Worcester 12/18 User manual

INSTRUCTION MANUAL

INSTALLATION COMMISSIONING

& SERVICING

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)

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

INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32

8 716 113 000a (01/07)

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)

SAFETY &

REGULATIONS

SAFETY PRECAUTIONS INSTALLATION REGULATIONS

OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE:

Extinguish any naked flames.

Open windows and doors.

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.

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)

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

370mm

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

TECHNICAL DATA INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32

8 716 113 000a (01/07)

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

2.5

3/4

21.5

230

150

55/81

105

110

<100

93.1

101

2.5

3/4

21.5

230

160

55/81

105

110

<100

93.2

102

2.5

11/4

3/4

21.5

230

160

55/81

105

110

<100

94.2

109

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)

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)

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)

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.

BN GJ

4m (13ft) max.

300mm

min.

B DB C

MAXIMUM PIPE RUN FOR SINGLE PIPE GRAVITY FEED SYSTEM

3.5m (11.5ft) max.

150mm

MAXIMUM PIPE RUN FOR DOUBLE PIPE SUB-GRAVITY FEED SYSTEM

3.5m (11.5ft) max.

MAXIMUM PIPE RUN FOR SINGLE PIPE SUCTION LIFT WITH DE-AERATOR

FUEL FLOW RATE FUEL FLOW RATE

OIL SUPPLY INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY KITCHEN 12/18-18/25-25/32

8 716 113 000a (01/07)

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.

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