oil pump for a single pipe
system:
The pump is factory set for single pipe
operation with the flexible oil pipe fitted.
Check connections before use.
Converting the oil pump for a double pipe
system:
1 Check the inlet pipe connection (1).
Unscrew return plug (2).
Screw in by-pass screw (3).
1
3
2 Connect the flexible oil pipe return hose
(not supplied) to the oil pump and return
pipe fixing (D on page 24) and tighten
to secure.
2
(on 12/18 model only)
Brass air deflector washer
Locating circlip
25
OIL BURNER & PUMP
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
KITCHEN SHOWN
REFITTING COMPONENTS
1 Align burner combustion head into boiler
collar.
Locate the burner retainer (A) over the
threaded lug on the collar (B), push the
burner firmly onto the flange and secure in
place with the retaining nut (C). Tighten
sufficiently but do not overtighten.
4
Check that the burner is seated correctly
on its mounting flange and that the oil
hose/s are not trapped in front of or
underneath the burner.
H
2 Refit the deflector plate (D) and secure
with screws (E). Ensure that the flexible oil
hose/s are not positioned between the
deflector plate and the combustion
chamber door.
3 Attach air duct and tighten clip (F) to
secure to the burner air intake.
G
4 Swing control box back up into operating
position and retain in place by replacing
the two securing screws (G) in the bottom
locations.
Plug burner lead (H) into control box.
INSTALLATION
D
2
E
C
A
1
3
F
B
1
E
26
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
REFITTING COMPONENTS
ELECTRICS
A
= EARTH
1
= LIVE
B
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
SUPPLY BEFORE STARTING ANY
WORK AND OBSERVE ALL
RELEVANT SAFETY PRECAUTIONS.
= NEUTRAL
IMPORTANT: OBSERVE ELECTRONIC
STATIC DISCHARGE PRECAUTIONS.
DO NOT TOUCH THE PCB CIRCUITS.
C
Access to 230V connections:
1Remove the four fascia retaining screws (A)
and position the fascia assembly (B) on the
two fascia location lugs (C) as shown.
2Release screws (D) from cable clamp (E).
Feed sufficient power cable (F) through the
cable clamp (E) and secure grip with screws (D).
Separate wires from cable end and strip to 6mm.
230V
1
2
F
E
C
D
B
INSTALLATION
F
3
230V
5
I
230V connections:
3Connect LIVE wire (Brown) to
terminal L.
Connect NEUTRAL wire (Blue) to
terminal N.
Connect EARTH wire (Green/Yellow) to
the terminal
.
Route the power cable down the side panel
using the clip provided on the support panel
to the external connection point avoiding any
potentially hot surfaces allowing sufficient
cable to pivot the control box into the service
position.
Any external device connected to the
boiler must take its power supply from
the boiler only and must NOT have a
separate supply.
N1 1 2 3
See the following pages of electrical
diagrams for details of different systems.
H
Extermal 230V programmer:
4 Remove link (G).
Connect wires as shown.
4
G
Optional Worcester 230V programmer:
5 Remove blanking plate (H).
Set the pin on the rear of the programmer
to ‘pumped’.
Remove link (G).
Clip programmer ( I ) into position and plug
into the terminal as shown.
Refit fascia panel:
Refit fascia panel (B) to control box
and secure with screws (A).
N1 1 2 3 4
*Move the orange wire from terminal 9 to
terminal 6 for a 3 port valve system.
G
7 8 9 10
27
ELECTRICS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
KITCHEN MODELS
ELECTRICS
230V STANDARD WIRING DIAGRAM:
= EARTH
Key to components:
= LIVE
A - EARTH STUD.
= NEUTRAL
B - HIGH LIMIT THERMOSTAT.
C - BOILER MANUAL RESET OVERHEAT
THERMOSTAT.
D - FLUE MANUAL RESET OVERHEAT
THERMOSTAT.
F - INTERNAL PROGRAMMER CONNECTOR.
G-TERMINAL CONNECTOR BLOCK.
H - LINK CONNECTOR.
G
I - CONTROL THERMOSTAT.
Green/Yellow
J - DEMAND NEON.
N1 1 2 3 4 5 6 6a
A
K - LOCKOUT NEON.
Brown
L - BURNER SOCKET.
Green/yellow
Grey
M-BURNER PLUG.
White
Green/Yellow
Blue
Blue
B
INSTALLATION
Brown
7 8 9 10
F
Green/Yellow
C
H
D
Orange
Brown
Brown
Green/yellow
Blue
Brown
Brown
PUMP
Brown
Brown
Green/Yellow
J
KITCHEN SYSTEM
Black
I
K
3
2
Blue
Grey
Red
L
12 34 5 6
12 34 5 6
M
Green/Yellow
Red
Black
Grey
Riello Burner
M
N L
28
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ELECTRICS
ELECTRICS
• = EARTH
• = LIVE
• = NEUTRAL
• = SWITCHED LIVE
O
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
PRE-WIRED REMOTE 2 OR 3 PORT VALVE
CONTROL SET USING INTERNAL
PROGRAMMER:
Key to components:
O - REMOTE JUNCTION BOX (10-way) to
connect the following:
HOT WATER OFF
Mains wiring 230V 50Hz.
HEATING ON
Hot water tank thermostat.
Room thermostat.
HOT WATER ON
System water valves.
Circulating pump.
P - 230V WORCESTER PROGRAMMER
(fitted into fascia panel).
F - INTERNAL PROGRAMMER CONNECTOR.
G- TERMINAL CONNECTOR BLOCK.
H - LINK CONNECTOR.
INSTALLATION
Remote (10 way) junction box (O)
requirements:
The junction box (O) must be a terminal block
type, current rated to at least 5 amps.
A 5 amp fuse must be fitted to the mains
supply.
The junction box (O) must be fitted externally
to the boiler.
Link 1 to 3 must be removed from the boiler
terminal connector block (G).
OUTSIDE BOILER
INSIDE BOILER
A frost thermostat can also be connected to the
remote junction box if required.
G
N1 1 2 3 4 5 6 6a
7 8 9 10
F
H
2 PORT
Internal Programmer (P) requirements:
2 and 3 port valve control sets:
Set the pin on the rear of the programmer to
‘pumped’.
Remove the link plug (H).
Connect the plug from programmer (P) into
connector (F).
Connect terminal 1 from the boiler terminal
block (G) to the ‘HOT WATER ON’ at the
remote junction box (O).
Connect terminal 2 from the boiler terminal
block (G) to the ‘HEATING ON’ at the
remote junction box (O).
3 port valve control sets:
A 3 port valve control set also requires a live feed
from ‘HOT WATER OFF’ switch position.
Brown
3 PORT
Orange
P
Remove the orange wire from terminal 9 and
pull back through the tie wraps. (Ensure that
the brown wire is firmly secured in terminal 9).
Connect the orange wire to terminal 6 on the
boiler terminal block (G).
Connect terminal 6 on the boiler terminal
block (G) to the ‘HOT WATER OFF’ at the
remote junction box (O).
12 34 5 6
29
ELECTRICS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ELECTRICS
• = EARTH
• = NEUTRAL
• = SWITCHED LIVE
O
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
PRE-WIRED REMOTE 2 OR 3 PORT VALVE
CONTROL SET USING REMOTE
PROGRAMMER:
Key to components:
O - REMOTE JUNCTION BOX (10-way) to
connect the following:
Mains wiring 230V 50Hz.
Hot water tank thermostat.
Room thermostat.
System water valves.
Circulating pump.
External programmer.
Remote (10 way) junction box (O)
requirements:
The junction box (O) must be a terminal block
type, current rated to at least 5 amps.
A 5 amp fuse must be fitted to the mains
supply.
The junction box (O) must be fitted externally
to the boiler.
INSTALLATION
F - INTERNAL PROGRAMMER CONNECTOR.
G- TERMINAL CONNECTOR BLOCK.
H - LINK CONNECTOR.
OUTSIDE BOILER
A frost thermostat can also be connected to the
remote junction box if required.
INSIDE BOILER
G
N1 1 2 3 4 5 6 6a
L
N
PUMP
7 8 9 10
F
H
KITCHEN SYSTEM
12 34 5 6
30
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ELECTRICS
ELECTRICS
= EARTH
•
•
Q
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
2 PORT VALVE CONTROL SET:
= LIVE
= NEUTRAL
Key to components:
Brown
Q - CH ZONE VALVE.
Blue
R - ROOM THERMOSTAT.
S - CIRCULATING PUMP (KITCHEN ONLY).
F - INTERNAL PROGRAMMER CONNECTOR.
Orange
Yellow/Green
Blue
Grey
R
G-TERMINAL CONNECTOR BLOCK.
H - LINK CONNECTOR.
Blue
T - HOT WATER CYLINDER THERMOSTAT.
S
T
U - HOT WATER VALVE.
2
Brown
Orange
1
P - OPTIONAL 230V WORCESTER
PROGRAMMER (fitted into fascia panel).
Brown
C
U
Terminator connector block (G):
Remove link 1 to 3.
Remove link 2 to 4.
Make link 3 to 4.
Orange
INSTALLATION
Yellow/Green
Optional 230V Worcester programmer (P):
Set the pin on the rear of the programmer to
‘pumped’.
Remove the link plug (H).
Connect the plug from programmer (P) into
connector (F).
Blue
Grey
G
N1 1 2 3 4 5 6 6a
L
N
PUMP
7 8 9 10
F
KITCHEN SYSTEM
H
P
12 34 5 6
31
ELECTRICS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ELECTRICS
= EARTH
= LIVE
DANGER - 230V:
ISOLATE THE MAINS ELECTRICITY
3 PORT VALVE CONTROL SET:
= NEUTRAL
Key to components:
R
R - ROOM THERMOSTAT.
S - CIRCULATING PUMP (KITCHEN ONLY).
Blue
F - INTERNAL PROGRAMMER CONNECTOR.
G-TERMINAL CONNECTOR BLOCK.
Blue
H - LINK CONNECTOR.
S
T - HOT WATER CYLINDER THERMOSTAT.
V - MID-POSITION VALVE.
T
P - OPTIONAL 230V WORCESTER
PROGRAMMER (fitted into fascia panel).
2
C
1
Brown
V
Grey
Optional 230V Worcester programmer (P):
Set the pin on the rear of the programmer to
‘pumped’.
Remove the link plug (H).
Connect the plug from programmer (P) into
connector (F).
Move the orange wire from terminal 9 to
terminal 6.
Orange
White
Blue
Yellow/Green
INSTALLATION
Terminator connector block (G):
Remove link 1 to 3.
Remove link 2 to 4.
Make link 3 to 5.
G
N1 1 2 3 4 5 6 6a
L
N
PUMP
7 8 9 10
F
KITCHEN SYSTEM
Brown
H
Orange
P
12 34 5 6
32
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
ELECTRICS
KITCHEN SYSTEM SHOWN
PRE-COMMISSIONING CHECKS APPLIANCE
CAUTION: ISOLATE THE MAINS SUPPLIES
BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
1Check that the service and water pipes are
connected correctly.
3
1
Check that all unused sockets are capped.
2 Check that the oil supply is 28 sec
kerosene and that the pipework is
connected correctly to the oil pump via the
supplied flexible oil hose.
Check that the burner is seated correctly
on its mounting flange and that the oil
hose/s are not trapped in front of or
underneath the burner.
Turn on the main oil supply valve at the
tank, check the oil supply pipework and
connections. Rectify any leaks.
3 Check the flue is correctly fitted and the
connections are secure.
4
4 Check the condensate pipework is
correctly fitted and connected.
Check the condensate trap is filled with
water.
COMMISSIONING
IMPORTANT: If the boiler is not to be
commissioned immediately then:
After successfully completing all of the
checks and any rectification work, close
the water valves, shut off the oil supply
and electrically isolate the boiler.
Complete the installation part of the
Guarantee Registration Card, and
complete a CD10 or equivalent to
inform the LABC of the installation.
2
KITCHEN SYSTEM ONLY:
Refit the expansion vessel support
bracket and the expansion vessel.
Secure in place by retightening the
expansion vessel clamping screw.
Refit the top panels.
33
FILLING THE SYSTEM
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
FILLING THE SYSTEM
1
1 Open all system and radiator valves.
Turn on the water main stop cock.
Open vented systems only:
Turn on the water to the system feed and
expansion cistern and allow the system to
fill.
2 Sealed systems only:
Check and if required, adjust the expansion
vessel pressure using the Schraeder type
valve (C).
2
Fill the system to between 1 and 2 bar
pressure via a WRAS approved filling link.
1 - 2 bar
Monitor the pressure gauge during venting
and repressurise if required.
C
3 Vent all radiators, retighten when completed.
Check the system and correct any leaks.
A
A
B
Bleed air from the primary heat
exchanger air vent (B).
COMMISSIONING
3
Bleed air from at least one of the secondary
heat exchanger air vents (a radiator key is
ideal for this). There are two venting
bosses (A) on the top of the secondary
heat exchanger. Only one is used if fluing
to the side. The (A) in use and (B) must be
bled.
34
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
PRE-COMMISSIONING
CHECKS - APPLIANCE
STARTING THE APPLIANCE
IMPORTANT: Never run the appliance when
the appliance/system is unpressurised
(sealed systems) or empty.
1
1Check the oil supply is correctly fitted and
in good working order before turning on
the oil supply valves to the boiler.
Turn on the main oil supply valve at the tank
and draw off oil until a steady flow of clear
uncontaminated oil can be seen as follows:
• The oil supply to the boiler should be
primed before the burner is operated to
avoid unnecessary pump wear.
RIELLO
RDB OIL PUMP
• The use of an oil suction pump will prime
and flush through any oil supply set up
simply and easily. Alternatively the
following procedures can be used:
C
D
B
Single pipe gravity feed systems:
A
Disconnect the flexible oil pipe and open
the isolating valve to discharge the oil into a
suitable container.
If a top entry tank has been used the
pipework will need to be primed before the
oil will discharge under gravity.
When completed, close the isolating valve,
reconnect the flexible oil pipe.
A - Bleed & pressure gauge port
B - Pressure adjustment
C - Vacuum gauge port
D - Retaining screws - cover
Double pipe sub-gravity feed systems
and single pipe suction lift with de-aerator:
Prime the oil supply pipework to prevent oil
pump damage .
COMMISSIONING
Return
Flow
E
TANK
F
G
BURNER LOCKOUT
I
H
BURNER LOCKOUT RESET BUTTON ( I )
BEHIND BOILER FRONT PANEL, ON BURNER
To prime a de-aerator, disconnect the
flexible oil inlet hose (F) from the isolation valve
and place in a container of kerosene (G).
Connect a spare flexible oil hose (E), to
discharge into container (G). Open the
isolating valve, turn on the power to the boiler
and set the programmer to ON. Prime the
de-aerator until there is a steady flow of oil into
container (G). Turn off the boiler then
reconnect the flexible oil inlet hose (F).
Turn on the boiler, the oil level in the de-aerator
will drop as the oil is used until the oil is drawn
from the tank. If the de-aerator empties and the
burner locks out before the oil is drawn from
the tank prime the de-aerator again.
Open the isolating valve and the oil pump
bleed valve (A) to discharge into a suitable
container once the boiler is started up.
Switch on the electricity supply to the boiler.
Set the programmer to ON.
Turn on the boiler control thermostat.
Allow the burner to run through to 'lock-out'
indicated by the illumination of the lockout
indicator (H), (note: some systems will not
lock out).
If lockout occurs wait 2 minutes then press
the lockout reset button ( I ).
Repeat the procedure at least 3 times or
until a steady stream of oil, without air, runs
from the bleed port, then relock the bleed port.
Switch off the boiler.
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.
35
STARTING THE
APPLIANCE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
STARTING THE APPLIANCE
2
D
E
SC
SC
F
Boiler lockout indicator on:
Adjust position of air damper discs to suit
burner output (see chart below), located as
above. Access by removing the two star
screws (SC) to release the air inlet manifold.
18/25
4
3
Wait 2 minutes then press the lockout
reset button (D) to initiate another start
sequence.
Repeat procedure until a flame is established.
K
3Start and run for 3 minutes then switch off.
Check for after-spurting from the nozzle,
indicated by oil saturation on the combustion
head (G).
G
If after-spurting occurs:
Release the burner retainer (F).
Remove the burner, combustion head (G).
and electrodes, hold the burner vertical
to unscrew the nozzle and fill the nozzle
holder with kerosene.
Refit nozzle, electrodes, combustion
head (G) and the burner.
Restart and run for 3 minute intervals until
after-spurting stops.
4Start and run for 20 minutes.
Remove sampling point plug (K) to check
the smoke reading is between 0-1. If the
smoke level is above 1, check the combustion
settings are correct and the oil nozzle is in
good condition.
RIELLO
RDB OIL PUMP
5
C
B
A
A - Bleed & pressure gauge port
D
B - Pressure adjustment
C - Vacuum gauge port
L
Note: smoke readings may be inaccurate until
the smoke from burning organic binder in the
access door insulation has ceased.
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
USING 28sec KEROSENE:
FUEL
OIL PUMP
NOZZLE
PRESSURE FLOW RATE
(p.s.i.)
Kg/h
l/h
APPROX.
FLUE GAS
%CO2
TEMP °C
If the burner fails to establish a normal firing
pattern or flame failure occurs the flame
monitoring photocell mounted in the burner
body will alert the burner control box to shut
the burner down and provide a safe lockout
state indicated by the illumination of the lockout indicator (E).
APPROX.
INPUT
OUTPUT
AIR
(APPLIANCE)
(APPLIANCE)
SETTING
kW
kW
AIR
DAMPER
DISC
SETTING
BURNER
HEAD
Boiler 12/18 RDB 1
0.40 60°ES
100
1.04 1.32
64
11.5
3.0
0.45 60°ES
120
1.28 1.63
73
11.5
0.55 8 0°EH
105
1.54 1.96
76
11.5
LD 2X SH 12/18
12.3
12.0
3.5
15.4
15.0
15-18 LD 2X SH 12/18
5.5
18.5
18.0
15-18 LD 2X SH 12/18
12
Boiler 18/25 RDB 2.2
18
COMMISSIONING
12/18
2 Remove plastic cover from the burner casing.
Fit a suitable pressure gauge to port (A) on
the oil pump.
Adjust the air shutter (L) and pump pressure
(B) as shown in the table opposite. The
burner should ignite following a pre-ignition
period of approx. 15 seconds.
If changing the burner output, check the
position of the air damper disc is correct to
the output as shown in the table below.
NOTE: For 25/32 appliance see following
page.
0.55 8 0°EH
115
1.58 1.96
75
11.5
4.5
18.5
18.0
0.60 60°ES
115
1.84 2.33
77
12.0
2.5
22.1
21.5 21.5-25 T2 SH 18/25
0.75 80°ES
110
2.15 2.72
82
12.5
3.75
25.7
25.0 21.5-25 T2 SH 18/25
T2 SH 18/25
Boiler 25/32 RDB 2.2
*0.65 80°EH
140
2.15 2.72
80
11.0
4.5
25.7
25.0
N/A
T2 L/H 25/32
0.75 80°EH
125
2.37 3.0
81
12.0
4.0
28.3
27.5
N/A
T2 L/H 25/32
0.85 80°EH
125
2.58 3.27
83
12.5
4.5
30.8
30.0
N/A
T2 L/H 25/32
*25/32 model for 25kW see following page.
Check the CO2 levels and adjust the air
shutter (L) setting according to the table
opposite.
Check the flue gas temperature is close to
the values shown in the table.
If the flue gas temperature is too high and the
baffles are correctly fitted, then reduce the oil
pump pressure (B) 5-10p.s.i. to compensate
for nozzle variations.
Turn off the electrical supply.
Isolate the oil supply to the burner.
Remove the oil pressure gauge.
Refit the blanking plug (A).
Check and rectify any oil leaks.
5Switch on the oil supply.
Switch on the electrical supply.
Restart the boiler and run for 5 minutes.
Recheck the CO2 levels and if required,
adjust the air shutter setting (L) to obtain
the correct CO2 level.
Refit the sample point cap (hand tighten
only, do not over tighten) and refit the burner
cover.
36
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
STARTING THE
APPLIANCE
STARTING THE APPLIANCE
On 25/32 Appliances:
To achieve the mimimum output of 25kW from the
25/32 RDB 2.2 it is necessary to remove the air
guide (D) from the burner. For any other required
output the air guide must remain in place.
A
Disassemble the burner, removing the red
plasic cover, flexible air hose and air intake
manifold (A).
Remove the fan housing (B) by undoing the
four securing screws.
Remove the two screws (C) securing the
plastic air guide.
Remove air guide (D) and reassemble the
burner in reverse order.
B
C
COMMISSIONING
D
37
STARTING THE
APPLIANCE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
STARTING THE APPLIANCE
A
1
B
A
The demand indicator (A) should illuminate and
the burner should be ON with the circulating
pump.
Ensure all radiators are heating up evenly
and balance the system to the temperature
difference required for the heating flow and
return according to the heating load.
2Set the room thermostat to minimum.
The demand indicator light (A), burner and
circulating pump should be off.
3Check that any other controls that are fitted
to the system are operating properly.
COMMISSIONING
2
Central heating:
1Open all radiator valves.
Set room thermostat to maximum.
Set programmer to ON for CH, OFF for
DHW (if applicable).
Turn the thermostat control (B) to max.
38
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
STARTING THE
APPLIANCE
WATER TREATMENT
1
IMPORTANT: Debris from the system can
damage the boiler and reduce efficiency.
Failure to comply with the guidelines for the
use of water treatment with the appliance
will invalidate the appliance warranty.
B
FLUSHING (Central Heating):
1Switch off the boiler.
Open vented systems only: turn off the
water to the system header tank.
Open all radiator valves/drain cocks (B) and
drain the system while the appliance is hot.
Close drain cocks (B).
B
2
A
A
C
B
3Drain (B) and thoroughly flush the system to
remove the flushing agent and debris.
3
INHIBITOR (Central Heating):
4Check drain cocks (B) and manual air vents
are closed and all radiator valves are open.
5Add a suitable inhibitor (I), (or combined
inhibitor/anti-freeze if the system is exposed
to freezing conditions) to the heating system
in accordance with the manufacturers
instructions.
B
COMMISSIONING
2Add a suitable flushing agent (F) and refill
the system at the correct strength for the
system condition in accordance with the
manufacturer's instructions.
Vent the boiler using a radiator key or
suitable screwdriver (there are two vent
points (A) at the top of the secondary heat
exchanger. Only one may be in use, the
other may be obscured by side fluing.
Always vent (A) and the vent point on the
primary heat exchanger (C) and all radiators.
Run the boiler/system at normal operating
temperature for the time stated by the
flushing agent manufacturer.
The inhibitor or combined inhibitor/anti-freeze
must not cause damage to the materials within
the boiler (mild steel, stainless steel, copper
and brass) and any other materials/components
within the system.
B
4
Open vented systems only: turn on the
water to the system header tank and allow
the system to fill.
Sealed systems only: fill the system to
between 1 and 2 bar via a WRAS approved
filling loop.
B
6Vent the boiler, (there are two vent points
(A) at the top of the secondary heat
exchanger. Only one may be in use, the
other may be obscured by side fluing.
Always vent (A) and the vent point on the
primary heat exchanger (C) and all
radiators; retighten vents when complete.
5
1 - 2 bar
6
A
A
C
7Record the date when the inhibitor was
added to the system on the guarantee card.
NOTE: The concentration level of inhibitor in
the system should be checked every 12
months or sooner if system content is lost.
The addition of sealing agents to the system
water is not permitted as this can cause
problems with deposits left in the heat
exchanger and invalidate the appliance and
heat exchanger warranty .
31
39
WATER TREATMENT
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
3
KITCHEN SHOWN
FINISHING COMMISSIONING APPLIANCE
1
I
1Pivot the control box (A) up and into the
boiler.
Secure with screws (B).
J
(Kitchen System only):
In the case of the Kitchen System boiler,
Replace the expansion vessel securing
bracket and and secure in place with the
two screws (C ).
Carefully replace the expansion vessel (D)
by sliding up and in then down so that it
comes to rest on the bracket, push the top
of the vessel to the left to locate it in the
top support bracket and tighten the
securing screw (E). Take care not to kink
or trap the flexible hose.
G
B
A
F
2
2Locate the top edge of panel (F ) onto the
supporting ledge ( G ) and secure near the
top and at the bottom by gently pushing
home the ball studs into the retaining slots
(H ). Remember always to apply pressure
at the edges of the panels to avoid
damage.
H
3Locate the top panel ( I ) onto the ball stud
connections ( J ) and press down to
secure.
Always apply pressure at the edges of the
boiler panels when securing to avoid
accidental damage.
COMMISSIONING
H
KITCHEN SYSTEM ONLY
D
Handover:
Complete the Guarantee Registration Card,
Combustion Record (page 50) and CD11 or
an equivalent commissioning form.
E
Set up the controls and show the user how
to operate all the controls shown in the User
Guide and all system controls.
C
Where applicable, instruct the customer how
to repressurise the system.
K
If the appliance is unused and exposed to
freezing conditions, shut off all the mains
supplies and drain the system and boiler.
NOTE: Release drain point (K) to drain the
secondary heat exchanger.
40
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
FINISHING
COMMISSIONING - APPLIANCE
3
KITCHEN SHOWN
INSPECTION AND SERVICE
E
CAUTION: ISOLATE THE WATER,
ELECTRICITY AND OIL MAINS SUPPLIES
BEFORE STARTING ANY WORK AND
OBSERVE ALL RELEVANT SAFETY
PRECAUTIONS.
F
C
Routine servicing:
To maintain efficient boiler operation, the following
should be carried out at least once a year:
D
Carry out a pre-service check and note any
operational faults:
2
Pre-Service Check:
1 Pull front panel (A) forward from the bottom
and near the top disengaging the ball studs
from their connections ( B) and lift off the
ledge (C) that runs along the bottom of the
fascia to remove and store safely away
from the working area.
B
2Remove securing screws (D) from each
side of control box (E).
Pivot control box (E) downwards into the
service position as shown.
1
K
Operate the appliance and system and note
any faults which may need to be corrected
during the service.
Switch off and electrically isolate the
boiler.
3Depress locking ears and unplug burner
lead (F) from control box (E).
B
4 Kitchen System only:
In the case of the Kitchen System boiler,
loosen the expansion vessel clamping
screw (G) and move the vessel to the right
to clear the top support. Lift the vessel (H)
and move the base down and out to remove.
Stand the expansion vessel (H) on the floor
next to the appliance.
Remove the two screws ( I ) securing the
expansion vessel retaining bracket and
remove it from the appliance.
A
4 KITCHEN SYSTEM ONLY
5Loosen clip ( J ) to detach air duct pipe.
H
SERVICING
& SPARES
Undo the two scews securing the deflector
plate (K) and remove the plate.
Unscrew burner retainer nut (L) and gently
pull burner forward so that the retainer (M)
is free of the lug (N).
G
Service requirements:
See the following instructions for detail of some
of the service requirements listed below:
I
5
N
L
J
K
M
Check and clean the burner.
Replace the burner nozzle and flexible oil
pipe/s.
Check and clean the baffle retainers.
Check and clean the baffles.
Check and clean the heat exchangers
surfaces.
Check the combustion chamber access
door insulation board.
Check that the flue system is unobstructed
and clean as necessary.
Clean or replace all oil filters.
Check that the condensate system is not
obstructed, clean and refill the condensate
trap as necessary.
Sealed systems only. Important:
The PRV is a safety device and must be
checked for correct operation.
The expansion vessel pressure must also be
checked and adjusted if required.
41
INSPECTION AND
SERVICE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
INSPECTION AND SERVICE
1 Clean the Burner:
Remove the air intake cover (A) and clear
any debris from the air intake and air damper.
Disassemble the burner to allow access to
the fan impeller.
Check the condition of the gaskets between
these parts and replace if necessary.
Note the position of the air damper
adjustment and check the air damper moves
freely.
Clean both sides of the fan impeller and
remove any debris from the burner housing.
Check that the impeller rotates freely.
Reassemble the components.
Remove the combustion head (B) and
thoroughly clean any deposits.
A
B
IMPORTANT: Before removing or fitting a
nozzle (C), loosen screw (D) and move
the electrodes (E) forward.
D (on 12/18 and 18/25 models only)
F
After refitting check that the electrode
gaps are correct, as shown opposite.
Remove the nozzle (C).
Check the nozzle holder is clear of any debris
and clean if neccessary.
Fit a new oil atomising nozzle (C).
DO NOT dismantle the nozzle and DO NOT
clean the nozzle tip.
Check the electrodes (E) and reset if
necessary as shown opposite.
E
C
5mm
C
(D on 25/32 model only)
Electrode gap
3.5 - 4.0mm
E
E
5mm
RIELLO
B
E
C
RDB OIL PUMP
G
H
C
2.0 - 2.5mm
(on 12/18 model only)
Brass air deflection washer
Refit the combustion head (B). Check that
the nozzle (C) is central in the combustion
head (B) and the head settings are as
shown. Ensure that the photocell is lined up
with the sight hole.
Withdraw the photocell (F) from its housing
and wipe clean.
Remove the oil pump internal filter, clean in
kerosene and reassemble.
The internal filter is accessed by removing
screws (G) and the oil pump cover (H).
SERVICING
& SPARES
NOTE: The 12/18 model has a brass air
deflection washer and locating circlip behind
the nozzle. These must be in place for the
correct operation of the burner.
Replace the standard flexible oil line/s at
every annual service to prevent the
possibility of leakage due to ageing.
Reassemble the burner components.
Check the O-ring seal located around the
combustion head and replace if necessary.
This seal must be in good condition, seal
failure will cause flue gases to escape into
the room.
Locating circlip
G - Retaining screws - cover
H - Cover - oil pump
42
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
INSPECTION AND
SERVICE
KITCHEN SYSTEM SHOWN
INSPECTION AND SERVICE
External oil filter:
Remove the paper element from the external
oil filter and replace it. If the filter contains a
washable element, thoroughly clean in
kerosene and reassemble into the filter.
Q
Clean the boiler:
K
(on either
side)
Manifold access:
Release screws (A) to remove the flue
manifold access cover (B) and remove any
debris.
Check the condensate route (C) is clear and
clean the condensate trap and pipework.
Check the flue system and clean if necessary.
Remove the baffle retainer (D) and baffles (E)
from the secondary heat exchanger.
Check and clean the secondary heat
exchanger surfaces.
NOTE: Do not use wire brushes and
cleaning agents to clean the stainless steel
secondary heat exchanger components.
Pour 500ml of water into drain (F) to refill the
condensate trap.
Clean the secondary heat exchanger baffles
(E) if necessary and refit correctly.
Refit the baffle retainer (D).
Check the seal on the manifold access cover
(A) and replace if necessary.
Refit the flue manifold access cover (A) and
secure with screws (B).
L
I
J
B
A
D
E
C
12/18
18/25
P
P
SERVICING
& SPARES
500ml
Plan sectional view
Plan sectional view
N
L
N
O
O
M
M
25/32
IMPORTANT when refitting
the combustion chamber
access door (6)
Plan sectional view
N
F
Combustion chamber:
Release the M10 retaining nuts and washers ( I )
and remove combustion chamber access door ( J ).
Check the fibreglass rope seal on the
combustion chamber access door ( J ) and
replace if necessary.
Remove the 2 screws (K) and baffle access
panel (L) located at the top of the primary heat
exchanger and remove the baffle retainers (M).
Remove the baffles (N) and restrictor plate/s
(O, not on 25/32 model), clean and check
the condition of the baffles and the restrictor
plate/s. Replace any parts considered to be
badly corroded/degraded.
Remove the acoustic insulation insert (P).
Thoroughly clean all of the heat exchanger
surfaces using a suitable brush and clear all
loose debris from the combustion chamber
and upper chamber.
Check the condition of the combustion
chamber access door insulation. If the
insulation is damaged the door assembly
must be replaced.
Check the condition of the baffle access
panel seal.
Refit the acoustic insulation insert (P).
Refit the items in reverse order ensure the
baffles (N), baffle retainers (M) and restrictor
plate/s (O, not on 25/32 model) are correctly
fitted for the boiler output as shown in the
plan view opposite.
Refit baffle access panel (L).
Refit combustion chamber access door (J).
Secure with nuts and washers ( I ) and
tighten until the door is firmly secured using
the sequence shown opposite. Do not over
tighten the nuts.
Fire valve:
M
Combustion chamber
access door tightening
sequence.
Check that the oil supply pipe has a fire valve
fitted externally to the building with the fire
valve sensor located within the
appliance case. A fire valve sensor clip (Q) is
provided for this purpose.
43
INSPECTION AND
SERVICE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
BAFFLE ARRANGEMENT 12/18
12/18 MODEL SHOWN
BAFFLE ACCESS DOOR
ACOUSTIC INSULATION INSERT
Remove last. Refit first.
RESTRICTOR PLATE
2 for 12/18 models, fitted into tubes 2 & 3.
Remove and fit through baffle access door.
1
BAFFLE RETAINER
Remove and fit through baffle access door.
2
3
4
BAFFLE
COMBUSTION CHAMBER ACCESS DOOR
SERVICING
& SPARES
2 for 12/18 models, fitted in tubes 1 & 4.
Lift baffle to remove the baffle retainer then
pull down to remove the baffle through the
combustion chamber.
44
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
INSPECTION AND
SERVICE
BAFFLE ARRANGEMENT 18/25
18/25 MODEL SHOWN
BAFFLE ACCESS DOOR
ACOUSTIC INSULATION INSERT
Remove last. Refit first.
RESTRICTOR PLATE
1 for 18/25 models, fitted into tube 2.
Remove and fit through baffle access door.
1
BAFFLE RETAINER
Remove and fit through baffle access door.
2
3
4
BAFFLE
SERVICING
& SPARES
3 for 18/25 models, fitted in tubes 1,3 & 4.
Lift baffle to remove the baffle retainer then
pull down to remove the baffle through the
combustion chamber.
COMBUSTION CHAMBER ACCESS DOOR
45
INSPECTION AND
SERVICE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
BAFFLE ARRANGEMENT 25/32
25/32 MODEL SHOWN
BAFFLE ACCESS DOOR
ACOUSTIC INSULATION INSERT
Remove last. Refit first.
1
2
BAFFLE RETAINER
Remove and fit through baffle access door.
3
4
5
6
BAFFLE
COMBUSTION CHAMBER ACCESS DOOR
SERVICING
& SPARES
6 for 25/32 models, fitted in all 6 tubes
Lift baffle to remove the baffle retainer then
pull down to remove the baffle through the
combustion chamber.
46
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
INSPECTION AND
SERVICE
KITCHEN SHOWN
INSPECTION AND SERVICE
2
Re-commission the burner:
1 Align burner combustion head into boiler
collar.
Locate the burner retainer (A) over the
threaded lug on the collar (B). Push the
burner firmly onto the flange and secure in
place with the retaining nut (C). Tighten
sufficiently but refrain from overtightening.
K
H
G
Check that the burner is seated correctly
on its mounting flange and that the oil
pipe/s are not trapped in front of or
underneath the burner.
L
3
J
Refit the deflector plate (D) and secure
with screws (E). Ensure that the flexible oil
pipe/s are not positioned between the
deflector plate and the combustion
chamber door.
Attach air duct pipe and tighten clip (F) to
secure to the burner air intake.
L
2 Swing control box back up into operating
position and retain in place by replacing
the two securing screws (G) in the bottom
locations.
Plug burner lead (H) into control box.
1
C
A
B
F
E
D
Connect an oil pressure gauge to the oil
pump, run the burner and check the oil
pressure is correct for the required boiler
output. Check that the smoke reading is
between 0 - 1. If above 1 check the air
setting. If the air setting is correct check
that the burner has been reassembled
correctly.
Allow the boiler to warm up then check the
combustion settings are correct as
indicated in the table below, adjust the
CO2 if necessary using the air shutter.
When the combustion is correct turn off the
boiler, remove the pressure gauge and refit
the blanking plug and plastic cover.
KITCHEN SYSTEM ONLY
SERVICING
& SPARES
H
G
I
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
USING 28sec KEROSENE:
FUEL
OIL PUMP
NOZZLE
PRESSURE FLOW RATE
(p.s.i.)
Kg/h
l/h
APPROX.
FLUE GAS
%CO2
TEMP °C
APPROX.
INPUT
OUTPUT
AIR
(APPLIANCE)
(APPLIANCE)
SETTING
kW
kW
(Kitchen System only):
In the case of the Kitchen System boiler,
Replace the expansion vessel securing
bracket and and secure in place with the
two screws (G ). Carefully replace the
expansion vessel (H) by sliding up and in
then down so that it comes to rest on the
bracket, push the top of the vessel to the
left to locate it in the top support bracket
and tighten the securing screw ( I ). Take
care not to kink or trap the flexible hose.
AIR
DAMPER
DISC
SETTING
BURNER
12
LD 2X SH 12/18
HEAD
Boiler 12/18 RDB 1
0.40 60°ES
100
1.04 1.32
64
11.5
3.0
12.3
12.0
0.45 60°ES
120
1.28 1.63
73
11.5
3.5
15.4
15.0
15-18 LD 2X SH 12/18
0.55 8 0°EH
105
1.54 1.96
76
11.5
5.5
18.5
18.0
15-18 LD 2X SH 12/18
Boiler 18/25 RDB 2.2
0.55 8 0°EH
115
1.58 1.96
75
11.5
4.5
18.5
18.0
0.60 60°ES
115
1.84 2.33
77
12.0
2.5
22.1
21.5 21.5-25 T2 SH 18/25
18
0.75 80°ES
110
2.15 2.72
82
12.5
3.75
25.7
25.0 21.5-25 T2 SH 18/25
T2 SH 18/25
Boiler 25/32 RDB 2.2
*0.65 80°EH
140
2.15 2.72
80
11.0
4.5
25.7
25.0
N/A
T2 L/H 25/32
0.75 80°EH
125
2.37 3.0
81
12.0
4.0
28.3
27.5
N/A
T2 L/H 25/32
0.85 80°EH
125
2.58 3.27
83
12.5
4.5
30.8
30.0
N/A
T2 L/H 25/32
3 Locate the top edge of panel ( J ) onto the
supporting ledge ( K ) and secure near the
top and at the bottom by gently pushing
home the ball studs into the retaining slots
( L ). Remember always to apply pressure at
the edges of the panels to avoid damage.
After service handover:
Make a note of the date of any water treatment.
Set the controls back to the users
requirements.
Complete the service interval record at the
back of this manual and a CD11 or an
equivalent form.
If the appliance is unused and exposed to
freezing conditions; shut off all the mains
supplies, isolate the boiler and drain the
system and boiler, including the secondary
heat exchanger.
* 25/32 model for 25kW remove the plastic
air guide (see page 36).
47
INSPECTION AND
SERVICE
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SHORT PARTS LIST 12/18
1 Burner - Riello RDB 1 12/18 HE
5
7
6
9
8
23
11
14
17
16
Part Number: 8 716 109 328 0
10 Control thermostat
Part Number: 7 716 107 621 0
11 Auto reset overheat thermostat
Part Number: 8 716 107 623 0
12 Manual reset overheat thermostat
Part Number: 8 716 107 625 0
13 Manual reset flue thermostat
Part Number: 8 716 107 624 0
14 Air damper disc 12 15-18
Part Number: 8 716 112 778 0
15
18
24
Part Number: 8 716 109 211 0
6 Motor
Part Number: 8 716 109 186 0
7 Oil pump - Riello RDB
Part Number: 8 716 109 182 0
7a Pump coupling
Part Number: 8 716 109 245 0
8 Flexible oil hose kit
Part Number: 8 716 106 346 0
9 Burner 'O' ring
7a
10
13
12
Part Number: 8 716 111 951 0
2 Combustion head - LD2X SH12/18
Part Number: 8 716 112 731 0
3 Control box 535 RSE/LD
Part Number: 8 716 109 203 0
4 Photocell
Part Number: 8 716 109 193 0
5 Ignition electrode
4
19
25
20
26
15 Cleaning brush
Part Number: 8 716 109 428 0
16 Manifold access cover seal
Part Number: 8 716 107 536 0
17 Secondary Heat Exchanger gasket
Part Number: 8 747 009 725 0
18 Nozzle holder
Part Number: 8 716 112 777 0
19 Circlip
Part Number: 8 716 112 773 0
20 Brass air restrictor washer
Part Number: 8 716 112 729 0
21 Flue sample point cap
SERVICING
& SPARES
2
1
21
3
Part Number: 8 716 113 177 0
22 Oil nozzle
0.40 60° ES (12kW output)
Part Number: 8 716 156 679 0
22
0.45 60° ES (15kW output)
Part Number: 8 716 114 545 0
0.55 80° EH (18kW output)
Part Number: 8 716 156 671 0
KITCHEN SYSTEM ONLY
23 Expansion vessel
Part Number: 8 716 407 296 0
24 Pump
Part Number: 8 716 112 293 0
25 Pressure relief valve
Part Number: 8 716 142 422 0
26 System pressure guage
Part Number: 8 716 112 729 0
48
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SHORT PARTS LIST 12/18
SHORT PARTS LIST 18/25
5
8
3
2
1
7
6
9
4
7a
11
10
1 Burner - Riello RDB 2.2 18/25 HE
Part Number: 8 716 112 346 0
2 Combustion head - T2 SH18/25
Part Number: 8 716 112 780 0
3 Control box 535 RSE/LD
Part Number: 8 716 109 203 0
4 Photocell
Part Number: 8 716 109 193 0
5 Ignition electrode
Part Number: 8 716 109 211 0
6 Motor
Part Number: 8 716 109 186 0
7 Oil pump - Riello RDB
Part Number: 8 716 109 182 0
7a Pump coupling
Part Number: 8 716 109 245 0
8 Flexible oil hose kit
Part Number: 8 716 106 346 0
9 Burner 'O' ring
Part Number: 8 716 109 328 0
10 Control thermostat
Part Number: 8 716 107 621 0
11 Auto reset overheat thermostat
13
12
16
17
14
18
15
19
Part Number: 8 716 107 623 0
12 Manual reset overheat thermostat
Part Number: 8 716 107 625 0
13 Manual reset flue thermostat
Part Number: 8 716 107 624 0
14 Air damper disc 18 21.5-25
Part Number: 8 716 112 783 0
15 Cleaning brush
Part Number: 8 716 109 428 0
16 Manifold access cover seal
Part Number: 8 716 107 536 0
17 Secondary Heat Exchanger gasket
Part Number: 8 747 009 725 0
SERVICING
& SPARES
18 Flue sample point cap
Part Number: 8 716 113 177 0
19 Oil nozzle
0.55 80° EH (18kW output)
Part Number: 8 716 156 671 0
20
21
22
23
0.60 60° ES (21.5kW output)
Part Number: 8 716 156 680 0
0.75 80° ES (25kW output)
Part Number: 8 716 109 387 0
KITCHEN SYSTEM ONLY
20 Expansion vessel
Part Number: 8 716 407 296 0
21 Pump
Part Number: 8 716 112 293 0
22 Pressure relief valve
Part Number: 8 716 142 422 0
23 System pressure guage
Part Number: 8 716 112 729 0
49
SHORT PARTS LIST 18/25
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SHORT PARTS LIST 25/32
5
8
3
2
1
7
6
9
4
7a
11
10
1 Burner - Riello RDB 2.2 25/32 HE
Part Number: 8 716 112 347 0
2 Combustion head - T2 LH25/32
Part Number: 8 716 112 769 0
3 Control box 535 RSE/LD
Part Number: 8 716 109 203 0
4 Photocell
Part Number: 8 716 109 193 0
5 Ignition electrode
Part Number: 8 716 109 184 0
6 Motor
Part Number: 8 716 109 186 0
7 Oil pump - Riello RDB
Part Number: 8 716 109 182 0
7a Pump coupling
Part Number: 8 716 109 245 0
8 Flexible oil hose kit
Part Number: 8 716 106 346 0
9 Burner 'O' ring
Part Number: 8 716 109 328 0
10 Control thermostat
Part Number: 8 716 107 621 0
11 Auto reset overheat thermostat
16
13
17
14
15
Part Number: 8 716 109 428 0
15 Manifold access cover seal
Part Number: 8 716 107 536 0
16 Secondary Heat Exchanger gasket
Part Number: 8 747 009 725 0
17 Flue sample point cap
Part Number: 8 716 113 177 0
18
18 Oil nozzle
0.65 80° EH (25kW output)
Part Number: 8 716 110 362 0
0.75 80° EH (27.5kW output)
19
20
21
22
Part Number: 8 716 109 387 0
SERVICING
& SPARES
12
Part Number: 8 716 107 640 0
12 Manual reset overheat thermostat
Part Number: 8 716 107 625 0
13 Manual reset flue thermostat
Part Number: 8 716 107 624 0
14 Cleaning brush
0.85 80° EH (30kW output)
Part Number: 8 716 156 644 0
KITCHEN SYSTEM ONLY
19 Expansion vessel
Part Number: 8 716 407 296 0
20 Pump
Part Number: 8 716 112 293 0
21 Pressure relief valve
Part Number: 8 716 142 422 0
22 System pressure guage
Part Number: 8 716 112 729 0
50
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SHORT PARTS LIST 25/32
FAULT FINDING
Oil/
combustion
smells
Noisy burner
operation
High smoke
number
Pulsation on
start up
Intermittent
lockout
51
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
Rectify oil leak, replace
components if necessary.
Yes
No
Replace seals.
Remove
blockage/restriction.
Check flue seals.
No
No
Yes
Yes
Are the boiler combustion
chamber door, baffle or flue
access door seals leaking?
Yes
No
Yes
Is the flue blocked or
restricted?
Worn motor bearings:
replace the motor.
Move the fan away from
the housing. Replace if
distorted or unbalanced.
Check all combustion
settings.
Is there an oil leak? Check
all oil pipes & connections
for traces of oil
Yes
Is the noise from the
motor?
No
Is the fan touching the
fan housing or causing
vibration?
Yes
No
Service the burner and
the boiler.
Rectify the flue system
to match one of the
available flue options.
Has the burner been
serviced?
No
Yes
Replace the nozzle and
recheck combustion.
No
Is the flue system
correct?
Yes
Change the flue system
to meet the literature
specifications.
No
Is the flue system
correct?
Yes
Is the noise due to
combustion?
The oil system must be drained
& refilled with kerosene, then
recheck the combustion.
No
Yes
Change the flue system
to meet the literature
specifications.
Rectify the combustion
settings.
Is the fuel correct?
Kerosene only
No
No
Is the flue system
correct?
Are the combustion
settings correct for the
boiler & burner output?
No
Is the oil system a gravity
Yes
system?
Check for air in the oil:
rectify oil line fault.
Yes
Yes
Rectify the combustion
settings.
No
Are the combustion
settings correct for the
boiler & burner output?
Start
Burner not operating normally.
Find symptom list below.
FAULT FINDING
& DIAGRAMS
Replace any seals that
are damaged or suspect.
Yes
No
No
Yes
Yes
Are the burner seals
leaking? Check all seals.
Air in the oil line:
investigate where the air
is getting into the oil line.
Yes
Bleed the pump. Does
the noise reduce?
Rectify the combustion
settings.
No
Are the combustion
settings correct for the
boiler & burner output?
Check all connections on
the burner and rectify
any faults.
No
Are the electrical
connections on the
burner all sound?
Check flue draught with
gauge. Check flue seals.
Check flue for damage.
CF
Is the flue CF or RS?
Worn oil pump: replace
the oil pump
Check incorrect
parts/rectify settings.
No
Are all the combustion
head settings and
components correct?
RS
Yes
Check the photocell using the
information under the control
box chart.
Check flue seals. Check
flue for damage.
Remove
blockage/restriction.
Check flue seals.
No
Is the flue blocked or
restricted?
Yes
replace the nozzle and
recheck combustion.
UNDER NO
CIRCUMSTANCES MUST
AN APPLIANCE BE LEFT
OPERATING WITH ANY
CONTROL LINKED OUT OR
OVER RIDDEN.
Indicated by the illumination of
the lockout indicator on the
fascia.
To reset, wait 2 minutes then
press the lockout reset button.
BOILER LOCKOUT:
These fault finding charts are provided to assist competent and suitably qualified engineers to
locate and rectify faults. 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.
FAULT FINDING - BURNER
FUNCTION
Replace high limit
thermostat.
Lack of system water circulation.
Check the pump, valves and
system. Rectify the fault.
Yes
Yes
No
No
Is the burner lockout
light illuminated?
No
Locate fault between the control
thermostat and the burner.
Repair fault/replace lead.
No
No power/demand to the boiler.
Check external supply and
wiring. Rectify the fault.
Check the wiring and
thermostats for open circuit.
Replace the faulty part.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
FAULT FINDING
& DIAGRAMS
Yes
No
Is there 230V on the L
connection on the burner
control box?
Is there 230V on terminal
L on the boiler connector
block?
Is there 230V on the
orange wire to the high
limit thermostat?
Yes
Yes
Is the boiler hot?
No
No
Yes
Yes
No
No
Yes
No
Check external controls
and wiring. Rectify fault.
Is the demand light
illuminated?
Is the boiler hot?
Yes
No
Is the flue or boiler
overheat thermostat
tripped out?
Yes
Is the programmer/timer
ON for heating/hot water?
No
Switch the
programmer/timer to ON.
Does the boiler fire up?
Is there 230V on pin 3 of
the control thermostat?
(Red wire)
Yes
Yes
Is there 230V on terminal
3 on the boiler connector
block?
Reset the thermostat and investigate
cause of overheat. If the thermostat will
not reset replace the thermostat.
Check and correct
programmer/timer
settings.
Start
No heating/hot water
Replace the burner
control box.
Replace the control
thermostat.
Lack of system water circulation.
Check the pump, valves and system.
Rectify the fault.
Follow the control box
fault finding chart to
locate fault.
MEASURE ALL 230V
TESTS BETWEEN
NEUTRAL (N) AND THE
PIN, WIRE OR TERMINAL
SPECIFIED.
UNDER NO
CIRCUMSTANCES MUST
AN APPLIANCE BE LEFT
OPERATING WITH ANY
CONTROL LINKED OUT OR
OVER RIDDEN.
These fault finding charts are provided to assist competent and suitably qualified engineers to
locate and rectify faults. 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.
FAULT FINDING - HEATING/
HOT WATER
FAULT FINDING
52
FAULT FINDING
Flue
overheat
thermostat
tripping out.
Short
cycling.
Boiler
overheat
thermostat
tripping out.
Yes
Check boiler & flue for damage,
replace any damaged
components before filling boiler.
No
Is the boiler filled with
water?
Yes
Refit baffles and restrictor
plate/s as appropriate for
output.
No
Are all the baffles and
restrictor plate/s fitted? (See
installation section for details).
Replace the control
thermostat.
Reduce the boiler/burner
output following the
instruction manual settings.
Is the short cycling
caused by the external
controls?
No
Yes
No
Is the boiler/burner
output matched to the
heating load?
Yes
Replace the flue
overheat thermostat
Check and correct all
external controls.
Push themostat fully
down the thermostat
pocket.
Fit an automatic bypass valve to give
at least a 3 metre circuit when
activated.
Is the control thermostat
bulb pushed firmly down
the thermostat pocket?
Check and rectify the
system/circulating pump.
Yes
No
Is there an automatic bypass fitted,
(3m min. circuit length), if TRVs are
used on all radiators?
No
Yes
No
Is the system water
circulating normally?
Start
Boiler not operating normally.
Find symptom list below.
FAULT FINDING
& DIAGRAMS
Yes
Replace high limit stat
(manual reset).
No
Is flow temperature
above 85°?
Yes
Replace control stat.
UNDER NO
CIRCUMSTANCES MUST
AN APPLIANCE BE LEFT
OPERATING WITH ANY
CONTROL LINKED OUT OR
OVER RIDDEN.
These fault finding charts are provided to assist competent and suitably qualified engineers to
locate and rectify faults. 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.
FAULT FINDING - BOILER
FUNCTION
53
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
NO
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
Replace
photo cell
Replace
control box
Yes
No
No
Yes
Replace
control box
Replace
solenoid coil
Replace
motor
Yes
Replace oil
pump
Yes
Oil to pump?
No
Drive
coupling
broken?
No
Purge
pressure
1-2 bar?
No
Pump
produces
pressure?
Unblock or
replace pipe
Yes
Yes
No
Yes
Replace
solenoid coil
No
(100Ω)?
Solenoid coil
Yes
functional
No
FAULT FINDING
FAULT FINDING
& DIAGRAMS
Replace
control box
No
Replace
pump stem
valve,
pressure
OK?
Yes
Solenoid
lead OK?
Solenoid operating?
increase the pump pressure.
Pressure now OK?
Yes
No
Combustion
air setting
correct?
No
Reset air
setting
Nozzle
atomising
fuel?
Pipe to
nozzle
holder OK?
All resistance measurements are actual measured values and some variation is to be expected, therefore measured
values should be similar to but not necessarily identical to the given values.
The operation of the photo cell can be tested by measuring the resistance across the photo cell, it should be a high
resistance (greater than 10MΩ or open circuit) in the dark and low resistance (3kΩ or less) in light.
Burners on balanced flue systems can recirculate flue products resulting in the burner cycling, if this happens check the
flue system integrity and the terminal position.
No
Yes
Replace
motor
Photo cell
functional?
No
Motor 40Ω
between blue &
black wires ?
(100Ω)?
Yes
Replace
motor/pump
No
Yes
Solenoid coil
functional
Motor gives
50 Volts on
white wire?
Motor or
pump
seized?
Check boiler
controls &
supply
No
Yes
No
Yes
No
Ignition
spark
proved?
Lockout
after 12 sec
purge?
Yes
Lockout
within 1
second?
Eectrodes &
leads OK?
Yes
Yes
Replace
electrodes/
leads
No
Replace
nozzle
Replace
control box
Replace
control box
Yes
230V to
control box?
No
Burner
motor runs?
Boiler not
operating
with a
heating /
hot water
demand
Yes
Replace
photo cell
No
Photo cell
functional?
No
If BF
remove
burner
snorkle tube
& retest.
Burner OK?
Yes
Flame off &
re-lights?
Yes
Combustion
head set
correctly?
No
Reset
combustion
head
Yes
Yes
No
Replace
control box
Reseal BF
or reposition
terminal
Boiler or flue
blocked
MEASURE ALL 230V
TESTS BETWEEN
NEUTRAL (N) AND THE
PIN, WIRE OR TERMINAL
SPECIFIED.
These fault finding charts are provided to assist competent and suitably qualified engineers to
locate and rectify faults. 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.
FAULT FINDING LOGIC FOR
535 SE/LD RDB CONTROL BOX
54
OIL BOILER COMBUSTION RECORD
BOILER MODEL
SERIAL No.
COMMISSIONING ENGINEER
COMBUSTION CHECKS
COMPANY NAME:
PUMP PRESSURE (PSI):
ADDRESS:
CO2 %:
ENGINEERS NAME:
SMOKE READING:
F.G.T°C:
SIGNATURE:
FLUE PRESSURE:
DATE:
BURNER MODEL:
FOR ALL BOILERS CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS
YES
OIL TYPE USED IS 28 SECOND KEROSENE
YES
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE INSTRUCTIONS?
YES
THE SYSTEM CLEANER USED:
THE INHIBITOR USED:
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and
that you complete the appropriate Service Interval Record overleaf.
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.
55
OIL BOILER
COMBUSTION RECORD
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
SERVICE 1 DATE
SERVICE 2 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
psi
CO2%:
YES
NO
FLUE PRESSURE:
SIGNATURE
SIGNATURE
SERVICE 3 DATE
SERVICE 4 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
psi
CO2%:
YES
NO
FLUE PRESSURE:
SIGNATURE
SIGNATURE
SERVICE 5 DATE
SERVICE 6 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
psi
CO2%:
YES
NO
FLUE PRESSURE:
SIGNATURE
SIGNATURE
SERVICE 7 DATE
SERVICE 8 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
psi
CO2%:
YES
NO
FLUE PRESSURE:
SIGNATURE
SIGNATURE
SERVICE 9 DATE
SERVICE 10 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
OFTEC REG No.
PUMP PRESSURE:
NOZZLE CHANGED?
F.G.T. °C
COMMENTS
SIGNATURE
psi
CO2%:
YES
NO
FLUE PRESSURE:
SIGNATURE
psi
CO2%:
YES
NO
FLUE PRESSURE:
psi
CO2%:
YES
NO
FLUE PRESSURE:
psi
CO2%:
YES
NO
FLUE PRESSURE:
psi
CO2%:
YES
NO
FLUE PRESSURE:
psi
CO2%:
YES
NO
FLUE PRESSURE:
56
NOTES
NOTES
57
NOTES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
NOTES
NOTES
58
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN/KITCHEN SYSTEM 12/18-18/25-25/32
8 716 114 497a (10.07)
NOTES
If in the unlikely event the boiler does not
give complete satisfaction, before calling for
a service engineer, the installer should
check the following:General checks
1. Is there 230V across the boiler live and neutral terminals?
2. Is the polarity correct? (230V across live and earth, 0V across neutral and earth)
2. Is the air bled from the primary system?
3. Is the air bled from the oil supply?
4. Is the flue sized and routed correctly?
Boiler runs straight to lockout
1. Has the oil line been purged of air?
2. Where an air eliminator is used in conjunction with a top feed oil tank
the non-return valve, (if fitted), should be removed from the oil dip pipe.
Boiler locks out at the start of a demand
(Heating off overnight for example)
1. If an air eliminator is being used, check that there are no leaks that allow
air to be pulled into the oil supply.
2. If a two pipe oil supply is a being used, has a non-return valve
been fitted to the inlet pipe? Refer to the instructions for guidelines.
CONTACT INFORMATION
No domestic hot water
1. Is there a domestic hot water demand from the programmer and has the
tank reached temperature?
2. Is the circulating pump operating?
3. Are the programmer, tank thermostat, circulating pump and diverter
valve/zone valves wired correctly?
4. Is there 230V across L and N? If not there is no demand to the
boiler from the controls or the controls wiring is not correct.
No central heating
1. Are both programmer and room thermostat on demand for central heating?
2. Are the room thermostat, programmer, circulating pump and diverter
valve/zone valves (if CH and DHW system) wired correctly?
3. Is the circulating pump operating?
4. Is there 230V across L and N? If not there is no demand to the
boiler from the controls or the controls wiring is not correct.
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
8 716 114 497a (10.07)
WORCESTER, BOSCH GROUP:
TECHNICAL:
08705 266241
SERVICE:
08457 256206
SPARES:
01905 752571
LITERATURE:
01905 752556
TRAINING:
01905 752526
SALES:
01905 752640
WEBSITE: www.worcester-bosch.co.uk
WATER TREATMENT:
FERNOX
01799 550811
www.fernox.com
SENTINEL
0151 420 9595
www.betzdearborn.com/sentinel
FLUE TERMINAL GUARD:
PART No. 7 716 190 050