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Heat is our Element

Page 40 of 40

Camray 5 External Boilers

14/04/2005

file://D:\PL61000\PL61000.htm

Содержание Camray 5

Страница 1: ...Company takes every reasonable care to ensure that these products are designed 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 appliance may contain some of the materials below When working on the appliance it is the Users Engineers responsibility to ensure th...

Страница 2: ...taminated with mineral oil 5 Never breath any mineral oil vapours Do not fire the Burner in the open i e out of the Boiler as a miss fire will cause unburnt oil vapours Barrier cream containing lanolin such as Rosalex Antisolv is highly recommended together with a strict routine of personal cleansing Under no circumstances should mineral oils be taken internally OFTEC Code of Practice OCP 1 1995 F...

Страница 3: ...safety features which are detailed in the relevant section of this manual 1 2 1 Heating System The heating system must comply with the latest editions of British Standards 5410 and the Building Regulations 1 5 8 Frost Protection 7 3 Reporting 1 5 9 Oil Delivery 7 4 Recommended Commissioning Check List 1 5 10 Maintenance Troubleshooting Guide 7 5 Recommended Commissioning tests SECTION 2 INTRODUCTI...

Страница 4: ... instructions may invalidate your right to free breakdown cover during the guaranteed period We recommend that you keep these instructions in a place near your appliance for easy reference England and Wales only Please note Since January 2002 all oil fired appliances must be installed by either an OFTEC Registered Installer or by way of a Local Building Control License An OFTEC CD 10 document or B...

Страница 5: ...ost efficient operation and use of fuel If the Boiler has not been commissioned it may not be operating at the maximum efficiency possible for your heating system and may also invalidate the guarantee Page 3 1 4 BOILER CONTROL PANEL Boiler Control Panel 1 Boiler Control Thermostat Switch Mains On Switch 2 Boiler Overheat Limit Thermostat reset button 1 5 OPERATING INSTRUCTIONS 1 5 1 BOILER CONTROL...

Страница 6: ...t your installer 1 5 3 LOCKOUT INDICATOR In the unlikely event of a burner malfunction it will automatically shutdown and the red lockout indicator on the Burner Control Box will be lit To reset the Burner wait for a period of at least 45 seconds Press the lockout reset button located on the front of the Burner If the Burner immediately goes to lockout again wait three minutes and then repeat the ...

Страница 7: ... heating system to its off position BOILER CONTROL THERMOSTAT 1 5 6 SHUTTING OFF FOR THE SUMMER If the Boiler is to be shut off for the summer it is advisable to have it thoroughly serviced Thorough cleaning will minimise corrosion during the idle period Remember when the Boiler is required to ensure that the oil supply is open before switching on 1 5 7 SEALED SYSTEM CENTRAL HEATING If your Boiler...

Страница 8: ... being replenished This is to allow any sediment to settle and not be drawn into the Boiler If not this could result in an inconvenient break down We advise that you keep your Boiler off for one hour after the oil delivery to your tank Please ask your supplier or the driver to notify you before the oil is discharged Page 5 1 5 10 MAINTENANCE AND TROUBLE SHOOTING GUIDE 1 5 10 1 Maintenance For norm...

Страница 9: ...om the flue discharge called pluming may be observed from time to time under certain weather conditions This is perfectly normal and should be no cause for concern 1 5 10 2 Failure to start If the Burner fails to start adopt the following procedure 1 Check that there is oil in the tank and that the supply valve is open 2 Check the programmer or time switch to ensure that it is operating and set to...

Страница 10: ...Boilers are supplied with a manual reset limit thermostat 4 Suitable for new installations and for replacing existing boilers 5 BOULTER BUDERUS Boilers offer greater freedom to select the most suitable position for siting 2 2 FLUE OPTIONS The exhaust flue supplied with the boiler may be sited on either side or rear of the boiler giving greater installation flexibility The terminal guard supplied w...

Страница 11: ...fied in the Code of Practice for Oil Firing BS 5410 Part 1 See OFTEC CD11 form on page 20 IMPORTANT It is the responsibility of the installer to ensure that the boiler is commissioned by a competent OFTEC Registered Commissioning Engineer 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 the boiler for cl...

Страница 12: ... Water Resistance Less than 300 m m w g With 11ºC temperature rise across the boiler Class C2 fuel only Kerosene Page 8 3 3 BURNER DETAILS Burner type RIELLO 484T50 483T50 Pressure Jet supplied as standard Manually adjustable air regulator The burner must be set to details given in section 3 6 For further details of the burner refer to the burner data sheets supplied in the literature envelope See...

Страница 13: ...ssure Fuel CO2 Smoke Flue Exit Model kW Btu h RDB Danfoss Bar psi Rate No Temp oC x1000 TYPE Delevan Kg h US GPH 11 7 40 0 4x60 oES 7 0 100 1 08 10 0 1 165 195 40 65 16 1 55 484T50 0 5x60 oES 8 0 115 1 49 11 0 1 180 225 19 65 0 6x60 oES 7 6 110 1 76 12 0 1 180 245 19 65 0 6x60 oES 7 6 110 1 76 10 0 1 180 65 90A 23 4 80 483T50 0 75x60 oW 7 2 105 2 17 11 0 1 200 26 4 90 0 85x60 oW 8 0 115 2 42 12 0 ...

Страница 14: ...system is such that the water circulation through the boiler can be totally or substantially reduced whilst the oil burner can still fire the water in the boiler will reach very high or boiling temperatures before the boiler thermostat can sense it and switch off the Burner If this condition is likely wire the controls so that the electrical supply to the burner is switched off simultaneously with...

Страница 15: ...uilding openings and surroundings This Boiler model is serviced from the front A space of 450mm 18 in front should be available FRONT SERVICING Page 11 4 4 THE HEARTH The Boulter Buderus has a Hearth Temperature of less than 85oC The boiler requires a level hearth on which to stand which should comply with the Building Regulations If the Boiler is to stand on a floor made of combustible material t...

Страница 16: ... be free from obstruction 4 7 OIL STORAGE 4 7 1 Oil Tank Consideration to the access by fuel delivery lorries should be given when positioning the oil tank Tank positioning should be in accordance with BS 5410 Part 1 and OFTEC Technical Book 3 4 8 OIL SUPPLY All joints in the Oil Lines must be oil tight and the Oil Line should be flushed clean before connecting to the burner Flared fittings should...

Страница 17: ...Not Supplied A remote acting FIRE VALVE must be fitted in the suction line at the time of installation see BS 5410 Part 1 The valve must be fitted external to the Boiler The sensor should be located above the Burner in the clip provided FIRE VALVE SENSOR LOCATION R A F FIRE VALVE BODY Remote Acting Fire Valves are available from Boulter Buderus through your merchant or installer Ref Capillary Leng...

Страница 18: ...Two Pipe System When the bottom of the Oil Tank is below the level of the Oil Pump on the Burner it is necessary to install an additional 10mm return pipe The Non Return Valve must be fitted to allow the flow in the correct direction and prevent drain back to the Tank Ensure that Valves are NOT fitted in the Return Line The Return Line must be unobstructed at all times Ensure that the Burner Oil P...

Страница 19: ...ed using a 3K Oil Loop Deaerator which removes the air from the oil feed on a single pipe lift The Burner Pump is piped to the Deaerator which should be positioned close to the burner A Non Return Valve is not required in the return line The advantage of this system is gained where a two pipe run from the oil supply tank is long or difficult to achieve Boulter Buderus 3K Deaerators are available f...

Страница 20: ... BURNER The Burner makers technical leaflet is supplied with this manual and provides supplementary information not included in this manual 4 9 1 Burner Pump for Single Pipe System The burner is supplied set for single pipe operation The return port is plugged and the Bypass Screw is not fitted Page 20 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL61000 htm ...

Страница 21: ...ope attached to the Burner This socket screw is inserted into the return port 4 10 PACKAGING AND ASSEMBLY INSTRUCTIONS 4 10 1 Packaging The carton contains the boiler burner and flue exhaust and guard 4 11 CONTROL PANEL The Control Panel is pre wired and ready for connection to the system wiring 4 11 1 Connecting Control Panel Page 21 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL610...

Страница 22: ...ain Phial into a pocket on the top of the Boiler Heat Exchanger as shown LOCATION OF THERMOSTAT PHIALS 2 Insert the Limit Stat 8mm Coiled Phial into the top of the Boiler Heat Exchanger LOCATION OF LIMIT THERMOSTAT PHIAL Page 15 4 12 PANEL WIRING DIAGRAM Page 22 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL61000 htm ...

Страница 23: ...s well as a switched live supply from the external system controls The permanent supply must be connected to the terminal 3 The switched wire to terminal 1 The Neutral must only be connected to terminal 2 and the Earth wire must be connected to terminal 4 Failure to correctly wire this appliance will create an immediate danger to life and will invalidate any warranty Page 23 of 40 Camray 5 Externa...

Страница 24: ...ng care not to damage any damp proof membrane Using the EDPM seal fix the pipe duct plate to the side panel using the nuts and washers provided Push the ducting through the seal and into the wall The duct can be cut if required The use of a high modulus silicon with provide a very good seal between the brickwork and the duct Page 24 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL61000...

Страница 25: ...anking cap is fitted to the hole vacated by the lock assembly Page 17 5 2 FLOW PIPE and RETURN PIPE Standing in front of the boiler the flow pipe is fitted to the left hand tapping on top of the heat exchanger The flow pipe not supplied can be routed anywhere within the boiler casing but remember to leave room for the flue pipe and any other fittings you may have to install We have shown the pipe ...

Страница 26: ...ENTS It is possible to install a circulating pump and or motorised valve s in the space behind the heat exchanger A possible way of installing a pump is shown below Page 18 SECTION 6 FLUES Page 26 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL61000 htm ...

Страница 27: ...minals of flues which can be touched are to be fitted with a guard Any proposed installation which deviates from the details provided or gives rise to any doubt should be referred to BOULTER BUDERUS LTD who will be pleased to consider and discuss it 6 2 TERMINAL GUARD The guard supplied should be fitted to the boiler casing as shown using the self tapping screws supplied FLUE LOCATION AND FITTING ...

Страница 28: ...mmended that the relevant section of BS 5410 Part 1 latest edition is carefully read It is recommended that you use a report sheet and checklist Make comments on the report where necessary and give a copy to whoever has engaged your services and retain and file your own copy A suggested layout is shown over 7 3 REPORTING REF DESCRIPTION DISTANCE REF DESCRIPTION DISTANCE A Below opening window air ...

Страница 29: ...e appliance Is the tank 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 towards the sludge cock Non plastic tanks Is the tank painted or suitably protected externally Customer Site Address Appliance Model Serial No Fuel Page 29 of 40 Camray 5 External Boilers 14 04 2005 file D PL61...

Страница 30: ... removed from the oil supply IF NOT THIS MAY DAMAGE THE PUMP Clear oil filters and de sludge the tank if necessary TWO PIPE OIL SYSTEMS Is a spring loaded non return oil valve fitted in suction line or a 3K Oil Deaerator Does the return oil line terminate in the take at the same level as the suction outlet BOILER Is the boiler standing on a level incombustible hearth Are the thermostat phials inse...

Страница 31: ...supply fuse correct Does the wiring comply with the latest IEE regulations Is the power supply cable to the control panel properly clamped GENERAL Has the boiler been installed in accordance with manufacturers instructions 7 5 BOULTER BUDERUS RECOMMENDED COMMISSIONING TESTS CARRY OUT COMBUSTION CHECKS BY INSERTING PROBES INTO SAMPLING POINTS PROVIDED Check the Smoke No if clean wait 10 minutes and...

Страница 32: ...ove solenoid coil to simulate flame failure Reinstate components and press lockout reset button Check that the control thermostat is operating when the set temperature is reached Check the operation of the limit thermostat if possible Reset Limit Thermostat once appliance temperature has dropped sufficiently Complete a maintenance report and give the customer BURNERS Turn off the oil cock and disc...

Страница 33: ...at the flue outlet Check Smoke No if clean wait 10 minutes and measure CO2 Adjust the air shutter see Fig 8 2a if necessary open to reduce CO2 close to increase CO2 If the air shutter is adjusted re check the Smoke No Check the flue gas temperature The figures should agree with data in Boiler Commissioning Data Section 3 Page 23 8 2 AIR SHUTTER ADJUSTMENT The burner has a fixed Air Shutter with ma...

Страница 34: ... on Is the programmer or Boiler Operating Switch set to call for heat Is the Boiler Thermostat set to the desired temperature Is the Lock out Reset Button on the Control Box and Control Panel neon illuminated If so press to reset Burner Check the fuse which should have been fitted to the mains electricity supply to the programmer boiler operating switch If the fuse has blown replace it If it blows...

Страница 35: ...n tank drain valve and check Tank vent blocked Check Filter blocked Check or water or blockage Air locks in supply pipe Check for high points in main oil supply Air lock in pump Bleed pump check flexible oil line 2 Burner will not start Interruption or absence of electrical supply at burner check this at Control Box mains terminal with test lamp Check mains switch on Check fuse in switched spur or...

Страница 36: ...ctioning correctly and not slipping Blocked atomiser nozzle Remove and replace nozzle Oil pressure abnormally low Check oil pressure on gauge and set to the correct pressure see Technical Data Solenoid valve faulty Break union at outlet to check presence of oil Check that seat is clear Check coil for continuity Inspect coil feed wiring to control box Pump rotation incorrect Check Ignition failure ...

Страница 37: ...d nozzle Checked and replace with correct size and type see Technical Data Air supply inadequate Check fan operation and cleanliness Worn nozzle with excess throughout or uneven spray pattern Replace with nozzle of correct type and size see Technical Data b at initial firing Air supply line Purge at pump to remove Blocked flue ways Clean boiler and flue 8 Burner locks out on morning starts then ru...

Страница 38: ...smoke Check CO2 oil pressure nozzle size see Technical Data Check all baffles are in place and correctly located High flue gas temperature Check air shutter nozzle size see Technical Data clean heat exchanger surfaces 12 Oil odour Leaking joints Break all leaking joints and re make 13 High operating temperature Control stat failed and operating on limit stat Replace control stat and reset Limit Th...

Страница 39: ...and build on Buderus success with hi efficiency condensing boilers Our oil fired boilers are manufactured in Ipswich Suffolk and the condensing boilers are imported from the Dutch organisation Nefit Buderus All products are approved to meet exacting European standards relating to quality safety efficiency and the environment Our design manufacturing delivery and after sales service is certified an...

Страница 40: ...Heat is our Element Page 40 of 40 Camray 5 External Boilers 14 04 2005 file D PL61000 PL61000 htm ...

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