INSTRUCTION MANUAL INSTALLATION, COMMISSIONING & SERVICING 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 THE APPLIANCE IS FOR USE WITH KEROSENE (28 SECOND OIL) ONLY GB
INSTALLATION & SERVICING INSTRUCTIONS SYMBOLS USED IN THIS MANUAL: Domestic hot water Central heating 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.
SAFETY & REGULATIONS CONTENTS IMPORTANT INFORMATION AND SYMBOLS 1 SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 3 APPLIANCE INFORMATION SAFETY & REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION 4 TECHNICAL DATA 5 LAYOUT & COMPONENTS CAMRAY EXTERNAL 6 LAYOUT & COMPONENTS CAMRAY EXTERNAL SYSTEM 7 CLEANING PRIMARY SYSTEMS MAINS SUPPLY PRE INSTALLATION PRE-INSTALLATION 8 9 10 WATER SYSTEMS & PIPEWORK 11-12 CONDENSATE PIPEWORK 13 PRESSURE RELIEF PIPEWORK 14 BOILER LOCATION & CLEAR
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).
GENERAL INFORMATION STANDARD PACKAGE: 780mm A - Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and domestic hot water cylinders. 565mm A B - Literature pack. D - 100mmØ services duct. E - Cabinet key APPLIANCE INFORMATION C - Condensate trap kit. 950mm B C D E Check List Item Qty Greenstar Camray External/External System Installation/Servicing Instructions..............................................................................................
TECHNICAL DATA DESCRIPTION UNITS 12/18 18/25 25/32 Primary water capacity (total) External litres 23 23 21 Primary water capacity (total) External System litres 30 30 28 Maximum static head metres 30 30 30 Minimum static head metres 1 1 1 mbar 26 52 69 mH2O 5.7 4.9 4.1 bar 2.5 2.5 2.
LAYOUT & COMPONENTS CAMRAY EXTERNAL 1 2 3 4 5 3 5 4 6 7 2 1 8 35 34 9 33 10 32 11 31 12 30 13 & 14 (location) 29 28 15 16 26 27 17 18 19 CONTROL BOX ASSEMBLY CASING SIDE PANEL FLUE OVERHEAT THERMOSTAT PHIAL AIR INLET CASING 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 BAF
LAYOUT & COMPONENTS CAMRAY EXTERNAL SYSTEM The diagram opposite excludes the top, front and RH side casing panels.
CLEANING PRIMARY SYSTEMS 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 t he use of wat er treatment with the appliance will invalidate the appliance warranty.
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 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.
- Oil storage tank. - Isolating valve. - Oil strainer & water seperator. - Fire valve to BS 5410. - External casing. - Fire valve sensor. - Oil burner. H J K L M N - Oil supply pipe. - Oil pump. - Full base (plastic tanks). - Non-return valve. - De-aerator. - Oil filter (16µm max 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.
WATER SYSTEMS & PIPEWORK IMPORTANT: The boiler should not be allowed t o operat e wit h a ret urn temperature of less than 40°C when the system is up to operating temperature. GREENSTAR CAMRAY EXTERNAL BOILER LAYOUT: 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. E S 1000mm min. 150mm max.
WATER SYSTEMS & PIPEWORK Water main supply Heating return Stop cock Temporary hose Heating return Test cock Stop cock 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.
CONDENSATE PIPEWORK CONDENSATE PIPEWORK: a - Internal waste drainage system • The condensate pipe must be a minimum of 21.5mmØ polypropylene pipe. C B • All national and, where appropriate, local regulations for the discharge and neutralisation of condensate should be followed. A D 75mm min. 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.
CAMRAY EXTERNAL SYSTEM SHOWN PRESSURE RELIEF PIPEWORK PRESSURE RELIEF PIPEWORK: • 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 A- External boiler casing. B- Drain pipe.
BOILER LOCATION & CLEARANCES 600mm WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. 2500mm FRONT 600mm This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface c apable of supporting the boiler weight. There must be a sufficient hard standing around the appliance to allow for servicing.
CABINET MOUNTED LOW LEVEL Minimum dimensions of flue terminal positions for oil fired appliances: FLUE TERMINAL POSITIONS TERMINAL POSITION B(H) • Flue terminals must be positioned to avoid combustion products entering into buildings.
Minimum dimensions of flue terminal positions for oil fired appliances: PRE INSTALLATION TERMINAL POSITION HIGH LEVEL FLUE TERMINAL B(H) B(V) POSITIONS 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 combustible material protected 75mm N/A D3 Below a plastic/painted gutter, drainage pipe or eaves without protection to combustible m
BALANCED EXTERNAL OILFIT FLUE OPTIONS 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. High level horizontal terminal (rear outlet) • To achieve the maximum flue length (L), a flue section will have to be reduced in length.
CABINET MOUNTED BALANCED HORIZONTAL FLUE OPTIONS • The horizontal flue is fitted to the rear or either side of the cabinet. REAR FLUE OUTLET A +C IMPORTANT: It is strongly recommended that the flue terminal faces away from walls to minimise the occurance of wetting. PRE INSTALLATION Plan view FRONT A - External horizontal flue kit LEFT HAND FLUE OUTLET A +B + C B - 90° inline elbow 80/125mm Part No. 7 716 190 034 Plan view C - Stainless steel terminal guard Part No.
IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. UNPACKING THE BOILER LIFTING AND CARRYING PRECAUTIONS: • Lift only a manageable weight, or ask for help. 1 • 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.
All dimensions in mm 295 259 PIPEWORK & FLUE POSITIONS Flue CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. 259 Services Rear service 102 ports below this line are NOT SUITABLE FOR EXTERNAL 254 SYSTEM MODELS. SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate.
WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY. BOILER INSTALLATION EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS. THIS APPLIANCE IS INSTALLED AND SERVICED EXTERNALLY TO THE PROPERTY, BUT THE ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING OR SERVICING THE APPLIANCE. CAMRAY EXTERNAL SYSTEM SHOWN 4 Note: The cabinet is not load bearing it only provides weather protection for the boiler inside.
FLUE INSTALLATION INSTALLATION NOTES: Ensure all the seals are in good condition and seated properly. To ease assembly of flue components, grease seals lightly with the solvent free grease supplied. A terminal guard must be fitted if the terminal is 2m or less above a surface where people have access. INSTALLATION All flue options: 1 Lightly grease the flue cowl seal with the solvent free grease supplied.
CAMRAY EXTERNAL SYSTEM SHOWN COMBUSTION CHAMBER Combustion chamber: 1 Release retaining nuts and washers (A). Remove combustion chamber access door (B). 2 Release screws (C) on either side and remove upper access door (D). 3 Ensure baffles (E) and baffle retainers (F), restrictor plates (G) and acoustic insulation insert (H - 25/32 model only) are correctly fitted for the boiler model as shown in the plan view opposite.
CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. C (Return pipe) located at the side of the secondary heat exchanger PIPEWORK CONNECTIONS A External regular models only A1 (Flow pipe) External System only (behind boiler) G External System only Pressure relief outlet (behind boiler) E INSTALLATION D F B A - Flow (External regular models only) optional open vent/air vent 1” BSP on 12/18, 18/25 and (11/4” BSP on 25/32 models).
CAMRAY EXTERNAL REGULAR SHOWN PIPEWORK CONNECTIONS J H I K L Condensate trap I - Condensate trap fixing bracket - supplied J - Condensate outlet (21.5mmØ) - supplied K - Flue manifold condensate outlet L - Condensate pipe - not supplied M - Condensate collector N - Flue manifold cover (includes seal) O - Flue manifold cover fixing screws CONDENSATE CONNECTION: The condensate trap (H ) must be installed onto the bracket ( I ) supplied.
OIL BURNER & PUMP CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT SAFETY PRECAUTIONS. OIL BURNER: 1 Check the nozzle (A) and electrode (B) settings are correct as shown opposite. NOTE: Burners are supplied with Mid-Range output nozzle. Ensure nozzle (A) is aligned centrally within the combustion head (C). Inspect for any visible defects. 2 IMPORTANT: Before removing or fitting a nozzle (A), loosen screw (D) and move the electrodes (B) forward.
CAMRAY EXTERNAL REGULAR SHOWN REFITTING COMPONENTS 2 1 Align burner combustion head into boiler collar. Locate the combustion head into the combustion chamber door, push the burner firmly onto the door and secure with retainer (A). Check that the burner is seated correctly on its mounting flange and that the oil hose/s are not trapped in front of or underneath the burner. F E Refit the deflector plate (B) and secure with screws (C).
ELECTRICS = EARTH 1 = PERMANENT LIVE A = NEUTRAL B = SWITCHED LIVE DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: THIS APPLIANCE PROVIDES A PERMENANT EXTERNAL ELECTRICAL SUPPLY FOR SERVICING AND MUST THEREFORE BE FED VIA A CIRCUIT BREAKER INCORPORATING EARTH LEAKAGE PROTECTION. A C WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS.
CAMRAY EXTERNAL REGULAR ELECTRICS 230V STANDARD WIRING DIAGRAM: Key to components: A - EARTH STUD. B - BOILER MANUAL RESET OVERHEAT = EARTH • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE THERMOSTAT. C - FLUE MANUAL RESET OVERHEAT THERMOSTAT. D - HIGH LIMIT THERMOSTAT. E - TERMINAL CONNECTOR BLOCK. F - CONTROL THERMOSTAT. G - BURNER SOCKET. H -BURNER PLUG. J - BURNER CONTROL BOX. K - FROST THERMOSTAT. L - MODE SWITCH. 1 2 3 A E M -DEMAND INDICATOR. N - SERVICE CONNECTION.
CAMRAY EXTERNAL SYSTEM ELECTRICS 230V STANDARD WIRING DIAGRAM: Key to components: A - EARTH STUD. B - BOILER MANUAL RESET OVERHEAT = EARTH • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE THERMOSTAT. C - FLUE MANUAL RESET OVERHEAT THERMOSTAT. D - HIGH LIMIT THERMOSTAT. E - TERMINAL CONNECTOR BLOCK. F - CONTROL THERMOSTAT. G - BURNER SOCKET. H -BURNER PLUG. J - BURNER CONTROL BOX. K - FROST THERMOSTAT. 1 2 3 A L - MODE SWITCH. P E M -DEMAND INDICATOR. N N - SERVICE CONNECTION. K P - PUMP.
CAMRAY EXTERNAL REGULAR ELECTRICS O • • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE = EARTH REMOTE 2 OR 3 PORT VALVE CONTROL SET USING REMOTE PROGRAMMER: Key to components: O - REMOTE JUNCTION BOX (10-way) to connect the following (refer to manufacturers instructions): Mains wiring 230V 50Hz, fed via a circuit breaker incorporating earth leakage protection. Hot water tank thermostat. Room thermostat. System water valves. Circulating pump. External programmer.
CAMRAY EXTERNAL SYSTEM ELECTRICS O • = EARTH • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE REMOTE 2 OR 3 PORT VALVE CONTROL SET USING REMOTE PROGRAMMER: Key to components: O - REMOTE JUNCTION BOX (10-way) to connect the following (refer to manufacturers instructions): Mains wiring 230V 50Hz, fed via a circuit breaker incorporating earth leakage protection. Hot water tank thermostat. Room thermostat. System water valves. Circulating pump. External programmer.
CAMRAY EXTERNAL REGULAR SHOWN PRE-COMMISSIONING CHECKS APPLIANCE CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. Check that the service and water pipes are connected correctly. Check that all unused sockets are plugged. 1 Check that the oil supply is kerosene and that the pipework is connected correctly to the oil pump, via the supplied flexible hose.
FILLING THE SYSTEM 1 Open all system and radiator valves. Turn on the water main stop cock. 2 Open vented systems only: Turn on the water to the system feed and expansion cistern and allow the system to fill. 3 Sealed systems only: Check and if required, adjust the expansion vessel pressure using the Schraeder type valve (C) before filling the system. The charge pressure of the built-in 12 Litre expansion vessel is 0.5 bar as dispatched, which is equivalent to a static head of 5m.
STARTING THE APPLIANCE IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 1 Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler.
STARTING THE APPLIANCE 2 2 Remove plastic cover from the burner casing. Fit a suitable pressure gauge to port (A) on the oil pump. Adjust the air shutter (L) and pump pressure (B) as shown in the table opposite. The burner should ignite following a pre-ignition period of approx. 15 seconds. If changing the burner output, check the position of the air damper disc is correct to the output as shown in the table below. NOTE: For 25/32 appliance see following page.
STARTING THE APPLIANCE On 25/32 Appliances: To achieve the minimum output of 25kW from the 25/32 RDB 2.2 it is necessary to remove the air guide (D) from the burner. For any other required output the air guide must remain in place. A Disassemble the burner, removing the red plasic cover, flexible air hose and air intake manifold (A). Remove the fan housing (B) by undoing the four securing screws. Remove the two screws (C) securing the plastic air guide.
STARTING THE APPLIANCE 1 Central heating: 1 Open all radiator valves. Set room thermostat to maximum. Set programmer to ON for CH, OFF for DHW (if applicable). Turn the thermostat control (B) to max. 2 service 4 0 max on 3 1 bar flue reset boiler reset GREENSTAR CAMRAY EXTERNAL SYSTEM 12/18 C B A The demand indicator (A) should illuminate and the burner should be ON with the circulating pump. On External System models only, the system pressure gauge (C) should read between 1 and 1.5 bar.
WATER TREATMENT 1 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. B FLUSHING (Central Heating): 1 Switch off the boiler. Open vented systems only: turn off the water to the system header tank. Open all radiator valves/drain cocks (B) and drain the system while the appliance is hot. Close drain cocks (B).
CAMRAY EXTERNAL REGULAR SHOWN FINISHING COMMISSIONING APPLIANCE A A COMMISSIONING 1 1 Refit the top panel and press down to compress the seal when fitting the securing screws (A). 2 Push the front panel (B) up behind the top panel and push in at the base to secure with the screws (C) using the tool povided.
CAMRAY EXTERNAL REGULAR SHOWN INSPECTION AND SERVICE CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 2 DO NOT USE PRESSURE WASHERS OR STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET.
INSPECTION AND SERVICE 1 Clean the Burner: Remove the air intake cover (A) and clear any debris from the air intake and air damper. Disassemble the burner to allow access to the fan impeller. Check the condition of the gaskets between these parts and replace if necessary. Note the position of the air damper adjustment and check the air damper moves freely. Clean both sides of the fan impeller and remove any debris from the burner housing. Check that the impeller rotates freely.
CAMRAY EXTERNAL SYSTEM SHOWN INSPECTION AND SERVICE External oil filter: Remove the paper element from the external oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter.
BAFFLE ARRANGEMENT 12/18 12/18 MODEL SHOWN BAFFLE ACCESS DOOR RESTRICTOR PLATE 2 for 12/18 models, fitted into tubes 2 & 3. Remove and fit through baffle access door. 1 BAFFLE RETAINER Remove and fit through baffle access door. 2 3 4 SERVICING & SPARES BAFFLE 2 for 12/18 models, fitted in tubes 1 & 4. Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber.
BAFFLE ARRANGEMENT 18/25 18/25 MODEL SHOWN BAFFLE ACCESS DOOR RESTRICTOR PLATE 1 for 18/25 models, fitted into tube 2. Remove and fit through baffle access door. 1 BAFFLE RETAINER Remove and fit through baffle access door. 2 3 4 COMBUSTION CHAMBER ACCESS DOOR SERVICING & SPARES BAFFLE 3 for 18/25 models, fitted in tubes 1,3 & 4. Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber.
BAFFLE ARRANGEMENT 25/32 25/32 MODEL SHOWN BAFFLE ACCESS DOOR ACOUSTIC INSULATION INSERT (25/32 models only) Remove last. Refit first. 1 2 BAFFLE RETAINER Remove and fit through baffle access door. 3 4 5 6 SERVICING & SPARES BAFFLE 6 for 25/32 models, fitted in all 6 tubes Lift baffle to remove the baffle retainer then pull down to remove the baffle through the combustion chamber.
CAMRAY EXTERNAL REGULAR SHOWN INSPECTION AND SERVICE I I Re-commission the burner: 1 Align burner combustion head into boiler collar. 2 Locate the burner retainer (A) over the threaded lug on the collar (B), push the burner firmly onto the flange and secure in place with the retaining nut (C). Tighten sufficiently but do not overtighten. 3 Check that the burner is seated correctly on its mounting flange and that the oil hose/s are not trapped in front of or underneath the burner.
SHORT PARTS LIST 12/18 5 9 7a 11 10 13 12 4 7 6 8 SERVICING & SPARES 3 2 1 14 15 16 17 18 19 20 21 22 23 24 25 1 Burner - Riello RDB 1 12/18 HE Part Number: 8 716 111 951 0 2 Combustion head - LD2X SH12/18 Part Number: 8 716 112 731 0 3 Control box 535 RSE/LD Part Number: 8 716 109 203 0 4 Photocell Part Number: 8 716 109 193 0 5 Ignition electrode Part Number: 8 716 109 211 0 6 Motor Part Number: 8 716 109 186 0 7 Oil pump - Riello RDB Part Number: 8 716 115 297 0 7a Pump coupli
SHORT PARTS LIST 18/25 5 7 6 9 8 17 16 20 7a 11 10 13 12 4 14 15 18 19 0.60 60° ES (21.5kW output) Part Number: 8 716 156 680 0 22 21 0.75 80° ES (25kW output) Part Number: 8 716 109 387 0 23 24 25 26 SERVICING & SPARES 3 2 1 1 Burner - Riello RDB 2.
SHORT PARTS LIST 25/32 5 4 7 6 9 8 SERVICING & SPARES 3 2 1 1 Burner - Riello RDB 2.
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009) Oil/ combustion smells Noisy burner operation High smoke number Pulsation on start up Intermittent lockout SHORT PARTS LIST 25/32 Replace seals. Remove blockage/restriction. Check flue seals.
FAULT FINDING - HEATING/ HOT WATER These fault finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent.
Flue overheat thermostat tripping out Short cycling Boiling/ boiler overheat thermostat tripping out. INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.2009) Yes Service the burner and the boiler. No Has the burner been serviced? FAULT FINDING & DIAGRAMS Check boiler & flue for damage, replace any damaged components before filling boiler. No Is the boiler filled with water? Replace the control thermostat.
FAULT FINDING NO Replace photo cell Replace control box 55 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.
OIL BOILER COMBUSTION RECORD BOILER MODEL COMMISSIONING ENGINEER COMPANY NAME: ADDRESS: SERIAL No. COMBUSTION CHECKS ENGINEERS NAME: SIGNATURE: PUMP PRESSURE (PSI): CO2 %: SMOKE READING: F.G.T.
SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS psi CO2%: YES NO FLUE PRESSURE: SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T.
NOTES NOTES 58 INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL & EXTERNAL SYSTEM 12/18-18/25-25/32 8 716 115 667a (05.
In the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:General checks 1. Is the mode switch in boiler/ON mode ? 2. Is there 230V across the boiler live and neutral terminals? 3. Is there 230V across the terminals 1 and N? If not there is no demand to the boiler from the controls or the control wiring is not correct. 4. Is the polarity correct? (230V across live and earth, 0V across neutral and earth) 5.
