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Worcester 12/18 Instruction Manual

Manual is about: GREENSTAR CAMRAY KITCHEN FLOOR STANDING OIL FIRED CONDENSING BOILER CONVENTIONAL FLUE & ROOM SEALED FLUE

Summary of 12/18

  • Page 1

    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 instruction manual installation, commissioning & servicing the a...

  • Page 2: Check List

    Installation & servicing instructions installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 1 symbols used in this manual: please read these instructions carefully before starting installation. These instructions ar...

  • Page 3

    Contents contents installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 2 s a fe ty & r e g u l a t ion s ap p l ian c e in f o r m a t ion p r e - in st al la ti o n ins t a l l a t io n c o mmi s s io n in g ser v...

  • Page 4

    Safety precautions & installation regulations installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 3 s a fe ty & r e g u l a t ion s safety precautions installation regulations oil smells, leaks or fumes from the a...

  • Page 5: Check List

    General information installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 4 ap p l ian c e in f o r m a t ion a b 780mm 950mm 565mm c d e general information standard package: a - floor standing oil fired condensing...

  • Page 6

    Technical data installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 5 ap p l ian c e inf o rm a t io n technical data central heating primary water capacity (total) external litres primary water capacity (total) ex...

  • Page 7

    The diagram opposite excludes the top, front and rh side casing panels. 1 control box assembly 2 casing side panel 3 flue overheat thermostat phial 4 air inlet casing 5 flexible air duct (connecting to air intake on burner) 6 casing support panel 7 secondary heat exchanger bleed point (one on either...

  • Page 8

    Layout & components installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 7 p r e - in st al la ti o n the diagram opposite excludes the top, front and rh side casing panels. 1 control box assembly 2 casing side pan...

  • Page 9

    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: cleanse the system in accordance with bs 759...

  • Page 10

    Mains supply electrical supply: • supply: 230v - 50hz. • cable: pvc insulated 0.75mm 2 (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. • it must be possible to...

  • Page 11

    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 ...

  • Page 12

    R a - appliance. B - additional expansion vessel (if required). C - automatic bypass valve. D - drain cock. E - feed and expansion cistern. F - feed and expansion 15mmØ min. G - pressure gauge (system models only). H - open vent 22mmØ min. J - circulating pump. K - zone valve. L - lockshield valve. ...

  • Page 13

    Water systems & pipework 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. Heating return hose...

  • Page 14

    Condensate pipework installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 13 p r e - in st al la ti o n condensate pipework condensate pipework: • all national and, where appropriate, local regulations for the disch...

  • Page 15

    Pressure relief pipework installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 14 p r e - ins t a l l a t io n pressure relief pipework pressure relief pipework: important: the pressure relief valve is a safety devi...

  • Page 16

    Boiler location & clearances installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 15 p r e - in st al la ti o n boiler location & clearances warning: this appliance should not be installed where there is a potentia...

  • Page 17

    Cabinet mounted low level terminal installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 16 p r e - ins t a l l a t io n minimum dimensions of flue terminal positions for oil fired appliances: terminal position b(h)...

  • Page 18

    Installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 17 p r e - in st al la ti o n minimum dimensions of flue terminal positions for oil fired appliances: terminal position b(h) b(v) a 1 2 directly below an opening...

  • Page 19

    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. ...

  • Page 20

    Cabinet mounted balanced horizontal flue options installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 19 p r e - in st al la ti o n cabinet mounted balanced horizontal flue options • the horizontal flue is fitted t...

  • Page 21

    Unpacking: it is advised that two or more persons are involved in the transfer of the packaged boiler from the van to the point of delivery. 1 once the packaged boiler has been delivered, the outer carton is removed first. Care should be taken when releasing the straps. If a sharp implement is used ...

  • Page 22

    All dimensions in mm 295 490 102 793 254 91 105 259 259 171 490 793 590 466 105 94 55 263 659 669 704 714 490 791 590 463 159 124 90 55 659 679 699 719 559 224 in s t a l l a t ion c o mmi s s io nin g safety: all relevant safety precautions must be undertaken. Protective clothing, footwear, gloves ...

  • Page 23

    Boiler installation note: the cabinet is not load bearing it only provides weather protection for the boiler inside. 1 mark position of the 100mm services duct on the exterior wall and make a hole through. 2 remove the screws securing the base panel to the transit pallet and lift the boiler off the ...

  • Page 24

    Flue installation installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 23 in s t a l l a t ion installation notes: ensure all the seals are in good condition and seated properly. To ease assembly of flue components...

  • Page 25

    Combustion chamber installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 24 ins t a l l a t io n combustion chamber: 1 release retaining nuts and washers (a). Remove combustion chamber access door (b). 2 release scr...

  • Page 26

    Pipework connections a - flow (external regular models only) optional open vent/air vent 1” bsp on 12/18, 18/25 and (1 1 / 4 ” bsp on 25/32 models). A1 - flow (external system models only) 22mm Ø copper (28mm Ø on 25/32 models) b - primary drain & optional feed and expansion/feed 3 / 4 ” bsp c - ret...

  • Page 27

    Pipework connections installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 26 ins t a l l a t io n 1m 50mm (min.) 500ml pipework connections h - condensate trap i - condensate trap fixing bracket - supplied j - cond...

  • Page 28

    Oil burner & pump installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 27 ins t a l l a t io n caution: isolate the oil & water mains supply before starting any w o r k an d o b s e r ve all r e le vant safety prec...

  • Page 29

    Refitting components installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 28 ins t a l l a t io n refitting components d a b c e 1 align burner combustion head into boiler collar. Locate the combustion head into th...

  • Page 30

    Electrics installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 29 ins t a l l a t io n danger - 230v: isolate the mains electricity supply before starting any work and observe all relevant safety precautions. Impor...

  • Page 31

    Electrics installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 30 ins t a l l a t io n = earth • = permanent live • = neutral • = switched live 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 a b c d g h riello burner green/yellow g...

  • Page 32

    Electrics installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 31 ins t a l l a t io n electrics = earth • = permanent live • = neutral • = switched live 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 a b c d g h riello burner gree...

  • Page 33

    Electrics • = earth • = permanent live • = neutral • = switched live o outside boiler inside boiler 1 2 3 1 2 3 4 5 6 3 2 e n l 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 instructi...

  • Page 34

    Electrics installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 33 ins t a l l a t io n electrics remote 2 or 3 port valve control set using remote programmer: key to components: o - remote junction box (10-way) to ...

  • Page 35

    Pre-commissioning checks - appliance installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 34 pre-commissioning checks - appliance caution: isolate the mains supplies before starting any work and observe all relevan...

  • Page 36

    Filling the system installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 35 c o mmi s s io n in g 1 open all system and radiator valves. Turn on the water main stop cock. 2 open vented systems only: turn on the wate...

  • Page 37

    Starting the appliance installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 36 c o mmi s s io n in g starting the appliance important: never run the appliance when the appliance/system is unpressurised (sealed syst...

  • Page 38

    5 4 %c o 2 no mi nal b oile r ra ti ng a t nor mal o pera ti ng t emper at ure using 28sec k ero sene: no zzl e boiler 12/18 rdb 1 oi l p ump p ressure (p .S .I .) f uel fl ow ra t e kg/h l/h a ppro x. Fl ue gas t emp ° c a ppro x. Ai r se tt in g input output kw kw 0.40 6 0 ° es 0.45 6 0 ° es 0.55 ...

  • Page 39

    Starting the appliance installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 38 c o mmi s s io n in g a c d d b starting the appliance on 25/32 appliances: to achieve the minimum output of 25kw from the 25/32 rdb 2....

  • Page 40

    Starting the appliance installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 39 c o mmi s s io n in g on greenstar camray external system 12/18 max flue reset boiler reset service bar 0 1 2 3 4 on greenstar camray e...

  • Page 41

    Water treatment installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 40 c o mmi s s io n in g water treatment important: debris from the system can damage the boiler and reduce efficiency. Failure to comply with th...

  • Page 42

    Finishing commissioning - appliance 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. Always apply pressure at the edges of t...

  • Page 43

    Inspection and service installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 42 ser v ic in g & s p ar e s inspection and service caution: isolate the water, electricity and oil mains supplies before starting any wo...

  • Page 44

    Inspection and service installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 43 s e rv ici n g & s p ar e s 1 clean the burner: remove the air intake cover (a) and clear any debris from the air intake and air damper...

  • Page 45

    Inspection and service installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 44 ser v ic in g & s p ar e s inspection and service external oil filter: remove the paper element from the external oil filter and replac...

  • Page 46

    Baffle arrangement 12/18 installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 45 s e rv ici n g & s p ar e s baffle arrangement 12/18 12/18 model shown baffle access door restrictor plate 2 for 12/18 models, fitted...

  • Page 47

    Baffle arrangement18/25 installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 46 ser v ic in g & s p ar e s baffle arrangement 18/25 18/25 model shown baffle access door restrictor plate 1 for 18/25 models, fitted i...

  • Page 48

    Baffle arrangement 25/32 installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 47 s e rv ici n g & s p ar e s baffle arrangement 25/32 25/32 model shown baffle access door acoustic insulation insert (25/32 models on...

  • Page 49

    Inspection and service installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 48 ser v ic in g & s p ar e s inspection and service re-commission the burner: 1 align burner combustion head into boiler collar. Locate t...

  • Page 50

    Short parts list 12/18 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 ...

  • Page 51

    Short parts list 12/18 installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 50 ser v ic in g & s p ar e s 7 8 11 15 16 17 13 12 14 2 3 4 5 6 9 10 1 7a 19 18 20 21 22 23 25 24 26 short parts list 18/25 1 burner - ri...

  • Page 52

    Short parts list 25/32 1 burner - riello rdb 2.2 25/32 he part number: 8 716 112 347 0 2 combustion head - t2 lh25/32 part number: 8 716 112 769 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: 8 716 109 183 0 6 motor ...

  • Page 53

    S h o rt p art s li s t 25/32 in s tal la ti o n & s e rvi c in g i n s t r u c t io n s fo r wo r c e s t e r g r e e n s tar c a m r a y e x te r n al & e x te r nal s y s t e m 12/18-18/25-25/32 8 7 16 115 6 6 7a (05.200 9) 52 fault finding & diagrams start burner not operating normally. Find sym...

  • Page 54

    Start no heating/hot water is the demand light illuminated? Follow the control box fault finding chart to locate fault. Is the burner lockout light illuminated? No is there 230v on pin 2 of the control thermostat? (the brown wire) is there 230v on the l connection on the burner control box? No locat...

  • Page 55

    F a ul t f ind in g in s tal la ti o n & s e rvi c in g i n s t r u c t io n s fo r wo r c e s t e r g r e e n s tar c a m r a y e x te r n al & e x te r nal s y s t e m 12/18-18/25-25/32 8 7 16 115 6 6 7a (05.200 9) 54 fault finding & diagrams start boiler not operating normally. Find symptom in li...

  • Page 56

    Fault finding & diagrams f a ul t f ind in g in s tal la ti o n & s e rvi c in g i n s t r u c t io n s fo r wo r c e s t e r g r e e n s tar c a m r a y e x te r n al & e x te r nal s y s t e m 12/18-18/25-25/32 8 7 16 115 6 6 7a (05.200 9) 55 boiler not operating with a heating / hot water demand ...

  • Page 57: Service Interval Record

    Service interval record it is recommended that the heating system is serviced regularly and that you complete the appropriate service interval record overleaf. Service provider. Before completing the appropriate service interval record overleaf, please ensure you have carried out the service as desc...

  • Page 58

    Service 1 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: comments signature service 3 date engineer name company name tel no. Oftec reg no. Pump pressure: psi co 2 %: nozzle changed? Yes no f.G.T. °c flue pressure: com...

  • Page 59

    Notes installation & servicing instructions for worcester greenstar camray external & external system 12/18-18/25-25/32 8 716 115 667a (05.2009) 58 no t e s notes.

  • Page 60

    Contact information worcester, bosch group: technical: 08705 266241 service: 08457 256206 spares: 01905 752571 literature: 01905 752556 training: 01905 752526 sales: 01905 752640 website: www.Worcester-bosch.Co.Uk water treatment: fernox 01799 550811 www.Fernox.Com sentinel 0800 389 4670 www.Sentine...