Boulter CAMRAY 5 COMBI Instruction Manual

COMBI
OPERATING, INSTALLATION &
MAINTENANCE MANUAL
for
CAMRAY 5 COMBI
Oil Fired Boilers (55, 70A & 90A)
Manual Part No PL50000
Issue No. 5
Date of Issue February 2003
HEALTH AND SAFETY
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a requirement to
provide information on substances hazardous to health (COSHH Regulations 1988).
The Company takes every reasonable care to ensure that these products are designed and constructed to
meet these general safety requirements, when properly used and installed.
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
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health and safety.
INSULATION & SEALS
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.
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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 unburnt 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
Boulter Buderus Limited
Magnet House,
30 White House Road,
Ipswich
IP1 5JA
Telephone: [phone]
Boulter Boilers Fax: [phone]
A
subsidiary of Buderus Heiztechnik GmbH
Due to a policy of continual development reserves the right to alter or amend the design of its products
without prior notice.
CONTENTS - COMBI
SECTION 1 - USERS GUIDE
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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
2:1 Introduction
2:2 Hydraulic Circuits
2:3 Flue Options
2:4 Commissioning
2:5 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 The Chimney
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
4:17 Programmer Instructions
SECTION 5 - BALANCED FLUES
5:1 Balanced Flue Boilers
5:2 Horizontal Balanced Flues
5:3 Vertical Balanced Flues
5:4 Positioning the Boiler
5:5 Terminal Guards
5:6 Horizontal Flue Terminal
5:7 Blanking Plates
SECTION 6 - BALANCED FLUE INSTALLATION
6:1 Notes on Installation
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Sections dealing with Installation, Commissioning, Maintenance and Fault Finding are ONLY for suitable
qualified personnel
CAMRAY 5 COMBI PAGE 1
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 of operation in mind, there are certain features and benefits which only
become obvious when you thoroughly understand how best to use your new 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
6:2 Low Level Horizontal Flue
6:3 High Level Horizontal Flue
6:4 Vertical Flue - Flat Roof
6:5 Vertical Flue- Pitched Roof
SECTION 7 - COMMISSIONING
7:1 Commissioning Boiler
7:2 Responsibility
7:3 Reporting
7:4 Commissioning Sealed System
7:5 Filling the System
7:6 Check Pressure Relief Valve Operation
7:7 Expansion Vessel Pressure
7:8 Commissioning Check List
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
SECTION 11 - EXTERNAL PROGRAMMER
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Combi Boiler.
1:1.2 Timer Programmer
A
n optional Programmer is available which will enable you to time both your Central Heating and Domestic
Hot Water (store) requirements.
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.
CAMRAY 5 COMBI PAGE 2
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 detailedin the
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relevant section of this manual.
1:3.1 Please Note
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 is first commissioned by preferably an O.F.T.E.C.* registered engineer. It is the
responsibility of the installer to ensure that the Boiler is commissioned.
If an engineer is not known, Boulter Buderus will be pleased to provide details of a commissioning
and servicing engineer from their register.
*The Oil Firing Technical Association for the Petroleum Industry - Banstead, Surrey 01737 373311.
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.
zWe recommend that you keep these instructions in a place near your appliance for easy reference.
1:3.2 Air Supply to Boiler Conventional Flue
Where your Boiler is used on an open conventional flue system, a permanent air supply is required for
combustion. Clearances provided at the sides and rear of the appliance for air entry must be kept free of
obstruction. For further explanation please refer to section 4 of this manual.
1:4 CONNECTIONS
Your Camray 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 preferably 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 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 ts i Flue be modified with the exception of flues which
require adjusting to length to suit site conditions, as detailed in this manual.
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1. 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 replacement parts.
Non-compliance with the above will invalidate the Guarantee.
NOTE
Due to the high efficiency of DHW production in certain circumstances i.e. very low flow 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 should be able to advise on a suitable temperature blending valve.
CAMRAY 5 COMBI PAGE 3
1:6 BOILER CONTROL PANEL
Boiler Control Panel (see fig 1a)
1. Boiler Control Thermostat
2. Hot Water Tank Thermostat
3. Boiler Overheat/Limit Thermostat Reset Button
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
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10. Domestic water flow indicator light-Green
11. Tank heating indicator light-Green
Items 10 & 11 are diagnostic indicators which are not visible with the front panel on.
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.
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.
1:6.3 Summer/Winter/Off Switch
Use this 3 position switch to select the required mode:
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 1a 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 depress the lockout
reset button on the front of the burner control box (see Fig 1b). lf the burner locks out again wait 3 minutes
and repeat the operation again.
If the problem occurs again, turn the boiler off and consult your installer.
CAMRAY 5 COMBI PAGE 4
SUMMER for domestic hot water only.
WINTER for domestic hot water & heating.
OFF to switch the boiler off.
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Fig. 1b Lockout Reset
1:7 OPERATING FEATURES AND INSTRUCTIONS
1:7.1 How does your boiler work?
Hot Water
1 If the Programmer is set for Hot Water only or the 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 ( ie 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 Programmer is OFF (ie during the night period) hot water may be drawn but is limited to the energy
stored in the tank. During the period of draw off the circulating water pump will operate but not the boiler.
Providing the tank has not discharged just prior to the Programmer switching off there is normally adequate
hot water for occasional use of wash basins.
e) For day time use of hot water, set the Programmer (if fitted) to give Hot Water ON at least 18 minutes prior
to normal anticipated use.
Heating and Hot Water
2 If the Programmer is set for Heating and Hot Water or the Summer/Winter switch is set to W inter :
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.
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1:7.2 Switching the Boiler Off - temporarily
The Boiler may be stopped by switching the Summer/Off/Winter switch to the OFF position on the standard
Control Panel, or the programmer switch to the OFF position on the optional 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
If there is any danger that your Boiler may freeze up during severe weather conditions, it is recommended that
you consult your installer who will be able to advise you on an appropriate course of action, either by installing
a frost thermostat or the addition of system anti-freeze.
CAMRAY 5 COMBI PAGE 5
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 off for one hour after the oil is delivered to your tank. Please ask your
supplier, or the 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 will invalidate the
guarantee/warranty.
THE BOILER SHOULD BE SERVICED AT TWELVE MONTHLY INTERVALS.
If 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
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 or 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 an 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
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Burner does not run and again goes to lockout with red indicators glowing:-
zWait three minutes.
zRepeat the procedure by pressing the button.
zFailure to start on the second attempt indicates a fault requiring attention.
zSwitch off the mains supply and call your service engineer.
CAMRAY 5 COMBI PAGE 6
2:1 INTRODUCTION
The Camray 5 Combi 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 and the opportunity to
install the boiler in a suitable outbuilding if required.
A
ll models are supplied for connection to a conventional chimney or any of the available Camray 5 Combi
Balanced Flue options.
NOTE: Right hand low level flue not available.
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 Schematic Diagram Camray 5 Combi
CAMRAY 5 COMBI PAGE 7
2:2 HYDRAULIC CIRCUITS
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Fig. 2b Hydraulic Circuits
2:3 FLUE OPTIONS
CAMRAY Boilers are designed to operate with high efficiency, clean combustion and low noise level. They
offer unique versatility and can be used in the following modes:
1. Low level rear outlet balanced flue.
2. High level rear outlet balanced flue.
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3. Vertical outlet balanced flue. (Insulated balanced draught chimney).
4. Low level left hand side outlet balanced flue only.
5. High level side outlet balanced flue (RH or LH).
6. For connection to a conventional chimney.
7. Other options may be available. Please contact Boulter.
Balanced flues are supplied in a carton which includes ALL parts for balanced flue installation. With
conventional flue leave gap of 15mm at rear of boiler for air entry.
2:4 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 is first commissioned by a competent and preferably an O.F.T.E.C.*
registered engineer. It is the responsibility of the installer to ensure that the Boiler is commissioned.
If an engineer is not known, Boulter Buderus will be pleased to provide details of commissioning and
servicing engineers from their register.
*The Oil Firing Technical Association for the Petroleum Industry - Banstead, Surrey 01737 373311.
CAMRAY 5 COMBI PAGE 8
2:5 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 ts Flue be modified except as specified in this i 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 replacement parts.
Non compliance with the above will invalidate the Guarantee.
3:1 LIQUID FUELS
The Camray 5 COMBI Boiler will burn liquid fuels complying with BS2869 Part 2 1988 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
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3:3 BURNER DETAILS
Pressure Jet - Riello RDB supplied as standard. Burner type - 483T50 Manually adjustable air regulator.
For further details of the burner, refer to the burner data sheets 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., 50Hz.
A
ll wiring to supply and all system components external to boiler must comply with the latest edition of
Heat Input (Full load based on Net efficiency of 91%)
Heat Output (Full load)
Maximum Boiler working pressure 3 bar Class 2 - 30.6m water head
Minimum return water temperature 600C
Maximum side panel temperature <350C above room temperature
Conventional flue - Minimum flue draught 0.09mbar (0.035"w.g.)
Conventional flue - Maximum flue draught 0.38mbar (0.152"w.g.)
Range of Boiler Control Thermostat 65 - 850C
Maximum Temperature of Boiler Control Thermostat 850C+/-2 C
Boiler Limit Thermostat Setting 110 C+/-6 C
Maximum Emissions Limit (Class 1) Nox 250mg/kWh CO 125mg/kWh
Exit Flue Gas Mass Flow 13.5 Kg/secx103
Mean DHW temperature @ 20 l/min (flow) to provide
90 litres capacity (100C Cold Water inlet)
500C
Store Capacity 40 litres
Storage recovery time (between draw offs) approx 5 to 12 mins depending on boiler size.
Boiler weight empty 175 kg
Boiler and store water content 63.5 litres
Water resistance (Heating) 295mbar with 150C Boiler temperature rise
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BS7671 :2001 formerly IEE Wiring Regulations.
This appliance must be effectively earthed and connection to the supply must be through a double pole
isolating switch fused 5 amp.
The isolating switch must have all pole contact separations at least 3mm.
CAMRAY 5 COMBI PAGE 9
3:5 DIMENSIONS
3:6 TUNDISH POSITION
A
Tundish 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
The Tundish should be positioned on the right hand side of the appliance.
The Tundish should be positioned on the right hand side of the appliance.
90A 70A 55
29kW 22.5kW 17.7kW
26.4kW 20.5kW 16.1kW
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Fig. 3b Tundish Position
CAMRAY 5 COMBI PAGE 10
3:7 COMMISSIONING DATA
3:7.1 Class C2 Kerosene Oil
1. There are two columns in the table for combustion gas temperature:-
FLUE EXIT temperature, and
BOILER TEST POINT temperature.
2. Where possible CO2, smoke and flue gas temperatures should be sampled from the FLUE EXIT (i.e.
external balanced flue discharge, or from the test point provided in the conventional flue adaptor)
3. These figures may be used to calculate combustion efficiency.
4. Alternatively (where the forgoing is impractical such as vertical BF) gases can be sampled at the BOILER
TEST POINT inside the casing.
Because the gas temperatures at this point are significantly higher it should not be used to calculate or
measure efficiency.
5. If the BOILER TEST POINT temperature agrees with the data in Table 3:7.1, then use the appropriate
FLUE EXIT temperature from the table to calculate the combustion efficiency.
6. On conventional flue only - flue draught should be measured at the flue exit test point.
Model Output Riello
Burner
Type
Danfoss
Nozzle
Pump
Pressure
Fuel
Rate
Kg/h
C02%Smoke
No.
Flue Exit
Temp oC
Gross
Boiler Test
Point Temp
oC
kW Btu/h
x1000
BAR psi
90A 26.4 90 RDB
483T50 0.85x60oW8115 2.57 12 0-1 204 335
70A 20.5 70 RDB
483T50 0.65x60oW7.6 110 2.0 12 0-1 188 280
55 16.1 55 RDB
484T50 0.50x60oW8115 1.57 11 0-1 200 280
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CAMRAY 5 COMBI PAGE 11
3:8 PERFORMANCE DATA
Fig. 3c Performance Graph
Fig. 3d Pump Head Graph
CAMRAY 5 COMBI PAGE 12
4:1 STANDARDS& REGULATIONS
The installation of the Boiler must comply with latest edition of :
BS 5410 Oil Installations Pt 1 under 44kW;
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BUILDING REGULATIONS.
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, page 8).
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 kitchen 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 small rooms or recesses with hard or hollow stud wall
surfaces. Due consideration to the siting of Boilers should be given.
Further advice from BOULTER 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 type of chimney, position relative to the Boiler and whether a draught stabilizer is to be fitted may affect
sound level in the room.
4. The Camray 5 Combi Boiler model is serviced from the front and top. A space of 450mm (18 ) in front and
above the Boiler should be available. (On CF a 15mm gap at the rear must be provided for air entry).
5. Any kitchen work top above the Camray 5 Combi Boiler must be made removable for service access or
replacement of parts.
BS 5449 Forced circulation hot water central heating systems for
domestic premises.
BS 4543 Pt. 1 & 3 Factory made insulated chimneys.
BS 7074 Pt 7 Codes of Practice for Sealed Systems.
BS 7671 Electrical Wiring Regulations.
Part J England and Wales
Part F Section III Scotland
Part G Section III
Part L Northern Ireland
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6. Boiler installation in bedrooms or living rooms should be avoided if possible.
4:4 THE HEARTH
The Camray 5 Combi has a Hearth Temperature of less than 850C. The Boiler require a level hearth on which
to stand which should comply with the Building Regulations.
If the Boiler is to stand on a floor made of combustible material then protection between the Boiler and the
floor should be provided by means of non combustible material.
Consideration should be given to the weight of the Boiler see Fig. 3:2.
CAMRAY 5 COMBI PAGE 13
4:5 BOILER ARRANGEMENT
Fig. 4.5 Camray 5 Combi Boiler Arrangement
CAMRAY 5 COMBI PAGE 14
4:6 SEALED SYSTEM DETAILS
1. 12 litre Expansion Vessel
The Expansion Vessel is suitable for systems with a static head of up to 5 metres (16.5ft) i.e. the vertical
distance between Expansion Vessel and highest point of system, usually the top of bedroom radiators. If the
static head is greater than 5 metres, then the charge in the vessel must be increased to equal this higher
static pressure. The pressure can be increased if required by simply pumping up the vessel with a standard
air type pump and checking the pressure with a tyre gauge with the system at zero pressure. A Schrader type
valve is provided on the vessel for this purpose (see note below).
NOTE: The air charge should not exceed a pressure of 1.5 Bar (22 p.s.i.)
Expansion Vessel Requirements
Vessel Charge and Initial System bar 0.5 1.0 1.5
Pa
g
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