Worcester 12/18 User manual

GREENSTAR CAMRAY EXTERNAL
12/18, 18/25, 25/32
FLOOR STANDING EXTERNAL OIL FIRED CONDENSING BOILER USING
BALANCED FLUE SYSTEM
FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER
CYLINDER
THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE
ONLY
INSTRUCTION MANUAL
INSTALLATION COMMISSIONING
& SERVICING
GB

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
1
Check List Hardware/Literature pack
Item Qty
Greenstar Camray External Installation/Servicing Instructions............1
Users Instructions ..........................................................................................1
Hardware Pack.................................................................................................1
100mm Ø Services Duct...............................................................................1
Condensate Trap Kit.......................................................................................1
Warranty Return Envelope ............................................................................1
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.
THE INSTRUCTIONS APPLY IN THE UK ONLY AND MUST BE FOLLOWED EXCEPT FOR ANY
STATUTORY OBLIGATION.
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.
OFTEC operate a competent persons scheme and registered installers are able to certify that their
work complies with building regulations. Under the scheme;
lOFTEC must be informed about every installation.
lOFTEC will issue a building regulations compliance certificate to the householder and will
notify the LABC.
OFTEC provide controlled document forms CD10 and CD11 for use during installation and
commissioning respectively.
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.
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.
ABBREVIATIONS USED IN THIS MANUAL:
ØDiameter
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 Petrolium Industry
IEE Institute of Electrical Engineers
LABC Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
INSTALLATION & SERVICING INSTRUCTIONS
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.
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply

CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
2
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
FAULT FINDING
& DIAGRAMS
NOTES
SAFETY & REGULATIONS
IMPORTANT INFORMATION AND SYMBOLS 1
SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 3
APPLIANCE INFORMATION
GENERAL INFORMATION 4
TECHNICAL DATA 5
LAYOUT & COMPONENTS 6
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 7
MAINS SUPPLY 8
OIL SUPPLY 9
WATER SYSTEMS & PIPEWORK 10-11
CONDENSATE PIPEWORK 12
PRESSURE RELIEF PIPEWORK 12
BOILER LOCATION & CLEARANCES 13
FLUE TERMINAL POSITIONS 14
BALANCED FLUE OPTIONS 15
INSTALLATION
UNPACKING THE BOILER 16
PIPEWORK & FLUE POSITIONS 17
BOILER INSTALLATION 18
FLUE INSTALLATION 19-20
COMBUSTION CHAMBER 21
PIPEWORK CONNECTIONS 22-23
OIL BURNER AND PUMP 24
REFITTING COMPONENTS 25
ELECTRICS 26-28
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE 29
FILLING THE SYSTEM 30
STARTING THE APPLIANCE 31-34
WATER TREATMENT 35
FINISHING COMMISSIONING - APPLIANCE 36
SERVICING & SPARES
INSPECTION AND SERVICE 37-40
SHORT PARTS LIST 12/18 41
SHORT PARTS LIST 18/25 42
SHORT PARTS LIST 25/32 43
FAULT FINDING & DIAGNOSIS
FAULT FINDING 44-45
FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX 46
COMBUSTION RECORD 47
SERVICE INTERVAL RECORD 48
BAFFLE ARRANGEMENT DIAGRAM BACK PAGE

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
3
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
4 Extinguish any naked flames.
4 Isolate the electrical supply.
4 Isolate the fuel supply to the boiler.
4 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.

GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
4
APPLIANCE
INFORMATION
A
B
780mm
950mm
565mm
C
D
E
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler for
open vent and sealed domestic central heating
and mains fed hot water.
B - Literature pack.
C -Condensate trap kit.
D - Hardware pack.
E - 100mmØ services duct.
Check List
Item Qty
Greenstar Camray External Installation/Servicing Instructions............1
Users Instructions ..........................................................................................1
Hardware Pack.................................................................................................1
100mm Ø Services Duct...............................................................................1
Condensate Trap Kit.......................................................................................1
Warranty Return Envelope ............................................................................1

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
5
TECHNICAL DATA
Central Heating
Primary water capacity (total) litres
Maximum static head metres
Minimum static head metres
Water side resistance (20°C difference) mbar
Max. permissible sealed system operating pressure bar
in accordance with WRAS guidelines
Flue
Exit flue gas mass flow kg/hr
Pipework connections
Fuel line (compression) mm
Return mm
Flow/optional open vent BSP
Drain/optional feed and expansion BSP
Condensate (polypropylene) mm
Electrical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption W
Thermostats
Control thermostat range (cut in/cut out) °C
Control thermostat differential °C
Boiler high limit thermostat set point °C
Boiler manual reset overheat thermostat set point °C
Flue reset overheat thermostat set point °C
General Data
Maximum hearth temperature °C
SEDBUK (Band A) %
Appliance protection rating IP
Weight (excluding packaging) kg
Emissions class for NOx and CO class
DESCRIPTION UNITS 12/18 18/25 25/32
APPLIANCE
INFORMATION
23
30
1
26
2.5
29
10
22
1
3/4
21.5
230
50
150
55/81
5
95
105
110
<100
93.1
45
114
3
23
30
1
52
2.5
40
10
22
1
3/4
21.5
230
50
160
55/81
5
95
105
110
<100
93.2
45
115
3
21
30
1
69
2.5
51
10
28
11/4
3/4
21.5
230
50
160
55/81
5
95
105
110
<100
94.2
45
122
3

LAYOUT & COMPONENTS
The diagram opposite excludes the top, front
and RH side casing panels.
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 FLUE OVERHEAT THERMOSTAT PHIAL
4 AIR INLET CASING
5 FLEXIBLE AIR DUCT (CONNECTING TO
AIR INTAKE ON BURNER)
6 CASING SUPPORT PANEL
7 SECONDARY HEAT EXCHANGER
BLEED POINT (ONE ON EITHER SIDE)
8 HEAT EXCHANGER FLOW PIPE
9 SECONDARY HEAT EXCHANGER
10 SECONDARY HEAT EXCHANGER
DRAIN
11 CONDENSATE OUTLET
12 FLOW/OPTIONAL OPEN VENT
CONNECTION
13 BAFFLE RETAINER ACCESS DOOR
14 CONTROL & MANUAL RESET
OVERHEAT THERMOSTAT PHIAL
15 AUTO-RESET HIGH LIMIT
THERMOSTAT PHIAL
16 PRIMARY HEAT EXCHANGER
17 CONDENSATE TRAP (supplied)
18 COMBUSTION CHAMBER ACCESS
DOOR
19 DRAIN/OPTIONAL FEED &
EXPANSION CONNECTION
20 BASE PLATE AND OIL DRIP TRAY
21 OIL SUPPLY ISOLATING VALVE
22 DEFLECTOR PLATE
23 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (5) TO AIR
INLET CASING (4) )
24 BURNER MOTOR (BEHIND PLASTIC
COVER)
25 OIL PUMP (BEHIND PLASTIC COVER)
26 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
27 BURNER CONTROL BOX (BEHIND
PLASTIC COVER)
28 RIELLO RDB BURNER
29 FLUE MANIFOLD ACCESS COVER
30 FLUE GAS SAMPLING POINT
31 DATA LABEL
32 MODE SWITCH
33 BOILER OVERHEAT RESET BUTTON
34 FLUE OVERHEAT RESET BUTTON
35 TEMPERATURE CONTROL KNOB
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
6
APPLIANCE
INFORMATION
1
2
37
456
8
10
12
11
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
29
30
31
32
33
34
35 9
28

CLEANING PRIMARY SYSTEMS
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK IS
IN GOOD WORKING ORDER.
FLUSH THE EXISTING SYSTEM WITH A
POWER FLUSHING MACHINE OR WITH A
CHEMICAL CLEANER BEFORE
INSTALLING NEW COMPONENTS.
CLEANING THE PRIMARY SYSTEM:
4Cleanse the system in accordance with
BS 7593.
4Fill the system with cold mains water to the
recommended pressure and check for leaks.
4Open all drain cocks and drain the system.
4Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
4Circulate the flushing agent before the boiler
is fired up.
4Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
4Drain and thoroughly flush the system to
remove the flushing agent and any debris.
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
the use of water treatment with the
appliance will invalidate the appliance
warranty.
CLEANING PRIMARY SYSTEMS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
7
PRE -
INSTALLATION

MAINS SUPPLY
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2(24 x
0.2mm) temperature rated to 90°C.
• Protection IP45.
• External 5A fuse to BS 1362.
• The appliance must be earthed.
• Please refer to IEE regulations for cross
bonding requirements.
• 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.
MAINS SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
8
PRE -
INSTALLATION
IMPORTANT: The appliance provides a permanent external electrical supply
for servicing and must therefore be fed via a circuit breaker incorporating
earth leakage protection.

OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
9
PRE -
INSTALLATION
OIL SUPPLY
OIL SUPPLY :
•This appliance is suitable for 28 second
kerosene 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.
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 addi-
tion 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).
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).
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).
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.
Pipework
4Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump (J).
4Lay 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.
4Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
4Fit an oil strainer and water seperator (C) to
the oil supply pipe, near the oil storage tank.
Fit an additional oil filter (N, 16µmmax
filtration size) close to the boiler, but not
inside the boiler casing.
4Fit 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)
located within the appliance case.
A fire valve with a shut off temperature of
85°C or higher is recommended to avoid
the possibility of nuisance shut offs.
A capillary type valve provides a neat and
simple installation. Alternatively, a fusible
link or electrical system may be used.
Under no circumstances should a
combination isolating/fire valve be used
as the sole fire protection device.
AF
BN GJ
4m (13ft) max.
K
a)
H
300mm min.
B DB C
MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM
B
A
DB
C
E
K
3.5m (11.5ft) max.
L
L
b)
H
FG
B
150mm
MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM
NJ
B
A
M
B
F
C
G
J
3.5m (11.5ft) max.
E
D
c)
MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR
H
FUEL FLOW RATE FUEL FLOW RATE
K
E
1m min
1m min
1m min
A - Oil storage tank.
B - Isolating valve.
C - Oil strainer & water seperator.
D - Fire valve to BS 5410.
E - External casing.
F - Fire valve sensor.
G - Oil burner.
H - Oil supply pipe.
J - Oil pump.
K - Full base (plastic tanks).
L - Non-return valve.
M - De-aerator.
N - Oil filter (16µmmax filtration size)
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.
HEAD 10mmØ 12mmØ
0.5 12 30
1.0 25 69
1.5 37 91
2.0 49 100
HEAD 10mmØ 12mmØ
2.5 62 100
3.0 74 100
3.5 87 100
4.0 99 100
HEAD 10mmØ 12mmØ
050 100
0.5 44 100
1.0 38 95
1.5 32 80
HEAD 10mmØ 12mmØ
2.0 26 66
2.5 20 50
3.0 14 37
3.5 8 22
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
0 100 55 26 100
0.5 95 45 23 100
1.0 80 40 20 90
1.5 70 35 17 75
HEAD 2.5kg/h 5kg/h 10kg/h 10kg/h
8mmØ 8mmØ 8mmØ 10mmØ
2.0 60 30 14 65
2.5 45 25 11 50
3.0 35 15 8 35
3.5 25 10 5 20
The table and illustration above is a guide only and does not in any way override the de-
aerator manufacturers instructions.

WATER SYSTEMS & PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
10
PRE -
INSTALLATION
R
TYPICAL OPEN VENT SYSTEM:
A - Appliance.
B - Expansion vessel.
C - Automatic bypass valve.
D - Drain cock.
E - Feed and expansion cistern.
F - Feed and expansion
15mmØ min.
G - Pressure gauge.
H - Open vent 22mmØ min.
J - Circulating pump.
K - Zone valve.
L - Lockshield valve.
M - Hot water cylinder.
N - Automatic air vent.
P - Pressure relief
discharge.
R - Radiators.
S - Static head.
T - Thermostatic radiator
valve (TRV).
U - To filling system.
E
1000mm min.
FH
A
R R
R R
D
C
TLTL
TL TL
JK
M
150mm max.
K
TYPICAL SEALED SYSTEM:
A
D
R R
R
B
P
D
C
TLTL
TL TL
G
JK
M
N
D
U
S
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
•Do not use plastic pipework on sealed
systems, *apart from underfloor heating
correctly installed as detailed below.
• Any plastic pipework used on an open vented
system must have a polymeric barrier with
1000mm (minimum) length of copper or steel
pipe connected to the boiler.
•*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.
The pipework from the boiler to the blending
valve must be in copper or steel (protected
from corrosion).
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 BS1010.
• 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.
• 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).
• 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.
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.
IMPORTANT: The boiler should not be
allowed to operate with a return
temperature of less than 40°C when the
system is up to operating temperature.

WATER SYSTEMS & PIPEWORK
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.
Heating return
Hose
return
Non return
valve Non return valve
Test cock
Stop
cock
Water main
supply
Stop
cock
Temporary hose
Heating return Auto air
vent Non return
valve
Stop
cock
Make up
vessel
1000mm above
the highest point
of the system
Fill Point
INSTALLATION
COMMISSIONING
WATER SYSTEMS & PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
11
PRE -
INSTALLATION

CONDENSATE &
PRESSURE RELIEF PIPEWORK
CONDENSATE PIPEWORK:
• 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.
• 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.
• The pipework must follow one of the options
shown opposite:
a - Internal waste drainage system
b - Soil/vent stack
c - External drainage system
d - External condensate absorption point
• Use waterproof pipe insulation in exposed
positions and for external pipework
IMPORTANT: Condensate pipework must not
leak and must discharge into a condensate trap
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 - 21.5mmØ polypropylene condensate pipe.
D - Gully.
E - Internal soil and vent stack.
F - 300mm x 100mmØ sealed plastic tube.
G - Ground level.
H - Drainage holes 50mm from base of tube
(12mmØ at 25mm centres) facing away
from building.
I - Limestone chippings.
PRESSURE RELIEF PIPEWORK:
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-External boiler casing.
K- Drain pipe.
K
J
b
E
C
Invert
450 min.
A
c
D
A
C
75mm
min.
a
A
BC
D
400mm
min.
500mm min.
d
F
I
H
G
A
C
25mm
min.
200mm min.
CONDENSATE &
PRESSURE RELIEF PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
12
PRE -
INSTALLATION

BOILER LOCATION &
CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
13
PRE -
INSTALLATION
BOILER LOCATION &
CLEARANCES
WARNING:
This appliance should not be installed where
there is a potential for excessive ground
water coverage.
This boiler is only suitable for installing
externally at a suitable location onto a fixed
permanent rigid surface capable of
supporting the boiler weight.
There must be a sufficient hard standing
around the appliance to allow for servicing.
The boiler must be installed on a flat level
surface to ensure that condensate does not
enter the primary heat exchanger.
Tarmac and wood hardstandings are not
recommended.
CLEARANCES: Min service & flue clearances
Above 600m
Front 600m
RH/LH clearance flue outlet on opposite side: 10mm
RH clearance flue outlet on rear: 45mm
LH clearance flue outlet on rear: 85mm
Rear clearance flue outlet on side: 50mm
Rear clearance flue outlet on rear: 2500mm
It is strongly recommended that the flue
terminal faces away from walls to reduce the
possibility of wetting occuring.
600mm
2500mm
600mm
BASE
FRONT
FRONT
2500mm
50mm
45mm85mm
600mm
10mm
600mm
2500mm
FRONT FRONT
2500mm
10mm
600mm
50mm
Plan
view
Plan
view
Plan
view
600mm min

FLUE TERMINAL POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
14
PRE -
INSTALLATION
Minimum dimensions of flue terminal positions for oil-fired appliances:
TERMINAL POSITION B(H)
A 1Directly below an opening, air brick, opening windows, etc 600mm
B 1Horizontally to an opening, air brick, opening window, etc 600mm
C Below a plastic/painted gutter, drainage pipe or eaves if 75mm
combustible material protected
D 2Below a plastic/painted gutter, drainage pipe or eaves without 600mm
protection to combustible material
E From vertical sanitary pipework 300mm
F From an external or internal corner or from a surface or boundry 300mm
alongside the terminal
G Above ground or balcony level 300mm*
H From a surface or boundary facing the terminal 2500mm**
I From a terminal facing the terminal 2500mm**
K Horizontally from a terminal on the same wall 750mm
B(H) Balanced Horizontal flue
1 An opening means an openable
element, such as an openable
window, or a permanent opening
such as a permanently open air vent.
Notwithstanding the dimensions
above, a terminal should be at least
300mm from combustible material,
e.g. a window frame.
2 A way of providing protection of
combustible material would be to fit
a heat shield at least 750mm wide.
FLUE TERMINAL POSITIONS
• Flue terminals must be positioned to avoid
combustion products entering into buildings.
• 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.
• 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
• A protective terminal guard must be fitted if
the terminal is 2m or less above a surface
where people have access.
The guard must be spaced equally (minimum
50mm) around the flue and fixed with plated
screws.
• 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.
boundary
F
I
H
B
A
G
E
C, D
F
F
J
K
boundary

BALANCED FLUE OPTIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
15
PRE -
INSTALLATION
BALANCED FLUE OPTIONS
• The balanced flue is fitted to the rear or either
side of the cabinet.
IMPORTANT:
It is strongly recommended that the flue
terminal faces away from walls to
minimise the occurance of wetting.
A - External horizontal flue kit
Part No. 7 716 190 052
B - 90° inline elbow 80/125mm
Part No. 7 716 190 034
C - Terminal guard (not included in flue kit)
Part No. 7 716 190 050
FRONT
FRONT
FRONT
Plan
view
Plan
view
Plan
view
REAR FLUE OUTLET
A + C
RIGHT HAND FLUE OUTLET
A + B + C
LEFT HAND FLUE
OUTLET
A + B + C

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.
1 4Once 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.
24Lift carton up and away from the boiler.
4Remove the plastic bag from the boiler and
place safely aside.
UNPACKING THE BOILER
LIFTING AND CARRYING PRECAUTIONS:
• Lift only a manageable weight, or ask for
help.
•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.
IIMPORTANT: All the previous Pre-Installation sections must be read
and requirements met before starting boiler or flue installation.
1
2
INSTALLATION
UNPACKING THE BOILER
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
16

All dimensions in mm
295
490
102 793
254
91
105
259
259
171
490
793
590
466
105
94 55
263
659
669
704
714
490
791
590
463
159
124 90 55
659
679
699
719
559
224
INSTALLATION
COMMISSIONING
SAFETY:
All relevant safety precautions must be undertaken.
Protective clothing, footwear, gloves and safety
goggles must be worn as appropriate.
PIPEWORK CONNECTIONS:
Flow/open vent 1” BSP 12/18, 18/25.
11/4” BSP 25/32.
Primary drain/cold feed 3/4” Ø BSP.
Return 22mm Ø copper 12/18, 18/25.
28mm Ø copper on 25/32 model.
Flue outlet 80/125mm Ø.
Condensate outlet 21.5mm Ø.
NOTE: For servicing purposes, keep the
condensate and pressure relief discharge
pipes away from components and pipework
connections.
CAUTION: Ensure there are no pipes,
electric cables, damp proof courses or
other hazards before drilling.
PIPEWORK & FLUE POSITIONS
PIPEWORK & FLUE POSITIONS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
17
Condensate
Flue
Services
PRV
Fire valve capillary
& drain access
Flue
Services
Condensate
PRV
Oil
Flue
Services
Condensate
Oil
PRV
LEFT HAND SIDE
RIGHT HAND SIDE
REAR
Fire valve capillary
& drain access

BOILER INSTALLATION
Note: The cabinet is not load bearing it
only provides weather protection for the
boiler inside.
14Mark position of the 100mm services
duct on the exterior wall and make a hole
through.
24Remove the screws from the bottom of
the front and rear panels and pull the
panels out and down to remove. Store
safely away from the installation point.
34Remove the screws from the top panel
and lift up to remove, store safely away
from the installation point.
44Remove the screws securing the control
box to the side panels and carefully rest
the control box on top of the heat
exchanger taking care not to snag or kink
the capillaries.
54Remove the screws securing the side
panels to the base panel and lift the side
panels off complete with the rear support
bar (shaded grey) and carefully stand the
panels away from the installation point.
6a4Loosen the flexable air duct clamp (A)
and remove the air duct from the burner.
6b 4Depress the locking ears to unplug the
burner lead (B) from the control box (C).
6c 4Undo the two screws securing the
deflector plate (D) and remove the plate.
6d 4Undo and remove the retaining nut (E)
on top of the burner. The burner
mounting (F) can now be eased
off the lug (G) on the burner collar to
remove the burner from the heat
exchanger. Store the burner and
retaining nut safely away from the boiler.
74Remove the screws securing the base
panel to the transit pallet and lift the boiler
off the pallet and into its installation
position taking care not to scrape the
base panel across the hard standing. Do
not attempt to lift and position the
boiler on your own. Do not use the
copper pipes to move the boiler.
4Fasten the base to the hard standing
using the holes provided. Care should be
taken to ensure that the base is level.
84Refit the side panels and rear support
bar and screw the side panels to the
baseplate and boiler.
4Refit the control box taking care not to
kink the capillary tubes.
4Measure the 100mmØ services duct to
give at least 10mm inside the casing and
to finish flush with the interior wall
surface, cut to size and fit the duct. Fit the
100mm sealing ring where the duct
enters the casing and seal the joint to the
exterior wall and inside the cabinet with a
suitable sealant.
BOILER INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
18
INSTALLATION
WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY.
EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR
REPAIRED UNDER ADVERSE WEATHER CONDITIONS.
THIS APPLIANCE IS INSTALLED AND SERVICE EXTERNALLY TO THE PROPERTY, BUT THE
ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING
OR SERVICING THE APPLIANCE.
2
2
3
4
5
D
6a A
6b
B
C
6c
D
6d
EF
G

INSTALLATION NOTES:
4Ensure all the seals are in good condition
and seated properly.
4To ease assembly of flue components,
grease seals lightly with the solvent free
grease supplied.
4A terminal guard must be fitted if the
terminal is 2m or less above a surface where
people have access.
All flue options:
1 4Lightly grease the flue cowl seal with the
solvent free grease supplied.
2 4Remove the panel blanking plate from the
relevant flue aperture (if necessary) and
refit the blanking plate in the unused
aparture.
3 4Carefully remove the insulation from
the aperture in the cabinet panel the flue is
to pass through.
4 4Fit the gasket (B) to the back of the air box
rear (A) and bolt the air box rear to the
cabinet panel with the M5 nuts provided.
5 4Carefully mark and cut the 80mmØ flue
pipe (H) to the length given in the chart
below. Make sure the cut is square to the
tube, remove any burrs and chamfer the
outside edge to assist in insertion into the
seal.
Rear flue outlet: 470mm*
Left hand flue outlet: 235mm**
Right hand flue outlet: 270mm
* For the right hand flue option reduce the air
inlet outer section by 100mm, carefully cut
square and remove burrs after cutting.
** The air inlet outer section is not needed for
this outlet position.
Rear flue options:
6.0 4Fit the air inlet inner section (K) to the
boiler flue cowl and secure with the clamp
(L).
6.1 4Fit the air inlet outer section (J) over the
inner section (K), push through the panel
so that the end of the tube is flush with the
tag (A1) on the air box rear (A) and secure
the tag with one of the longer self tapping
screws provided.
6.2 4Carefully drill the inner section (K) with
the drill bit and secure to the outer section
(J) with one of the longer self tapping
screws provided.
FLUE INSTALLATION
A - Air box rear.
A1- Tag.
B - Air box rear gasket.
C - Air box front.
D - Retaining bracket.
E - Terminal guard support.
F - Air inlet cover.
G - Flue terminal.
H - 80mmØ Flue pipe.
J - Air inlet outer section.
K - Air inlet inner section.
L - Inlet clamp.
M - Stainless steel terminal guard (not supplied, Part No. 7 716 190 050).
N - Accessory pack.
Note: To use the right hand or left hand flue options a 90° swept flue elbow
is required, (Part No. 7 716 190 034).
L
K
J
H
M
DC
A
A1
N
F
G
E
B
FLUE INSTALLATIONINSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32
8 716 112 700a (02.07)
19
INSTALLATION
Cut
here Measure here
80mmØ flue
pipe
IMPORTANT: REFER TO FLUE INSTALLATION MANUAL FOR MORE
INFORMATION.