Worcester GREENSTAR CAMRAY EXTERNAL User manual

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

INSTALLATION &
SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
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;
OFTEC must be informed about every installation.
OFTEC 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:
Ø Diameter
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
CF Conventional flue
BF Balanced flue
N/A Not allowed
SEDBUK Seasonal Efficiency of Domestic Boilers in the United Kingdom
OFTEC Oil Firing Technical Association for the Petroleum Industry
IEE Institute of Electrical Engineers
LABC Local Authority Building Control Body
STORE THE APPLIANCE IN A DRY AREA PRIOR TO INSTALLATION.
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
Electricity supply
Check List Hardware/Literature pack
Item Qty
Greenstar Camray External/External System Installation/Servicing
Instructions.......................................................................................................1
Users Instructions ..........................................................................................1
Hardware Pack.................................................................................................1
100mm Ø Services Duct...............................................................................1
Condensate Trap Kit.......................................................................................1
Warranty Return Envelope ............................................................................1
Cabinet Key.......................................................................................................1

CONTENTS
CONTENTS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
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 CAMRAY EXTERNAL 6
LAYOUT & COMPONENTS CAMRAY EXTERNAL SYSTEM 7
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 8
MAINS SUPPLY 9
OIL SUPPLY 10
WATER SYSTEMS & PIPEWORK 11-12
CONDENSATE PIPEWORK 13
PRESSURE RELIEF PIPEWORK 14
BOILER LOCATION & CLEARANCES 15
LOW LEVEL FLUE TERMINAL POSITIONS 16
HIGH LEVEL FLUE TERMINAL POSITIONS 17
BALANCED FLUE OPTIONS 18 -19
INSTALLATION
UNPACKING THE BOILER 20
PIPEWORK & FLUE POSITIONS 21
BOILER INSTALLATION 22
FLUE INSTALLATION 23
COMBUSTION CHAMBER 24
PIPEWORK CONNECTIONS 25-26
OIL BURNER AND PUMP 27
REFITTING COMPONENTS 28
ELECTRICS 29-33
COMMISSIONING
PRE-COMMISSIONING CHECKS - APPLIANCE 34
FILLING THE SYSTEM 35
STARTING THE APPLIANCE 36-39
WATER TREATMENT 40
FINISHING COMMISSIONING - APPLIANCE 41
SERVICING & SPARES
INSPECTION AND SERVICE 42-48
( INSPECTION AND SERVICE - BAFFLE ARRANGEMENTS 45-47 )
SHORT PARTS LIST 12/18 RIELLO 49
SHORT PARTS LIST 18/25 RIELLO 50
SHORT PARTS LIST 25/32 RIELLO 51
FAULT FINDING & DIAGNOSIS
FAULT FINDING 52-54
FAULT FINDING LOGIC FOR 535 SE/LD RDB CONTROL BOX 55
COMBUSTION RECORD 56
SERVICE INTERVAL RECORD 57
NOTES 58

SAFETY PRECAUTIONS
& INSTALLATION REGULATIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
3
SAFETY &
REGULATIONS
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:
 Extinguish any naked flames.
 Isolate the electrical supply.
 Isolate the fuel supply to the boiler.
 Rectify fault.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the construction
process that contravene the COSHH Regulations (Control of Substances Hazardous to Health
Regulations 1988). Where applicable, the CE mark indicates compliance with relative EU
Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside or within the
vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances which can corrode
the appliance and invalidate any warranty.
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by a competent
engineer in accordance with these instructions and the relevant Installation Regulations.
Flue systems must not be modified in any way other than as described in the fitting instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated components and
systems could invalidate the warranty. The manufacturer accepts no liability arising from any
such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified engineer (such
as OFTEC registered personnel) using approved spares, to help maintain the economy, safety
and reliability of the appliance.
Failure to install appliances correctly could lead to
prosecution.
The appliance should be installed by a competent
person. The person installing the appliance should
be aware of the Health and Safety at Work Act and
take appropriate action to ensure that the
regulations are adhered to. In order to give
optimum efficiency and trouble free operation the
appliance must be commissioned by a qualified
OFTEC engineer.
The compliance with a British Standard does not,
in itself, confer immunity from legal obligations. In
particular the installation of this appliance must be
in accordance with the relevant requirements of the
following British Standards and regulations in
respect of the safe installation of equipment:
BS 5410: part 1: Code of practice for Oil Fired
Boilers.
BS 799: part 5: Specification for Oil Storage
Tanks.
BS 7593: Code of Practice for treatment of water
in domestic hot water central heating systems.
BS 5449: part 1: Specification for forced
circulation hot water central heating for domestic
premises.
BS 5955: part 8: Specification for the installation
of thermoplastic pipes and associated fittings for
use in domestic hot and cold water services and
heating systems.
BS 7291: Thermoplastic pipes and associated
fittings for hot and cold water for domestic
purposes and heating installations in buildings.
BS 7074: part 1: Application, selection and
installation of expansion vessels and ancillary
equipment for sealed water systems.
BS 7671: IEE Wiring Regulations, current edition.
BS 1362: Specification for general purpose fuse
links for domestic and similar purposes.
The Building Regulations Part J and L1 England
and Wales; Part F and Part J Section III Scotland;
Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
OFTEC Standards.
Where no specific instruction is given, reference
should be made to the relevant codes of practice.

GENERAL INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
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 domestic hot water cylinders.
B - Literature pack.
C -Condensate trap kit.
D - 100mmØ services duct.
E - Cabinet key
Check List
Item Qty
Greenstar Camray External/External System Installation/Servicing
Instructions.......................................................................................................1
Users Instructions ..........................................................................................1
Hardware Pack.................................................................................................1
100mm Ø Services Duct...............................................................................1
Condensate Trap Kit.......................................................................................1
Warranty Return Envelope ............................................................................1
Cabinet Key.......................................................................................................1

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
5
APPLIANCE
INFORMATION
TECHNICAL DATA
Central Heating
Primary water capacity (total) External litres
Primary water capacity (total) External System litres
Maximum static head metres
Minimum static head metres
Water side resistance (20°C difference) External mbar
Max. available pumphead (20° difference) External System mH2O
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
External System flow mm
External flow and optional vent/air vent BSP
Primary drain BSP
Condensate (polypropylene) mm
Pressure relief valve outlet - External System mm
Electrical
Electrical power supply voltage AC...V
Frequency Hz
Max. power consumption External W
Max. power consumption External System 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 manual reset overheat thermostat set point °C
General Data
Maximum hearth temperature °C
SEDBUK (Band A) %
Appliance protection rating IP
Weight (excluding packaging) External kg
Weight (excluding packaging) External System kg
Expansion vessel (External System only) litres
Emissions class for NOx and CO class
Typical NOx emission figures mg/kWhr
DESCRIPTION UNITS 12/18 18/25 25/32
23
30
30
1
26
5.7
2.5
29
10
22
1
3/4
21.5
15
230
50
150
255
55/81
5
95
105
110
<100
93.1
45
114
133
12
3
209
23
30
30
1
52
4.9
2.5
40
10
22
1
3/4
21.5
15
230
50
160
265
55/81
5
95
105
110
<100
93.2
45
115
134
12
3
198
21
28
30
1
69
4.1
2.5
51
10
28
11/4
3/4
21.5
15
230
50
160
265
55/81
5
95
105
110
<100
94.2
45
122
152
12
3
156

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 SECONDARY HEAT EXCHANGER
9 SECONDARY HEAT EXCHANGER
DRAIN
10 CONDENSATE OUTLET
11 FLOW/OPTIONAL OPEN VENT
CONNECTION
12 BAFFLE RETAINER ACCESS DOOR
13 CONTROL & MANUAL RESET
OVE R H E AT TH E R M OSTAT P H IAL &
14 AUTO-RESET HIGH LIMIT
TH E R M OSTAT P H IA L (LO CAT IO N)
15 PRIMARY HEAT EXCHANGER
16 CONDENSATE TRAP & BRACKET (supplied)
17 COMBUSTION CHAMBER ACCESS
DOOR
18 DRAIN/OPTIONAL FEED &
EXPANSION CONNECTION
19 BASE PLATE AND OIL DRIP TRAY
20 DEFLECTOR PLATE
21 OIL SUPPLY ISOLATING VALVE
22 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (5) TO AIR
INLET CASING (4) )
23 BURNER MOTOR
24 OIL PUMP (BEHIND PLASTIC COVER)
25 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
26 BURNER CONTROL BOX
27 RIELLO RDB BURNER
28 RIELLO RDB BURNER COVER
29 FLUE MANIFOLD ACCESS COVER
3 0 DATA LA B E L
31 FLUE GAS SAMPLING POINT
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 &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
6
APPLIANCE
INFORMATION
1
2
37
456
8
9
11
10
12
13 & 14 (location)
15
16
17
19
20
21
22
232425
26
28
29
30
32
33
34
35
27
18
31
LAYOUT & COMPONENTS
CAMRAY EXTERNAL

LAYOUT & COMPONENTS INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
7
PRE -
INSTALLATION
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 SECONDARY HEAT EXCHANGER
9 SECONDARY HEAT EXCHANGER
DRAIN
10 CONDENSATE OUTLET
11 FLOW/OPTIONAL OPEN VENT
CONNECTION (NOT USED ON SYSTEM)
12 BAFFLE RETAINER ACCESS DOOR
13 CONTROL & MANUAL RESET
OVE R H E AT TH E R M OSTAT P H IAL &
14 AUTO-RESET HIGH LIMIT
TH E R M OSTAT P H IA L (LO CAT IO N)
15 SYSTEM EXPANSION VESSEL
16 PRIMARY HEAT EXCHANGER
17 CONDENSATE TRAP & BRACKET (supplied)
18 COMBUSTION CHAMBER ACCESS
DOOR
19 DRAIN/OPTIONAL FEED &
EXPANSION CONNECTION
20 BASE PLATE AND OIL DRIP TRAY
21 DEFLECTOR PLATE
22 OIL SUPPLY ISOLATING VALVE
23 BURNER AIR INTAKE (CONNECTED
BY FLEXIBLE DUCT (5) TO AIR
INLET CASING (4) )
24 BURNER MOTOR
25 OIL PUMP (BEHIND PLASTIC COVER)
26 LOCKOUT RESET BUTTON (ON FRONT
OF BURNER CONTROL BOX)
27 BURNER CONTROL BOX
28 RIELLO RDB BURNER
29 RIELLO RDB BURNER COVER
30 FLUE MANIFOLD ACCESS COVER
31 DATA LABEL
32 FLUE GAS SAMPLING POINT
33 SYSTEM PUMP ASSEMBLY
34 SYSTEM PRESSURE RELIEF VALVE
35 SYSTEM FLOW PIPE
36 MODE SWITCH
37 SYSTEM PRESSURE GUAGE
38 BOILER OVERHEAT RESET BUTTON
39 FLUE OVERHEAT RESET BUTTON
40 TEMPERATURE CONTROL KNOB
1
2
37
456
8
9
11
10
12
13 & 14 (location)
16
17
18
20
21
22
23
242526
27
29
30
31 33
38
39
40
28
19
32
15
34
35
36
37
LAYOUT & COMPONENTS
CAMRAY EXTERNAL SYSTEM

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:
Cleanse the system in accordance with
BS 7593.
Fill the system with cold mains water to the
recommended pressure and check for leaks.
Open all drain cocks and drain the system.
Close drain cocks and add a suitable flushing
agent at the correct strength for the system
condition in accordance with the manufacturer's
instructions.
Circulate the flushing agent before the boiler
is fired up.
Run the boiler and system at normal operating
temperature in accordance with the
manufacturer's instructions.
Drain and thoroughly flush the system to
remove the flushing agent and any debris.
Refil with clean water and inhibitor to
manufacturers instructions.
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 &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
8
PRE -
INSTALLATION

MAINS SUPPLY
ELECTRICAL 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.
IMPORTANT: The appliance provides a permanent external electrical supply
for servicing and must therefore be fed via a circuit breaker incorporating
earth leakage protection.
MAINS SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
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) may 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
Use copper pipe of the correct diameter
according to the information shown opposite.
Use flexible hoses to connect to the oil pump (J).
Lay the oil supply pipe (H) as straight and
level as possible to avoid air pockets and
unnecessary friction losses. Route away
from the boiler access door or other hot
surfaces.
Install a manual isolating valve (B) to the oil
supply pipe (H), as close to the oil storage
tank (A) as possible.
Fit an oil strainer and water seperator (C) to
the oil supply pipe, near the oil storage tank.
Fit an additional oil filter (N, 16µmmax
filtration size) close to the boiler, but not
inside the boiler casing.
Fit a fire valve in accordance with BS 5410.
The fire valve (D) should be fitted externally
to the building with the fire valve sensor (F)
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.
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.
OIL SUPPLY
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
10
PRE -
INSTALLATION

R
A - Appliance.
B - Additional expansion
vessel (if required).
C - Automatic bypass valve.
D - Drain cock.
E - Feed and expansion
cistern.
F - Feed and expansion
15mmØ min.
G - Pressure gauge
(System models only).
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.
V - Appliance expansion
vessel (System models
only).
E
1000mm min.
FH
A
R R
R R
D
C
T L T L
LL T L
J K
M
150mm max.
K
A
D
R R
R
B
P
D
C
T L LL
T L T L
G
J
K
M
N
D
U
S
V
GREENSTAR CAMRAY EXTERNAL BOILER LAYOUT:
GREENSTAR CAMRAY EXTERNAL SYSTEM BOILER LAYOUT:
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework used must have a
polymeric barrier, comply with BS 7921and
be installed to BS 5955 with 1000mm
(minimum) length of copper or steel pipe
connected to the boiler.
• Plastic pipework used for underfloor heating
must be correctly controlled with a
thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C
with 1000mm (minimum) length of copper or
steel pipe connected to the boiler.
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), set to operate at
3bar, is fitted to the heating flow pipe.
• Where the system volume is more than 100
litres at 0.5 bar or exceeds 2.65 bar at
maximum heating temperature an extra
expansion vessel (B) must be fitted to the
heating return pipe as close as possible to
the boiler.
• Pressurise the extra expansion vessel (B) to
the same figure as the expansion vessel (V)
built into the appliance (0.5 bar factory
setting).
• A pressure gauge (G), 3 bar minimum is
fitted to the appliance
• 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 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
11
PRE -
INSTALLATION

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
INSTALLATIONCOMMISSIONING
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
12
PRE -
INSTALLATION
WATER SYSTEMS & PIPEWORK

CONDENSATE PIPEWORK INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
13
PRE -
INSTALLATION
CONDENSATE 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.
Routing the pipework:
Wherever possible, the condensate
pipework should be routed internally to
prevent freezing.
• The condensate pipework must fall at least
50mm per metre towards the outlet.
• Take the shortest practicable route.
• Support the pipe at least every 0.5m for near
horizontal sections and 1m for vertical sections.
When a boiler is to be installed in an unheated
location, such as a garage, all condensate
drainage pipes should be considered as external.
External pipework:
• The pipework length should be kept to a
minimum and the route as vertical as possible.
• Do not exceed 3 metres outside the dwelling.
• Terminate as close to the ground or drain as
possible(below the grating and above the
water level) while still allowing for safe
dispersal of the condesate. This helps to
reduce wind blowing up the pipe and freezing.
Connection of a condensate drainage pipe to a
drain may be subject to local building controls.
• Pipework subject to extreme cold or wind chill
conditions should be 32mm Ø pipe.
• Protect ALL external pipework with weather
resistant insulation and box-in, if necessary,
to reduce the risk of freezing.
Making it safe:
• Condensate pipework must not leak, freeze or
block up.
• Condensate traps must be filled before firing
up the boiler to prevent the possibility of
potetially harmful flue products evacuating via
the condensate route.
• Do not dispose of condensate into a water
recovery system where it is retained for reuse.
Condensate can be discharged into a rainwater
hopper which is part of a sewer system carrying
both rainwater and foul water.
• The pipework must follow one of the options
shown opposite:
A - Condensate from the boiler condensate
trap (supplied) which has a 75mm
minimum water seal.
B - Sink.
C - 21.5mm Ø polypropylene condensate pipe.
D - Gully.
E - Internal soil and vent stack.
F - 300mm x 100mm Ø sealed plastic tube.
G - Ground level.
H - Drainage holes 50mm from base of tube
(12mm Ø at 25mm centres) facing away
from building.
I - Limestone chippings.
E
C
Invert
450 min.
A
D
A
C
75mm
min.
a - Internal waste drainage system
A
BC
D
400mm
min.
500mm min.
F
I
H
G
A
C
2 5mm
min.
2 00mm min.
U n su it abl e fo r clay so i l t yp e s
b - Soil/vent stack
d - External condensate absorption point
c - External drainage system

PRESSURE RELIEF PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
14
PRE -
INSTALLATION
PRESSURE RELIEF PIPEWORK
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 (B) 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 (B) should be finished with a partial
bend, near the outlet to face an external wall
or appliance casing (as shown) to help
prevent freezing.
A - External boiler casing.
B - Drain pipe.
C - Hard standing.
Typical pressure relief drain pipe routing.
B
A
C
CAMRAY EXTERNAL SYSTEM SHOWN

BOILER LOCATION &
CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
15
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
Plan
view
Plan
view
Plan
view
600mm min
50mm**

CABINET MOUNTED LOW LEVEL
TERMINAL
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
16
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 boundary 300mm
alongside the terminal
G Above ground or balcony level 300mm*
H 1From a surface or boundary facing the terminal with 2500mm 1200mm
clearance to both sides of the terminal
H 2From a surface or boundary facing the terminal with less than 2500mm
2500mm clearance to either side of the terminal
I 1From a terminal facing the terminal with 2500mm clearance to 1200mm
clearance to both sides of the terminal
I 2From a terminal facing the terminal with less than 2500mm 2500mm
clearance to either side of the terminal
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 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.
Stainless steel terminal guard.
Part No: 7 716 190 050
• 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.
boundary
F
I
H
B
A
G
E
C, D
F
F
J
K
boundary
CABINET MOUNTED LOW LEVEL
FLUE TERMINAL POSITIONS

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
17
PRE -
INSTALLATION
Minimum dimensions of flue terminal positions for oil fired appliances:
TERMINAL POSITION B(H) B(V)
A1 2 Directly below an opening, air brick, opening window, etc 600mm N/A
B1 2 Horizontally to an opening, air brick, opening window, etc 600mm N/A
C Below a plastic/painted gutter, drainage pipe or eaves if 75mm N/A
combustible material protected
D3Below a plastic/painted gutter, drainage pipe or eaves without 600mm N/A
protection to combustible material
E From vertical sanitary pipework 300mm N/A
F From an external or internal corner or from a surface or boundary 300mm N/A
alongside the terminal
G Above ground or balcony level 300mm* N/A
H From a surface or boundary facing the terminal 600mm** N/A
J From a terminal facing the terminal 1200**mm —
K Vertically from a terminal on the same wall 1500mm N/A
L Horizontally from a terminal on the same wall 750mm —
M Above the point of highest intersection with the roof — 600mm
N From a vertical structure to the side of the terminal — 750mm
O Above a vertical structure less than 750mm from the side of the terminal — 600mm
P From a ridge terminal to a vertical structure on the roof — —
Q Above or to the side of any opening on a flat or sloping roof — 300mm
R Below any opening on a sloping roof — 1000mm
Key: — Not applicable, N/A Not allowed, B(H) Balanced Horizontal flue, B(V) Balanced Vertical flue.
Notes:
1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or
entering into buildings.
2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers etc.
3. Terminating positions should be at least 1.8m from an oil storage tank unless a wall with at least 30 min fire resistance and
extending 300mm higher and wider than the tank is provided between the tank and the terminating position.
4. Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastics or has a
combustible or painted surface, then a heat shield of at least 750mm wide should be fitted.
5. If the lowest part of the terminal is less than 2m above the ground, balcony, flat roof or other place to which any person has
access, the terminal should be protected by a guard.
6. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300mm to combustible material. In the
case of a thatched roof, double this separation distance should be provided. It is also advisable to treat the thatch with a fire
retardant material and close wire in the vicinity of the flue.
7. It is essential that a flue or chimney does not pass through the roof within the shaded area delineated by dimensions Q and R.
8. Where protection is provided for plastic components, such as guttering, it is essential that this is to the standard specified by the
manufacturer of the plastic components.
• 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
BS 5410.
• 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 to the wall
with plated screws.
Stainless steel terminal guard.
Part No: 7 716 190 050
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
J
H
B
A
G
E
M
C, D
N
F
F
K
L
boundary
Q
Q
Q
R
Q
Q
Q
Q
Pitched roof
Flat roof
P
O
HIGH LEVEL FLUE TERMINAL
POSITIONS
HIGH LEVEL TERMINAL POSITIONS

IMPORTANT: The weather seal (supplied)
must be fitted to every flue joint to give
the required level of weather protection.
The diagrams (opposite) show the components
used and the maximum flue length (L) for
each flue configuration.
In all cases L is measured from the outside of
the boiler casing.
• To achieve the maximum flue length (L), a flue
section will have to be reduced in length.
• Only the straight flue extensions can be
reduced in length by cutting.
IMPORTANT: All horizontal sections must
rise away from the boiler by 52mm per
metre (3°) to allow the condensate to
drain back to the boiler.
A - Straight flue extension
B - Flue bend 90°
C - Flue bend 45°
D - Vertical Terminal Kit (incl. 90° elbow)
E - Horizontal terminal kit (incl. 90° elbow)
Calculating the flue length:
Measure the total flue length required, noting
that the maximum straight flue length including
the terminal is:
2000mm.
Vertical 80/125mmØ / 100/150mmØ (25/32
only): 7000mm.
Then reduce the total straight flue length for
each extra flue bend (excluding the vertical flue
kit 90° elbow) by:
1000mm for 90°
500mm for 45°
Flue Extension lengths:
Horizontal & Vertical: 1000mm overall length.
Effective length when engaged into sockets
within the flue run is 950mm.
Flue Terminal lengths:
Horizontal Oilfit External = 305mm
Vertical Oilfit External: 80/125 = 185mm + cage
Vertical Oilfit External: 100/150 (for 25/32 only)
= 270mm + cage
For satisfactory flue performance it is
recommended that no more than 2m of the
vertical flue is run horizontally.
* Rear exit only.
** Horizontal flue runs should be kept as
short as possible.
BALANCED EXTERNAL OILFIT
FLUE OPTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
18
PRE -
INSTALLATION
BALANCED EXTERNAL OILFIT
FLUE OPTIONS
High level horizontal terminal (rear outlet)
*
**
Vertical terminal (rear outlet)
Vertical terminal (rear outlet)
Vertical terminal (side outlet)
**
**
**

CABINET MOUNTED BALANCED
HORIZONTAL FLUE OPTIONS
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
19
PRE -
INSTALLATION
CABINET MOUNTED BALANCED
HORIZONTAL FLUE OPTIONS
• The horizontal 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
B - 90° inline elbow 80/125mm
Part No. 7 716 190 034
C - Stainless steel terminal guard
Part No. 7 716 190 050
FRONT
FRONT
FRONT
Plan
view
Plan
view
Plan
view
REAR FLUE OUTLET
A + C
LEFT HAND FLUE OUTLET
A + B + C
RIGHT HAND FLUE
OUTLET
A + B + C