Boulter Buderus Camray 5 Combi Instruction Manual

Installation & maintenance manual for
Camray 5 Combi External
Boilers
Heat is our Element
Health & Safety
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a requirement to
provide information on substances hazardous to health (COSHH Regulations 1988).
The Company takes every reasonable care to ensure that these products are designed and constructed to
meet these general safety requirements, when properly used and installed.
To fulfil this requirement products are comprehensively tested and examined before dispatch.
This appliance may contain some of the materials below.
When working on the appliance it is the Users/Engineers responsibility to ensure that any necessary personal
protective clothing or equipment is worn appropriate to parts that could be considered as being hazardous to
health and safety.
INSULATION &SEALS
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Glass Rope, Mineral Wool, Insulation Pads, Ceramic Fibre, Fibre Glass Insulation.
May be harmful if inhaled. May be irritating to the skin, eyes, nose or throat. When handling avoid inhalation
and contact with the skin or eyes. Use (disposable) gloves, face masks and eye protection.
A
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handling wash hands and other exposed parts. When disposing, reduce dust with water spray, ensure
parts are securely wrapped.
GLUES, SEALANTS & PAINT
Glues, Sealants and Paint are used in the product and present no known hazards when used in the manner
for which they are intended.
KEROSENE & GAS OIL FUELS (MINERAL OILS)
1. The effect of mineral oils on the skin vary according to the duration of exposure.
2. The lighter fractions also remove the protective grease normally present on the surface of the skin
rendering the skin dry, liable to crack and more prone to damage caused by cuts and abrasions.
3. Skin rashes (oil Acne). Seek immediate medical attention for any rash, wart or sore developing on any part
of the body, particularly the scrotum.
4. Avoid as far as possible any skin contact with mineral oil or with clothing contaminated with mineral oil.
5. Never breath any mineral oil vapours. Do not fire the Burner in the open i.e. out of the Boiler as a miss fire
will cause unbumt oil vapours.
Barrier cream containing lanolin such as Rosalex Antisolv, is highly recommended together with a strict
routine of personal cleansing.
Under no circumstances should mineral oils be taken internally.
OFTEC Code of Practice OCP/1: 1995 For the Safe Installation, Commissioning, Maintenance and Fault
Rectification of Oil Firing Equipment should be consulted.
Boulter Buderus Limited
Magnet House, 30 White House Road, Ipswich IP1 5JA
Telephone: [phone]
Fax: [phone]
Contents
SECTION 1 - USERS GUIDE
1.1 Introduction
1.2 Useful Information
1:3 Important Safety Notes
1:4 Connections
1:5 Installation and Commissioning
1:6 Boiler Control Panel
1:7 Operating Features and Instructions
1:8 Maintenance
1:9 Failure to Start
SECTION 2 - INTRODUCTION
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2:1 Introduction
2:2 Hydraulic Circuits
2:3 Commissioning
2:4 Safety
SECTION 3 - TECHNICAL DATA
3:1 Liquid Fuels
3:2 Boiler Technical Details
3:3 Burner Details
3:4 Electrics
3:5 Dimensions
3:6 Tundish Position
3:7 Commissioning Data
3:8 Performance Data
SECTION 4 - INSTALLATION
4:1 Standards and Regulations
4:2 The Heating System
4:3 Siting & Positioning
4:4 The Hearth
4:5 Boiler Arrangement
4:6 Sealed System Details
4:7 Domestic Hot Water System
4:8 Connections to the Boiler
4:9 Flue exhaust
4:10 Air Supply
4:11 Oil Storage
4:12 Oil Supply
4:13 Oil Burner
4:14 Control Panel
4:15 Panel Wiring Diagram
4:16 Fitting Programmer
SECTION 5 FLUES
5:1 Positioning the Boiler
5:2 Terminal Guard
SECTION 6 BALANCED FLUES
Not applicable
SECTION 7 COMMISSIONING
7:1 Commissioning Boiler
7:2 Responsibility
7:3 Reporting
7:4 Commissioning Sealed System
7:5 Fillng the System
7:6 Check Pressure Relief Valve Operation
7:7 Expansion Vessel Pressure
7:8 Commissioning Check List
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Page 01
Section 1- Users Guide
1:1 INTRODUCTION
Thank you for choosing the Camray Combi manufactured in the UK by Boulter Buderus who are renowned
oil-firing specialists.
To obtain the best possible performance and trouble free operation from your Boiler, it is important that you
read section 1 of this manual carefully.
A
ll Camray appliances are the result of many years of research, development and experience. Whilst our
Boilers are designed with simplicity or operation in mind, there are certain features and benefits which only
become obvious when you thoroughly understand how best to use your Camray product.
We trust that you will enjoy many years of reliable service from your new Camray Boiler and, once again
thank you for choosing Camray.
1:1.1 Manual
This manual covers safety, User Instructions, Installation, Commissioning and Maintenance of the Camray
Combi External Boiler.
1:2 USEFUL INFORMATION
Your installer will help you complete this where necessary.
Information can be found on appliance data label located inside the left-hand side panel of the casing. Also on
the front cover of your installation manual.
7:9 Recommended Commissioning
Tests
SECTION 8 MAINTENANCE
8:1 Maintenance
8:2 Air Shutter Adjustment
8:3 Baffle Arrangement
8:4 Heating System
SECTION 9 SPARES & ACCESSORIES
See Spare Parts
SECTION 10 FAULT FINDING
10:1 Fault Finding
10:2 Fault Finding - Boiler
10:3 Fault Finding - System (Summer)
10:4 Fault Finding - System (Winter)
10:5 Parts Replacement Instructions
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1:3 IMPORTANT SAFETY NOTES
To obtain the best possible performance and trouble free operation from your Boiler, it is important that you
read these instructions carefully. Your Camray Boiler has built-in safety features, which are detailed in the
relevant section of this manual.
Page 02
1:3:1 Please Note
The heating system must comply with the latest editions of British Standard 5410 and The Building
Regulations.
(England and Wales only): Please note: This oil fired appliance must be installed by either an OFTEC
Registered Installer or by way of a Local Building Control License. An OFTEC CD10 document or
Building Control Completion Certificate must be obtained prior to commissioning of this appliance.
The first commissioning of this appliance, and the system that it is connected to, must be undertaken
by an O.FT.E.C.* registered engineer. It is the responsibility of the installer to ensure the Boiler can be
and is commissioned.
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If an engineer is not known, Boulter Buderus will be pleased to provide details of a commissioning and
servicing engineer from their register.
*The Oil Firing Technical Association for the Petroleum Industry. Telephone [phone]
IMPORTANT
zIf it is known or suspected that a fault exists on the Boiler, it MUST NOT be used until the fault has
been corrected by a competent engineer (see Failure to Start).
zIt is essential that the instructions in this manual are strictly followed for safe and economic operation of
the Boiler Failure to observe these instructions may invalidate your right to free breakdown cover
during the guarantee period.
We recommend that you keep these instructions in a place near your appliance for easy reference.
1:4 CONNECTIONS
Your Camray External Boiler should be connected to an electrical supply complying with the Electrical Wiring
Regulations (BS7671): as well as an oil supply complying with BS5410; and an appropriate flue system.
zALWAYS SWITCH OFF THE ELECTRICAL SUPPLY before removing any of the covers for cleaning.
zIf any part of the Boiler or its flue is modified, then the guarantee/warranty will be invalidated.
1:5 INSTALLATION & COMMISSIONING
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your Camray Boiler has been installed it MUST be commissioned by an O.F.T.E.C. Registered
Engineer. Commissioning involves testing the Boiler to ensure that it is working correctly, and also setting the
Burner correctly to ensure the most efficient operation and use of fuel. If the Boiler has not been
commissioned, it may not be operating at the maximum efficiency possible for your heating system, and may
also invalidate the guarantee.
READ HEALTH AND SAFETY INFORMATION ON INSIDE FRONT COVER OF THIS
MANUAL.
Page 03
On no account should any part of the Boiler or its Flue be modified with the exception of flues which require
adjusting to length to suit site conditions, as detailed in this manual.
The wiring of the control panel should be as the wiring diagrams included in this manual. Wiring should not be
tampered with, modified or changed for any reason.
Only use Boulter Buderus replacement parts.
Non-compliance with the above will invalidate the Guarantee.
NOTE
Due to the high efficiency of DHW production in certain circumstance i.e. very low rates, the temperature of
the hot water at the tap can be high. If this temperature is likely to cause nuisance or discomfort your installer
will advise that you fit thermostatic mixer valves at the appropriate draw off points.
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1:6 BOILER CONTROL PANEL
Fig 1 a
Boiler Control Panel (see Fig 1a)
1. Boiler control thermostat
2. Hot water thermostat
3. Boiler overheat/limit thermostat
4. Lockout indicator light - red
5. Mains indicator light - green
6. Limit indicator light - red
7. Heating ON indicator light - green
8. Summer/winter switch
9. System pressure indicator dial
10. Domestic water flow indicator light - green
11. Tank heating indicator light - green
1:6.1 Boiler Control Thermostat
The Boiler Control Thermostat controls the water temperature in the boiler. The recommended setting is
shown in Fig 1a.
This thermostat automatically switches the burner ON & OFF to maintain the selected temperature. The
burner is lit by an automatic ignition system and therefore there is no pilot flame.
The Boiler should not be operated below 60°C, as this will cause corrosion which will reduce the life of the
boiler.
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1:6.2 Hot Water Tank Thermostat
This thermostat controls the water temperature in the tank. Guidance on its use is given in Section 1:7 of this
manual.
Page 04
1:6.3 Summer/Winter/Off Switch
Use this 3 position switch to select the required mode:
SUMMER For domestic hot water only.
WINTER For domestic hot water & heating.
OFF To switch the boiler off.
1:6.4 Boiler Overheat/Limit Thermostat
This thermostat will interrupt the power supply to the burner and shut it down completely in the unlikely event
of overheating.
Should this occur, the green indicator light on the control panel will illuminate. Wait for the boiler to cool, and
reset the thermostat by depressing the limit thermostat reset button located on the control panel - see Fig 1 a.
If this problem recurs, turn the boiler off and consult your installer.
1:6.5 Lockout Lamp
In the unlikely event of a burner malfunction or you run out of oil it will automatically shutdown, and the red
lockout indicator on the control panel and the lamp on the burner will illuminate.
Wait 45 seconds before attempting to restart the burner. To restart the burner, remove the front boiler panel
and repress the lockout reset button on the front burner control box (see Fig 1 b). If the burner lockout again
wait 3 minutes and repeat the operation again.
If the problem occurs again, turn the boiler off and consult your installer.
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Fig 1 b
Page 05
1:7 OPERATING FEATURES AND INSTRUCTION
1:7.1 How does your Boiler work?
Hot Water
If the Programme is set for Hot Water only or Summer/Winter switch is set to Summer: -
a) The Boiler will operate until the hot water tank reaches the temperature you have set on the Hot Water
Tank Thermostat. From cold, this will take approximately 18 minutes. To obtain the maximum temperature
and quantity of hot water (i.e. for a bath) set this to maximum.
b) When any hot water tap is turned ON to give a flow rate in excess of 2.5 litres/minute, the Boiler will
operate during the draw of hot water. When the tap is turned OFF the Boiler will continue to operate until the
hot water tank reaches the temperature set on the Hot Water Tank Thermostat. The period of operation to
replenish the energy used depends on the quantity of hot water drawn.
c) As the rate of water is increased by opening the hot water tap, the water temperature reduces and the tap
should be adjusted to give the desired temperature.
d) If the Programme is OFF (i.e. during the night period) hot water may be drawn but is limited to the energy
stored in the tank. During the period of draw of the circulating water pump will operate but not the Boiler.
Providing the tank has not discharged just prior to the Programme switching off these is normally adequate
hot water for occasional use of wash basins.
e) For daytime use of hot water, set the Programme (if fitted) to give Hot Water ON at least 18 minutes prior to
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normal anticipated use.
Heating and Hot Water
If the Programme is set for Heating and Hot Water or the Summer/Winter switch is set to Winter: -
a) The Boiler will operate until the temperature in the boiler reaches the temperature you have set on the
Boiler Control Thermostat or until your Room Thermostat is satisfied.
b) Provision of Domestic Hot Water takes priority over Central Heating, so that during the period when the hot
wate
r
tap is turned on or when the hot water tank is being recharged (only a matter of minutes) the central
heating is automatically but only temporarily turned off. Central Heating is restored when the hot water tank
has fully recharged and when the hot water tap is turned off.
1:7.2 Switching the Boiler Off - temporarily
The Boiler may be stopped by switching the Summer/Winter switch to the OFF position on the standard
Control Panel or the programmer switch to the OFF position on the operational programmer.
1:7.3 Sealed System Central Heating
Your Camray 5 COMBI Boiler may only be used on a SEALED SYSTEM.
It is important that the correct operating system pressure is maintained. If the System Pressure Gauge, in the
Control Panel, should indicate low pressure i.e. below the marker, contact your installer.
1:7.4 Frost Protection
A
frost thermostat is fitted to the Boiler. However if there is any danger that your Boiler may freeze up during
very severe weather conditions, it is recommended that you consult your installer who will be able to advisee
you on an appropriate course of action, possibly the addition of system anti-freeze.
Page 06
1:7.5 Oil Delivery
Where possible, it is advisable to temporarily switch the Boiler off when your oil supply is being replenished.
This is to allow any sediment to settle and not be drawn into the Boiler. If not this could result in an
inconvenient break down. We advise that you keep your Boiler on for one hour after the oil is delivered to your
tank. Please ask your supplier, or driver to notify you before the oil is discharged.
1:8 MAINTENANCE
For normal cleaning of the outside casing, simply wipe with a dry cloth. To remove stubborn marks and stains,
wipe with a damp cloth and finish off with a dry cloth. DO NOT use abrasive cleaning materials.
The Boiler must be serviced at regular intervals by a qualified service engineer. Failure to comply will
invalidate the guarantee/warranty.
THE BOILER MUST BE SERVICED AT TWELVE MONTHLY INTERVALS.
Your Boiler has a conventional flue. Make sure that air intake entries on the casing panels are never
obstructed. This could lead to premature failure.
1:9 FAILURE TO START
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If the Burner fails to start, adopt the following procedure: -
1) Check that there is oil in the tank and that the supply valve is open.
2) Check the programmer on Summer/Winter switch to ensure that it is operating and set to the correct time to
be "ON".
3) Check that the Boiler Control Thermostat is set high enough to be "ON" or calling for heat.
4) Check whether the limit light on the control fascia is glowing, if so it indicates on overheat situation. Press
the reset button once the temperature has dropped sufficiently.
5) Check whether the red LOCKOUT lamp on the Control Panel and Burner Control Box are glowing. This
indicates that the Burner has attempted to start but has not fired successfully. Press the reset button on the
Burner Control box, when released, the lights will go out and the Burner will again attempt to start. If the
Burner does not run and again goes to lockout with red indicators glowing: -
Wait three minutes.
zRepeat the procedure by pressing the button.
zFailure to start on second attempt indicates a fault requiring attention.
zSwitch off the mains supply and call your service engineer.
Page 07
Section 2 - Introduction
2:1 INTRODUCTION
The Camray 5 Combi External is:
1) Designed for producing Hot water and Central Heating.
2) Suitable for sealed Central Heating systems which are within the maximum permitted working pressure. All
Boilers are supplied with a manual reset limit thermostat.
3) Suitable for new installations and for replacing existing sealed system Boilers.
CAMRAY Boilers offer greater freedom to select the most suitable position for siting. All models are supplied
for connection to an integral flue supplied with the boiler.
IMPORTANT
To achieve the high flow rates specified there must be dynamic working pressures as specified in the
performance graph* at the cold feed to the boiler. If this is not achievable DO NOT INSTALL THE
BOILER.
(see section 3.8)
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Fig 2a
Page 08
2:2 HYDRAULIC CIRCUITS
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2:3 COMMISSIONING
The heating system must comply with the latest editions of British Standard 5410 and The Building
Regulations.
Please note: It is essential in the interest of the Boiler efficiency and reliable performance that once the Boiler
has been installed it if first commissioned by a competent O.F.T.E.C.* registered engineer. It is the
responsibility of the installer to ensure that the Boiler is commissioned.
If an engineer is not known, Boulter Buderus will be please to provide details of commissioning and servicing
engineers from their register.
*The Oil Firing Technical Association for the Petroleum Industry.
2:4 SAFETY
READ HEALTH AND SAFETY INFORMATION ON INSIDE FRONT COVER OF THIS MANUAL.
IMPORTANT
Should you wish to remove or dismantle any covers or parts of the boiler for cleaning or maintenance
ALWAYS FIRST SWITCH OFF THE ELECTRICITY SUPPLY.
1) On no account should any part of the Boiler or its Flue be modified except as specified in this manual.
2) The wiring of the Control Panel should be as the wiring diagrams included in this manual. Wiring should not
be tampered with, modified or changed for any reason.
3) Only use Boulter Buderus replacement parts.
Non compliance with the above will invalidate the Guarantee.
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Page 09
Section 3 - Technical data
3:1 LIQUID FUELS
The Camray 5 COMBI Boiler will burn liquid fuels complying with BS2869 Part 2 1998 Class C2 specified in
the Code of Practice for Oil Firing BS5410 Part 1.
Class C2 (Kerosene)
This fuel is suitable for Camray 5 COMBI. Burners are supplied with the appropriate nozzle and pump
pressure as standard for this fuel.
3:2 TECHNICAL DATA
3:3 BURNER DETAILS
Pressure Jet - Riello RDB supplied as standard. Burner type - 483T50
For further details of the burner, refer to the burner data sheet supplied in the literature envelope.
A
s the burner has been specifically matched to this Boiler, the information in the Boiler manual takes
precedence.
3:4 ELECTRICS
IMPORTANT
The electrical installation of this appliance must be performed by a suitably qualified electrical
engineer/installer.
Electrical Supply 230v., 1 Ph., 50 Hz.
A
ll wiring to supply and all system components external to boiler must comply with the latest edition of
BS7671: 2001 formerly IEE Wiring Regulations.
Heat Input (Full load based on NET efficiency of 91 %) 29kW
Heat Output (Full load) 26.4kW
Maximum Boiler working pressure 3 bar Class 2
Minimum return water temperature 60°C
Maximum side panel temperature <35°C above ambient
Range of Boiler Control Thermostat 65-85°C
Maximum Temperature of Boiler Control Thermostat 85°C +/-2°C
Boiler Limit Thermostat Sitting 110°C +/-2°C
Maximum Emissions Limit (Class 1) NOx 250mg/kWh - CO 125mg/kWh
Exit Flue Gas Mass Flow l3.5Kg/secxl0-3
Mean DHW temperature @ 20 I/min (flow) to
provide 90 litres capacity (10°C Cold Water inlet) 50°C
Store Capacity 40 litres
Storage recovery time (between draw offs) approx. 5 mins.
Boiler weight empty 175 kg
Boiler and store water content 63.5 litres
Water resistance (Heating) 295 mbar with 15°C boiler temperature rise.
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This appliance must be effectively earthed and connection to the supply must be through a double pole
isolating switch fused 5 amp.
The isolating switch must have all pole contact separators at least 3mm.
Page 10
3:5 DIMENSIONS
Fig 3a
3:6 TUNDISH POSITION
A
Tundish (not supplied) must be fitted to provide a visual indication of water flowing from the Pressure Relief
Valve of the Boiler.
Installation of the Tundish must be located in a position clearly visible to the householder i.e. to comply with
Part G of the Building Regulations - typically as Fig 3.b.
Pipe to Tundish Min. size of discharge
pipe from Tundish
Max. length of straight pipe
- no elbows or bends
Reduce length for
each elbow bend by
15mm
22mm up to 9m 0.8m
28mm up to 18m 1.0m
35mm up to 27m 1.4m
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Page 11
3:7 COMMISSIONING DATA
3:7.1 Class C2 Kerosene Oil
3:8 PERFORMANCE DATA
Dynamic Inlet pressures / flow rates
Model Output Riello R00
type
Nozzle
Danfoss
Delevan
US/GPH
Pump
pressure
fuel rate
Kg/h C02% Smoke no.
Flue
exit
temp. °
C
kW Btu/hx1000 bar psi
90A 26.4 90 483T50 0,85x60°W 8.0 115 2.57 12 0-1 204
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Page 12
Section 4 - Installation
4:1 STANDARDS & REGULATIONS
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The installation of the Boiler must comply with latest edition of: -
BS5410 Oil installations Part 1: under 44kW.
BS5449 Forced circulation hot water central heating system for domestic premises.
BS7074 Part 7: Codes of Practice for Sealed Systems.
BS7671 Electrical Wiring Regulations.
BUILDING REGULATIONS.
Part J England and Wales
Part F Section III Scotland
Part G Section III
Part L Northern Ireland
The Control of Pollution (Oil) Regulations
OFTEC
Oil boilers should be installed in accordance with good practice as recommended by OFTEC
(Ref. 2:4 COMMISSIONING).
4:2 THE HEATING SYSTEM
This should be installed in accordance with current good practice as advised by HVCA. It is not the purpose of
the manual, nor is it possible, to adequately deal with the subject in this manual.
On existing heating systems where a Boiler is replaced, ensure that the system is chemically cleaned, consult
a reputable manufacturer.
The system should contain clean water and be free from leaks. Suitable inhibitors against limescale and
corrosion should be added to the system.
Kettling and system noises can be avoided by suitable pre-treatment at the onset.
4:3 SITING & POSITIONING
The noise level from Camray Boilers is quite low and other installations have not given rise to complaints.
Consideration must be given however, to the following points.
1) Noise may be accentuated by the installation in recesses with hard or hollow stud wall surfaces. Due
consideration to the siting of Boilers should be given.
Further advice from Boulter Buderus should be sought where any doubt exists.
2) Some individuals may be particularly sensitive to even low noise levels and this should be discussed before
installation.
3) The Camray Combi Boiler model is serviced from the front and top. A space of 450mm (18") in front and
above the Boiler should be available.
The top casing panel can be raised at one end or side to prevent water gathering on the top of the appliance.
The use of the additional plate, suppied when screwed to the wall will help prevent water or debris falling
between the boiler and the wall of the building, as shown in Fig 4.3.
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Fig 4.3
Page 13
4:4 THE HEARTH
The Camray 5 Combi has a Hearth Temperature of less than 85°C. The Boiler requires a level hearth on
which to stand which should comply with the Building Regulations. Pre-cast concrete slabs satisfies this
requirement. If the Boiler is to stand on a base made of combustible material then protection between the
Boiler and the floor should be provided by means on non-combustible material.
Consideration must be given to the weight of the Boiler.
4:5 BOILER ARRANGEMENT
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4:6 SEALED SYSTEM DETAILS
12 litre Ex
p
ansion
V
essel
1. 12Ltr expansion vessel 7. Boiler heat exchanger
2. Storage tank 8. 3 port motorised valve
3. Pressure gauge 9. Plate heat exchanger
4. Pressure relief valve 10. Flow switch
5. Circulating pump 11. Manual vent
6. Tundish (not shown)
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