Boulter Camray 5 Service Manual

Installation & maintenance manual for Camray 5 Combi External Boilers Heat is our Element Health & Safety INFORMATION FOR THE INSTALLER AND

normal anticipated use. Heating and Hot Water If the Programme is set for Heating and Hot Water or the Summer/Winter switch is set to Winter: - a) The

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 p

Fig 2a Page 08 2:2 HYDRAULIC CIRCUITS Page 12 of 57Installation & maintenance manual for Camray 5 Combi External Boilers14/04/2005file://D:\PL615

2:3 COMMISSIONING The heating system must comply with the latest editions of British Standard 5410 and The Building Regulations. Please note: It is e

Page 09Section 3 - Technical data 3:1 LIQUID FUELS The Camray 5 COMBI Boiler will burn liquid fuels complying with BS2869 Part 2 1998 Class C2 specifi

This appliance must be effectively earthed and connection to the supply must be through a double pole isolating switch fused 5 amp. The isolating swit

Page 11 3:7 COMMISSIONING DATA 3:7.1 Class C2 Kerosene Oil 3:8 PERFORMANCE DATA Dynamic Inlet pressures / flow rates Model Output Riello R00 typeNo

Page 12 Section 4 - Installation 4:1 STANDARDS & REGULATIONS Page 17 of 57Installation & maintenance manual for Camray 5 Combi External Boil

The installation of the Boiler must comply with latest edition of: -BS5410 Oil installations Part 1: under 44kW. BS5449 Forced circulation hot water c

Fig 4.3 Page 13 4:4 THE HEARTH The Camray 5 Combi has a Hearth Temperature of less than 85°C. The Boiler requires a level hearth on which to stand wh

Glass Rope, Mineral Wool, Insulation Pads, Ceramic Fibre, Fibre Glass Insulation.May be harmful if inhaled. May be irritating to the skin, eyes, nose

4:6 SEALED SYSTEM DETAILS 12 litre Expansion Vessel 1. 12Ltr expansion vessel 7. Boiler heat exchanger2. Storage tank 8. 3 port motorised valve3. Pre

The Expansion Vessel is suitable for systems with a static head of up to 5 metres (16.5ft) i.e. the vertical distance between Expansion Vessel and hig

8) Boiler Primary Heat Exchanger Insulated steel Heat Exchanger with combustion chamber and access cover at front for servicing. 9) Three Port Motoris

Bidets : Subject to local Water Company regulations the supply of hot and cold mains water direct to a bidet ispermitted if it is of 'over-rim fl

Fig 4.9 4:10 AIR SUPPLY The air supply to the boiler is through the grilles on the casing panel door. 4:11 OIL STORAGE 4:11.1 Oil Tank Consideration

Tanks made from plastic are now available. These should be UV stabilised for protection against sunlight, andcoloured green. Plastic tanks do not need

Ensure that the Burner Oil Pump is correctly set for 'Single Pipe' operation. (See 4:13.2). 4:12.4 Two Pipe System Fig 4.12c When the botto

Fig 4.12 Page 19 Single pipe oil system - Tank outlet above burner Do not fit pump bypass to burner- see 4.9.2 Page 27 of 57Installation & mainte

Table giving maximum pipe length in metresSingle pipe oil system - oil connections Items 1-5 supplied with boiler Fig.4.12b LH Fuel entry available

Two pipe oil system - oil connections Items 1-5 supplied with boiler- see fig 4.12d Items 6-10 not supplied with boiler Fig.4.12d LH Fuel entry av

2:1 Introduction2:2 Hydraulic Circuits2:3 Commissioning2:4 SafetySECTION 3 - TECHNICAL DATA 3:1 Liquid Fuels 3:2 Boiler Technical Details3:3 Burner D

Schematic diagram fit both hose as shown in Fig 4.12cPage 21 Dearator oil system - Tank outlet below burner Fit pump bypass screw to burner Fig 4.12e

Fig 4.12f Page 22 4:13 OIL BURNER The Burner makers' technical leaflet is supplied with this manual and provides supplementary information not i

Fig 4.13a ONLY USE BYPASS SCREW FOR ALLEN KEY (2.5MM). DO NOT USE SLOTTED SCREW 4:13.2 Burner Pump for Single Pump System The burner is supplied set

Fig 4.13b Page 23 4:14 CONTROL PANEL The Control Panel is pre-wired and fitted to the Boiler ready for connection to the system wiring. For operation

4:15 FUNCTIONAL FLOW DIAGRAMS Page 24 4:16 FITTING PROGRAMMER Page 34 of 57Installation & maintenance manual for Camray 5 Combi External Boilers

IMPORTANT The electrical installation of the programmer must be carried out by a suitably qualified electrical engineer/installer. It is not recommen

1) These instructions are ONLY for suitably qualified personnel. 2) When selecting a Programmer make sure that it is suitable for combi boiler applic

completely, but the vacated hole must be blanked off.Page 26 Section 5 - Flues 5:1 POSITIONING THE BOILER Read Sections 5:2 & 5:3 Some combustion

'Where the terminal is within 1m of any plastic material, such material should be shielded from the effects of the combustion products of the flu

It is recommended that the relevant section of BS 5410 Part 1: latest edition is carefully read. 7:3 REPORTING It is recommended that you use a report

Page 01 Section 1- Users Guide 1:1 INTRODUCTION Thank you for choosing the Camray Combi manufactured in the UK by Boulter Buderus who are renowned oil

7:7 EXPANSION VESSEL PRESSURE When the system water is heated, the pressure will rise above the Cold Fill setting. If the pressure reaches 2.5 bar whe

Ensure that soldered connections on copper pipes have not been used. Is the size of the pipe adequate for the boiler rating? Are all joints leak pr

Is the flue connected and properly located? VENTILATION Are the air grilles in the casing panel door clear from obstruction? Is the flue adapter fi

connection, and replace burner. Set the boiler thermostat to between Summer and Winter positions, see Fig 1. Switch on the electric supply to the bo

A boiler fired with Class C2 Oil should only require attention once a year.8:1.1 General Inspection With the Boiler operating, inspect for signs of un

Fit combined air bleed manifold and 0-300psi (0-20 bar) pressure gauge to the appropriate oil pump connection, and replace burner. Switch on the elect

Fig 8.2a 8:3 BAFFLE ARRANGEMENT Page 46 of 57Installation & maintenance manual for Camray 5 Combi External Boilers14/04/2005file://D:\PL61500\PL6

Fig 8.3a Page 35 8:4 HEATING SYSTEM During routine servicing, the system water should be "topped up" if necessary, using the Filling Loop w

pressure must be reduced. The Boiler and storage tank each have a drain to facilitate this. After replacing the relevant parts, refill the system as d

supply switched on? Is the programmer (or Boiler Operating Switch) set to call for heat? Is the Boiler Thermostat set to the desired temperature? Is t

1:3 IMPORTANT SAFETY NOTES To obtain the best possible performance and trouble free operation from your Boiler, it is important that you read these i

Flame instability. Check combustion setting and re-set if necessary. 4 Burner starts but will not light up. This can be due either to absence of oil o

throughput or uneven and spray pattern. Technical Data). (b) at initial firing. Air in supply line. Purge at pump to remove. Blocked flue ways. Clean

Pages 40 to 43 10:3 FAULT FINDING SYSTEM SUMMER MODE (DHW ONLY) puffing, ignition cuts in intermittently. improperly adjusted or faulty nozzle or unsa

Pages 44 and 45 10:4 FAULT FINDING SYSTEM SUMMER MODE (DHW & CH) Pages 45 and 46 Air trapped in boiler heat exchanger Bleed air from boiler heat e

10.5 PARTS REPLACEMENT INSTRUCTIONS Note. Before attempting any parts replacement always isolate appliance from mains electricity supply. 1) To remove

g) Remove both elbow fittings (9) h) Unscrew valve body from the storage tank i) Replace with new unit and reassemble in reverse order using jointing

e) Reassemble in reverse order, reinstate cold mains supply and test correct functioning of flow switch Page 47 Manual Part No. PL61500 Issue No. 1 Da

Heat is our Element Page 57 of 57Installation & maintenance manual for Camray 5 Combi External Boilers14/04/2005file://D:\PL61500\PL61500.htm

If an engineer is not known, Boulter Buderus will be pleased to provide details of a commissioning and servicing engineer from their register. *The Oi

1:6 BOILER CONTROL PANEL Fig 1 a Boiler Control Panel (see Fig 1a) 1. Boiler control thermostat 2. Hot water thermostat 3. Boiler overheat/limit ther

1:6.2 Hot Water Tank Thermostat This thermostat controls the water temperature in the tank. Guidance on its use is given in Section 1:7 of this manual

Fig 1 b Page 05 1:7 OPERATING FEATURES AND INSTRUCTION 1:7.1 How does your Boiler work? Hot Water If the Programme is set for Hot Water only or Summe