Worcester 12/18 User manual

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

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
1
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
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.
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply
Check List
Item Qty
Greenstar Camray Kitchen Installation/Servicing Instructions............1
Users Instructions ..........................................................................................1
Fascia Information Card.................................................................................1
Warranty Return Envelope ............................................................................1
Guarantee Registration Card........................................................................1
Condensate Trap Kit........................................................................................1
Return Pipe Kit..................................................................................................1
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 com-
missioning 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.

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 13-14
FLUE TERMINAL POSITIONS 15
CONVENTIONAL FLUE 16
ROOM SEALED FLUE OPTIONS 17
INSTALLATION
UNPACKING THE BOILER 18
PIPEWORK POSITIONS & FLUE OPENING 19
BOILER INSTALLATION 20
FLUE INSTALLATION 21
COMBUSTION CHAMBER 22
PIPEWORK CONNECTIONS 23
OIL BURNER AND PUMP 24
REFITTING COMPONENTS 25
ELECTRICS 26-31
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE 32
FILLING THE SYSTEM 33
STARTING THE APPLIANCE 34-37
WATER TREATMENT 38
FINISHING COMMISSIONING - APPLIANCE 39
SERVICING & SPARES
INSPECTION AND SERVICE 40-43
SHORT PARTS LIST 12/18 44
SHORT PARTS LIST 18/25 45
SHORT PARTS LIST 25/32 46
FAULT FINDING & DIAGNOSIS
FAULT FINDING 47-48
FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX 49
COMBUSTION RECORD 50
SERVICE INTERVAL RECORD 51
BAFFLE ARRANGEMENT DIAGRAM BACK PAGE
CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
2
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE -
INSTALLATION
INSTALLATIONCOMMISSIONING
SERVICING
& SPARES
FAULT FINDING
& DIAGRAMS

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
3
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
4 Extinguish any naked flames.
4 Open windows and doors.
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.
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 KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
4
APPLIANCE
INFORMATION
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing oil fired condensing boiler.
B - Literature pack.
C -Condensate trap kit.
D - Return pipe kit.
855mm
600mm
A
370mm
C
B
Check List
Item Qty
Greenstar Camray Kitchen Installation/Servicing Instructions............1
Users Instructions ..........................................................................................1
Fascia Information Card.................................................................................1
Warranty Return Envelope ............................................................................1
Guarantee Registration Card........................................................................1
Condensate Trap Kit........................................................................................1
Return Pipe Kit..................................................................................................1
D

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
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
Flow/optional vent BSP
Return mm
Primary drain BSP
Condensate (polypropylene) mm
Electrical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption W
Thermostats
Boiler flow temperature 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 (with programmer blanking plate fitted) IP
Appliance protection rating (with fascia programmer fitted) 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
1
22
3/4
21.5
230
50
150
55/81
5
95
105
110
<100
93.1
20
20
101
3
23
30
1
52
2.5
40
10
1
22
3/4
21.5
230
50
160
55/81
5
95
105
110
<100
93.2
20
20
102
3
21
30
1
69
2.5
51
10
11/4
28
3/4
21.5
230
50
160
55/81
5
95
105
110
<100
94.2
20
20
109
3

1
25
34
8
11
18
19
12
30
29
28
32
34
33
31
26
25
22
23
a
16
27
6
9
7
10
13
14
15
17
20
21
24
LAYOUT & COMPONENTS
The diagram opposite excludes the top, front
and RH side casing panels.
1 CONTROL BOX ASSEMBLY
2 CASING SIDE PANEL
3 FLUE GAS SAMPLING POINT
4 FLUE MANIFOLD ACCESS COVER
5 FLUE OVERHEAT THERMOSTAT PHIAL
6 POWER CABLE CLIP
7 FIRE VALVE SENSOR CLIP
8 AIR INLET CASING
9 FLEXIBLE AIR DUCT (CONNECTING TO
AIR INTAKE ON BURNER)
10 SECONDARY HEAT EXCHANGER
BLEED POINT (ONE ON EITHER SIDE)
11 SECONDARY HEAT EXCHANGER
12 SECONDARY HEAT EXCHANGER
DRAIN
13 CONDENSATE OUTLET
14 BAFFLE RETAINER ACCESS DOOR
15 HEAT EXCHANGER FLOW PIPE
16 CONTROL & MANUAL RESET
OVERHEAT THERMOSTAT PHIAL
17 AUTO-RESET HIGH LIMIT
THERMOSTAT PHIAL
18 PRIMARY HEAT EXCHANGER
19 COMBUSTION CHAMBER ACCESS
DOOR
20 BASE PLATE AND OIL DRIP TRAY
21 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (9) TO AIR
INLET CASING (8) )
22 BURNER MOTOR (BEHIND PLASTIC
COVER)
23 OIL PUMP (BEHIND PLASTIC COVER)
24 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
25 BURNER CONTROL BOX (BEHIND
PLASTIC COVER)
26 RIELLO RDB BURNER
27 OIL SUPPLY ISOLATING VALVE
28 DEFLECTOR PLATE
29 BOILER OVERHEAT RESET BUTTON
30 FLUE OVERHEAT RESET BUTTON
31 QUICK REFERENCE GUIDE SLOT
32 LOCKOUT INDICATOR
33 TEMPERATURE CONTROL KNOB
34 DEMAND INDICATOR
OPTIONAL ACCESSORIES (not supplied)
a - 7 day TWIN CHANNEL DIGITAL
PROGRAMMER
Part No. 7 716 192 033
LAYOUT & COMPONENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
6
APPLIANCE
INFORMATION

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 KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
7
PRE -
INSTALLATION

MAINS SUPPLIES
ELECTRIC SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm2(24 x
0.2mm) temperature rated to 90°C.
• Protection IP20.
• External 5A fuse to BS 1362.
• The appliance must be earthed.
• All pipes to the boiler must be
cross-bonded.
• 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 SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
8
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 B S5410.
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
OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32
8 716 113 000a (01/07)
9
PRE -
INSTALLATION
A - Oil storage tank.
B - Isolating valve.
C - Oil strainer & water seperator.
D - Fire valve to BS 5410.
E - External wall.
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
0 50 100
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.