Boulter Buderus Camray 5 Combi Installation & Maintenance Manual Download Page 17 | Manualshive

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Section 4 - Installation

4:1 STANDARDS & REGULATIONS

Page 17 of 57

Installation & maintenance manual for Camray 5 Combi External Boilers

14/04/2005

file://D:\PL61500\PL61500.htm

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Summary of Contents for Camray 5 Combi

Page 1: ...ned and constructed to meet these general safety requirements when properly used and installed To fulfil this requirement products are comprehensively tested and examined before dispatch This applianc...

Page 2: ...g on any part of the body particularly the scrotum 4 Avoid as far as possible any skin contact with mineral oil or with clothing contaminated with mineral oil 5 Never breath any mineral oil vapours Do...

Page 3: ...tem 4 8 Connections to the Boiler 4 9 Flue exhaust 4 10 Air Supply 4 11 Oil Storage 4 12 Oil Supply 4 13 Oil Burner 4 14 Control Panel 4 15 Panel Wiring Diagram 4 16 Fitting Programmer SECTION 5 FLUES...

Page 4: ...and once again thank you for choosing Camray 1 1 1 Manual This manual covers safety User Instructions Installation Commissioning and Maintenance of the Camray Combi External Boiler 1 2 USEFUL INFORMA...

Page 5: ...d Wales only Please note This oil fired appliance must be installed by either an OFTEC Registered Installer or by way of a Local Building Control License An OFTEC CD10 document or Building Control Com...

Page 6: ...our Camray Boiler has been installed it MUST be commissioned by an O F T E C Registered Engineer Commissioning involves testing the Boiler to ensure that it is working correctly and also setting the B...

Page 7: ...g indicator light green 1 6 1 Boiler Control Thermostat The Boiler Control Thermostat controls the water temperature in the boiler The recommended setting is shown in Fig 1a This thermostat automatica...

Page 8: ...ermostat by depressing the limit thermostat reset button located on the control panel see Fig 1 a If this problem recurs turn the boiler off and consult your installer 1 6 5 Lockout Lamp In the unlike...

Page 9: ...perature set on the Hot Water Tank Thermostat The period of operation to replenish the energy used depends on the quantity of hot water drawn c As the rate of water is increased by opening the hot wat...

Page 10: ...tion A frost thermostat is fitted to the Boiler However if there is any danger that your Boiler may freeze up during very severe weather conditions it is recommended that you consult your installer wh...

Page 11: ...Wait three minutes z Repeat the procedure by pressing the button z Failure to start on second attempt indicates a fault requiring attention z Switch off the mains supply and call your service enginee...

Page 12: ...Fig 2a Page 08 2 2 HYDRAULIC CIRCUITS Page 12 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL61500 PL61500 htm...

Page 13: ...ical Association for the Petroleum Industry 2 4 SAFETY READ HEALTH AND SAFETY INFORMATION ON INSIDE FRONT COVER OF THIS MANUAL IMPORTANT Should you wish to remove or dismantle any covers or parts of t...

Page 14: ...0 Hz All wiring to supply and all system components external to boiler must comply with the latest edition of BS7671 2001 formerly IEE Wiring Regulations Heat Input Full load based on NET efficiency o...

Page 15: ...g from the Pressure Relief Valve of the Boiler Installation of the Tundish must be located in a position clearly visible to the householder i e to comply with Part G of the Building Regulations typica...

Page 16: ...Model Output Riello R00 type Nozzle Danfoss Delevan US GPH Pump pressure fuel rate Kg h C02 Smoke no Flue exit temp C kW Btu hx1000 bar psi 90A 26 4 90 483T50 0 85x60 W 8 0 115 2 57 12 0 1 204 Page 1...

Page 17: ...Page 12 Section 4 Installation 4 1 STANDARDS REGULATIONS Page 17 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL61500 PL61500 htm...

Page 18: ...rrosion should be added to the system Kettling and system noises can be avoided by suitable pre treatment at the onset 4 3 SITING POSITIONING The noise level from Camray Boilers is quite low and other...

Page 19: ...crete slabs satisfies this requirement If the Boiler is to stand on a base made of combustible material then protection between the Boiler and the floor should be provided by means on non combustible...

Page 20: ...ger 2 Storage tank 8 3 port motorised valve 3 Pressure gauge 9 Plate heat exchanger 4 Pressure relief valve 10 Flow switch 5 Circulating pump 11 Manual vent 6 Tundish not shown Page 20 of 57 Installat...

Page 21: ...ided as a visual indication on the water pressure within the system A pressure below the set Cold Fill Pressure indicates the system requires topping up 4 Pressure Relief Valve 3 bar Supplied fitted o...

Page 22: ...nlet valve The final 600mm of mains water supply pipe to the Boiler must be copper All combination Boilers suffer performance degradation due to the effects of hard water limescale build up on heat ex...

Page 23: ...R Connection to the Boilers 15mm and 22mm pipes should be made using compression fittings either elbow or straight couplings can be used dependent on installation 4 8 1 Cold Mains In To achieve optimu...

Page 24: ...he following 1 Sludge Cock on steel tanks 2 Outlet Valve 3 Contents Indicator 4 Screw fill connection and independent vent The Fill and Vent should be suitably capped to prevent ingress of water or fi...

Page 25: ...ition of the guarantees that the Filter is fitted correctly 4 12 2 Fire Check Valve Not supplied A Remote acting FIRE VALVE must be fitted in the suction line at the time of installation see BS 5410 P...

Page 26: ...er but NOT inside the Boiler Case A Non Return Valve is not required in the return line as the deaerator is fitted with one as standard The advantage of this system is gained where a two pipe run from...

Page 27: ...19 Single pipe oil system Tank outlet above burner Do not fit pump bypass to burner see 4 9 2 Page 27 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL6150...

Page 28: ...e burner Fit pump bypass screw to burner Table giving maximum pipe length in L metres Item H metres 0 5 1 0 1 5 2 0 Kerosene 10mm OD Pipe Burner to supply 20 40 80 100 Item Part QTY Code 1 Filter 251...

Page 29: ...l entry available LH Shown Part 0 0 5 1 0 1 5 2 0 Kerosene 10mm OD Pipe Burner to supply 100 100 100 90 70 Item Part QTY Code 8 Longlife hose 900mm 1 BS03106 9 Washers 2 FS00159 10 1 4 BSPx10mm coupli...

Page 30: ...system oil connections Items 1 5 supplied with boiler see fig 4 12f Pipe Size mm Lift H metres 13 5m Mall OD 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 6 24 21 19 16 13 11 6 6 8 100 100 93 84 71 59 46 33 10 100 10...

Page 31: ...ystem For two pipe oil systems the Burner Oil Pump has to be fitted with the Bypass Screw supplied Boilers are dispatched with the Bypass Screw in a labeled envelope attached to the Burner This SOCKET...

Page 32: ...Burner Pump for Single Pump System The burner is supplied set for single pipe operation The return port is plugged and the Bypass Screw is not fitted See Fig 4 13b Page 32 of 57 Installation maintenan...

Page 33: ...onnect the mains electric supply to the terminals L N E 4 14 2 Boiler Tank Phial Positions The Thermostat Phials are inserted into the relevant pockets as shown in Fig 4 14 4 14 3 Room and Frost Therm...

Page 34: ...4 15 FUNCTIONAL FLOW DIAGRAMS Page 24 4 16 FITTING PROGRAMMER Page 34 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL61500 PL61500 htm...

Page 35: ...nstaller It is not recommended that a programmer be fitted to the fascia of this boiler Boulter Buderus recommends that an external programmer is fitted and connected as shown on the next page Page 25...

Page 36: ...programmer through a spare knockout using a strain relief bush Cable to have 4 wires and earth 8 Connect as shown in the diagram ie Programmer L to JP8 2 Programmer N to JP 12 3 Programmer CH ON to JP...

Page 37: ...es or doors or windows of any neighbouring house Fig 5 1 Table to above Flue Terminal Positions MINIMUM dimensions REF DESCRIPTION DISTANCE IN MM A Directly below an Opening Air Brick or Window 600 B...

Page 38: ...LER It is essential in the interest of boiler efficiency and reliable performance that once the Boiler has been installed it is first commissioned by a qualified engineer If an engineer is not known B...

Page 39: ...d refill 6 Vent radiator and any other manual Air Release Vents 7 Check for leaks particularly on older systems which may operate on a lower pressure system 8 When the system is completely full and ve...

Page 40: ...adequately supported Is a damp proof membrane inserted between the tank and support Non plastic tanks Does the tank slope at least 20mm per meter of length downwards the sludge cock Non plastic tanks...

Page 41: ...level as the suction outlet Has an anti syphon cut been made in the return oil line inside the tank Page 30 BOILER Is the boiler standing on a level incombustible hearth Are the thermostat phials ins...

Page 42: ...em pressure Record initial system pressure cold STATIC bar DYNAMIC bar Has a chemical dosing type water conditioner been fitted to the water supply to the boiler Page 31 7 9 BOULTER BUDERUS RECOMMENDE...

Page 43: ...first firing may be necessary Once the burner is firing check and if necessary adjust the oil pressure Page 32 7 9 2 COMMISSIONING TEST SYSTEM Isolate boiler electricity Check cold mains static and d...

Page 44: ...connect the flexible oil hose from the oil cock Page 33 Remove burner and clean thoroughly the burner draught tube the electrodes and generally the head assembly CHANGE the nozzle for one with the spe...

Page 45: ...s should agree with data in Boiler Commissioning Data Section 3 FINAL CHECKS Check lockout function either remove photocell and cover it or remove solenoid coil to simulate flame failure Reinstate com...

Page 46: ...Fig 8 2a 8 3 BAFFLE ARRANGEMENT Page 46 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL61500 PL61500 htm...

Page 47: ...ssary using the Filling Loop Filling should be carried out on a cold system so that the pressure can be increased to the original cold fill design pressure indicated by the red pointer on the system P...

Page 48: ...ystem The design of the Camray 5 Combi enables the Pressure Vessel to be lifted and laid on to the floor whilst still connected to the Boiler enabling full access to the Burner and Heat Exchanger Fig...

Page 49: ...ata Water contamination Open tank drain valve and check Tank vent blocked Check Filter blocked Check or water or blockage Air locks in supply pipe supply Check for high points in main oil Air lock in...

Page 50: ...le smoke or shows excess smoke on combustion check Air shutter closed Reset to correct position Wrong nozzle Check make type and spray angle Worn atomiser nozzle Replace if necessary Oversize nozzle f...

Page 51: ...sure against rating Boiler has become undersized due to heating system expansion Check with heating installer Low efficiency and C02 Check combustion readings reset air Low efficiency due to high flue...

Page 52: ...seized check correct operation of actuator head replace if faulty Boiler doesn t fire circulating pump on no DHW at taps only cold both relay indicator neon s illuminated DHW stat failed in NO positio...

Page 53: ...or replace if faulty Boiler fires heats CH and not DWH tank LED indicator Illuminated boiler high limit manual reset stat tripped Diverter valve seized in CH position Check valve body and actuator re...

Page 54: ...ary i Reinstate mains electricity supply and test correct operation of replacement pump 2 To remove replace motorised valve actuator head a Remove control panel rear cover note position of motorised v...

Page 55: ...brass body g Remove cold mains supply pipe 7 BS 50048 C h Remove DHW supply pipe 19 BS 50047 C i Remove return manifold l4 BS 50046 C j Remove and replace plate heat exchanger k Reassemble in reverse...

Page 56: ...our customers which means that we lead the way in the development of new features for oil fired boilers and build on Buderus success with hi efficiency condensing boilers Our oil fired boilers are ma...

Page 57: ...Heat is our Element Page 57 of 57 Installation maintenance manual for Camray 5 Combi External Boilers 14 04 2005 file D PL61500 PL61500 htm...

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