Boulter Camray 3 Oil Boiler Manual
Afternoon guys, Does anyone have the manual available for a Boulter Camray 3 oil boiler at all? Have tried a few links and I am getting nowhere. (Posted on behalf of a friend:) 'I could do with a pdf of the burner. The part I need is a piston located on the right hand side of the burner that operates the air shutter allowing the correct air mix to the burner. Problem is I know the boiler is discontinued and I think the parts are also.
. Page 1 of 77 COMBI OPERATING, INSTALLATION & MAINTENANCE MANUAL CAMRAY 5 COMBI Oil Fired Boilers (55, 70A & 90A) Manual Part No PL50000 Issue No. 5 Date of Issue February 2003 HEALTH AND SAFETY INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
30 White House Road, Ipswich IP1 5JA Telephone: (01473) 241555 Boulter Boilers Fax: (01473) 241321 A subsidiary of Buderus Heiztechnik GmbH Due to a policy of continual development reserves the right to alter or amend the design of its products without prior notice. Page 3 of 77 1:1 Introduction 1:2 Useful Information 1:3 Important Safety Notes 1:4 Connections 1:5 Installation and Commissioning 1:6 Boiler Control Panel 1:7 Operating Features and Instructions 1:8 Maintenance 1:9 Failure to Start SECTION 2 - INTRODUCTION 2:1 Introduction 2:2 Hydraulic Circuits 2:3 Flue Options 2:4 Commissioning. CAMRAY 5 COMBI PAGE 1 1:1 INTRODUCTION Thank you for choosing the Camray Combi manufactured in the UK by Boulter Buderus who are renowned oil-firing specialists.
To obtain the best possible performance and trouble free operation from your Boiler, it is important that you read section 1 of this manual carefully. Information can be found on appliance data label located inside the left hand side panel of the casing. Also on the front cover of your installation manual. CAMRAY 5 COMBI PAGE 2 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 instructions carefully. O.F.T.E.C.
registered engineer. It is the responsibility of the installer to ensure that the Boiler is commissioned. If an engineer is not known, Boulter Buderus will be pleased to provide details of a commissioning and servicing engineer from their register. If this temperature is likely to cause nuisance or discomfort your installer should be able to advise on a suitable temperature blending valve. CAMRAY 5 COMBI PAGE 3 1:6 BOILER CONTROL PANEL Boiler Control Panel (see 1. Lf the burner locks out again wait 3 minutes and repeat the operation again. If the problem occurs again, turn the boiler off and consult your installer.
CAMRAY 5 COMBI PAGE 4 file://D: PL50000 PL50000.htm. Page 9 of 77 Fig.
1b Lockout Reset 1:7 OPERATING FEATURES AND INSTRUCTIONS 1:7.1 How does your boiler work? Hot Water 1 If the Programmer is set for Hot Water only or the Summer/Winter switch is set to Summer:- a) The boiler will operate until the hot water tank reaches the temperature you have set on the Hot Water Tank Thermostat. Control Panel, or the programmer switch to the OFF position on the optional programmer. 1:7.3 Sealed System Central Heating Your Camray 5 COMBI Boiler may only be used on a SEALED SYSTEM. It is important that the correct operating system pressure is maintained.
If the System Pressure Gauge, in the Control Panel, should indicate low pressure i.e. CAMRAY Boilers offer greater freedom to select the most suitable position for siting and the opportunity to install the boiler in a suitable outbuilding if required.
All models are supplied for connection to a conventional chimney or any of the available Camray 5 Combi Balanced Flue options. Page 12 of 77 Fig.
2a Schematic Diagram Camray 5 Combi CAMRAY 5 COMBI PAGE 7 2:2 HYDRAULIC CIRCUITS file://D: PL50000 PL50000.htm. Page 13 of 77 Fig.
2b Hydraulic Circuits 2:3 FLUE OPTIONS CAMRAY Boilers are designed to operate with high efficiency, clean combustion and low noise level. They offer unique versatility and can be used in the following modes: 1.
Low level rear outlet balanced flue. Non compliance with the above will invalidate the Guarantee.
3:1 LIQUID FUELS The Camray 5 COMBI Boiler will burn liquid fuels complying with BS2869 Part 2 1988 Class C2 specified in the Code of Practice for Oil Firing BS5410 Part 1. Page 15 of 77 Heat Input (Full load based on Net efficiency of 91%) Heat Output (Full load) Maximum Boiler working pressure 3 bar Class 2 - 30.6m water head Minimum return water temperature Maximum side panel temperature OFF3 is 23hrs 50mins. CAMRAY 5 COMBI PAGE 28 4:17.6 PROGRAMMES MON - FRI SAT &. Page 38 of 77 FIRST ON 1 6:30am 6:30am 7.00am 7.00am PERIOD 8:30am 8:30am 9.00am 9.00am OFF 1 SECOND PERIOD ON 2 12 noon 12 noon 12 noon 12 noon OFF 2 12 noon 12 noon 12 noon 12 noon 4:30pm 4:30pm 4.00pm. 4:17.9 TEST The Test facility is a unique feature of the Boulter Programmer. Test enables a quick review of the 7 day programme. TO USE ‘TEST’ With the Timer/Programmer in the operating mode and the Display showing the correct Time and Day.
The terminals of balanced 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. 5:1.1 Balanced Flue Types Three types are available 1. (see BS5410:1). Care should be taken to ensure that there is clearance between the outer surface of the flue and any combustible material. CAMRAY 5 COMBI PAGE 30 5:4 POSITIONING THE BOILER Read Sections 5:2 &5:3.
BOULTER BUDERUS would be pleased to advise on any difficult positioning Fig. 5.4 Balanced Flue Terminal Positions CAMRAY 5 COMBI PAGE 31. Page 43 of 77 Generally, exhaust 2 metres above ground level alleviates the necessity for a guard. A suitable guard is available from BOULTER BUDERUS as shown below. 5.5 5:6 HORIZONTAL FLUE TERMINAL The Terminal for Horizontal Balanced Flue is secured to the wall by means of four screws. The indexing plate should have its four edges siliconed to the outside wall to provide a weather seal.
Oil Boiler Uk
Ensure that the outlet of the Terminal points downward (TOP upper-most and Boulter correct way up). Ensure that the boiler to offtake gasket is fitted (foil face upwards) and the clamp is made with four nuts and washers securely fixed. Page 45 of 77 that it is not damaged and that either end is connected via the jubilee clip provided to ensure correct boiler operation. CAMRAY 5 COMBI PAGE 33 6:2 LOW LEVEL HORIZONTAL FLUE 6:2.1 Rear Fig. 6.2a Low Level Horizontal Rear 6:2.2 Side - Left hand only. Page 46 of 77 6:2.3 Low Level Assembly LOW LEVEL FLUE INSTALLATION Site conditions will dictate to a certain extent the best method of assembling low level balanced flues. The illustration shows a typical rear outlet flue.
Assemble the flue generally as follows: 1. Boulter is upright. 15.Secure the terminal to the flange using the four screws. 16.Fit an approved terminal guard if in an accessible position. Available from Boulter Buderus. 17.Inside: Using the clips supplied fix the flexible air duct to the burner spigot and flue offtake securely.
Page 48 of 77 Fig. 6.3a High Level Horizontal Rear CAMRAY 5 COMBI PAGE 36 file://D: PL50000 PL50000.htm. Page 49 of 77 Fig. 6.3b Low Level Horizontal Flue Assembly HIGH LEVEL SIDE & REAR INSTALLATION Assemble the flue generally as follows: 1. Position boiler check that all water connections and proposed flue position are according to clearances specified.
Taking the terminal end, keeping it square to the external flange push home over the internal flue exhaust pipe until the four holes on the flange align. Ensure that TOP is on the upper-most surface of the terminal and BOULTER is upright. 19.Secure the terminal to the flange using the four screws. This is attained by pushing two telescopic flues together until the desired dimension is obtained.
Secure any vertical lengths by using a drill and 4 self tapping screws supplied. CAMRAY 5 COMBI PAGE 38 6:4 VERTICAL FLUE FLAT ROOF INSTALLATION file://D: PL50000 PL50000.htm. Page 52 of 77 Fig. 6:4a Vertical Flue - Flat Roof CAMRAY 5 COMBI PAGE 39 6:4 VERTICAL FLUE FLAT ROOF INSTALLATION - CONTINUED 6:4.1 Notes on installation Site conditions will dictate the best method of assembling the Vertical Balanced Flue.
Page 53 of 77 IMPORTANT WARNING Where a flue system passes through a joist frame, it is essential that the integrity of the ceilings fire barrier is retained. This can be achieved by ALWAYS using the support plate and firestop ceiling trim. We would also recommend strongly the use of the Adjustable Joist Sleeve (optional) to complete the fire stop. Continue with the rest of the installation. NOTE: Ensure that there is a minimum of a 50mm overlap at all telescopic flue joints CAMRAY 5 COMBI PAGE 40 Fig. 6:4b Vertical Flue - Flat Roof Assembly CAMRAY 5 COMBI PAGE 41 file://D: PL50000 PL50000.htm. Page 55 of 77 6:5 VERTICAL FLUE PITCH ROOF INSTALLATION Fig.
6:5a Vertical Flue - Pitched Roof CAMRAY 5 COMBI PAGE 42 6:5 VERTICAL FLUE PITCHED ROOF INSTALLATION - CONTINUED 6:5.1 Notes on installation Site conditions will dictate the best method of assembling the Vertical Balanced Flue. Page 56 of 77 IMPORTANT WARNING Where a flue system passes through a joist frame, it is essential that the integrity of the ceilings fire barrier is retained. This can be achieved by ALWAYS using the support plate and firestop ceiling trim. We would also recommend strongly the use of the Adjustable Joist Sleeve (optional) to complete the fire stop.
Oil Boiler Spares
Using the clips supplied fix the air duct to the burner spigot and vertical flue offtake spigot. Continue with the rest of the installation. NOTE: Ensure that there is a minimum of a 50mm overlap at all telescopic flue joints CAMRAY 5 COMBI PAGE 43 Minimum overlap of telescopic flues 50mm. File://D: PL50000 PL50000.htm.
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 Boulter will be pleased to provide details of a commissioning and servicing engineer from their register.
Page 59 of 77 7:2 RESPONSIBILITY It is the responsibility of the installer to ensure that the boiler is properly commissioned. It is essential that the commissioning procedures detailed in this manual are carried out preferably by a qualified OFTEC engineer using recognised test equipment. BS 7074 Part 1 for information on sizing of the additional expansion vessel. CAMRAY 5 COMBI PAGE 45 7:8 BOULTER RECOMMENDED COMMISSIONING CHECKLIST - SHEET 1 OF 2 Tick off each item OIL TANK Is there sufficient oil, and of the correct grade for the appliance? Is the tank adequately supported?
Is a damp-proof membrane inserted between the tank and support? (Non plastic tanks).
Page 61 of 77 Outer valve Filter Sludge cock (Non plastic tanks). HEIGHT OF TANK Is the bottom of the tank above the oil pump if a single pipe system is installed? OIL SUPPLY LINE Ensure that galvanised iron has not been used. If black iron has been used, is it protected against corrosion? Ensure that soldered connections on copper pipes have not been used. Is the boiler flueway inspection cover screwed down sufficiently firmly to form a seal? Is the flexible air duct connected correctly.
CAMRAY 5 COMBI PAGE 46 7:8 BOULTER RECOMMENDED COMMISSIONING CHECK LIST- SHEET 2 OF 2 CASING PANELS Have grommets been fitted to relevant oil supply entry points (knockouts)?. Page 63 of 77 Has the chimney been adequately lined and insulated? NOTE:- Lining the flue and back filling will help prevent condensate problems BALANCED FLUE APPLIANCES Is the correct flue kit fitted?
Is the Flue off take correctly secured to the boiler by four nuts and washers. Is the gasket provided fitted correctly?
Has the rear Air Entry Plate been fitted with Blanking Plates where necessary? Can leakage from flues tubes or air ducts occur? All seals fitted correctly?. Is there sufficient system pressure? Record initial system pressure cold. Has a chemical dosing type water conditioner been fitted to the water supply to the boiler?
CAMRAY 5 COMBI PAGE 47 7:9 BOULTER BUDERUS RECOMMENDED COMMISSIONING TESTS Have the manufacturers on-site assembly instructions been followed? 7:9.1 COMMISSIONING TESTS - BOILER. Check the operation of the limit thermostat Complete commissioning report and enter the details on to the guarantee form which should be returned to BOULTER BOILERS in the envelope provided. Instruct the user on the operation of the appliance and leave this manual with the customer. Allow boiler and tank to reach temperature again and switch to winter mode, adjust boiler control thermostat to maximum and repeat the last instruction.
Continue with normal system checks. CAMRAY 5 COMBI PAGE 49 8:1 MAINTENANCE A boiler fired with Class C Oil should only require attentions once each year.
Page 67 of 77 assembly. CHANGE the nozzle for one with the specified make, oil rate, spray pattern and angle. Inspect the ignition electrodes for crazing in the porcelain. Replace if there are signs of deterioration. A dirty fan impeller can impair the performance of a burner, inspect and clean if necessary. Inspect photocell, if badly discoloured, change it. Page 68 of 77 Complete a maintenance report and give the customer a copy, retaining a copy for your records.
CAMRAY 5 COMBI PAGE 50 8:2 AIR SHUTTER ADJUSTMENT The Burner has a fixed Air Shutter with manual adjustment. To adjust the CO2 at the Air Shutter use a 3mm allen key as shown. To increase the setting turn the airshutter clockwise and to decrease turn anticlockwise. Page 69 of 77 Fig. 8.3a Baffle Arrangement CAMRAY 5 COMBI PAGE 51 8:4 HEATING SYSTEM During routine servicing, the system water should be topped up if necessary, using the Filling Loop when the system is cold. Refer to 7:5 Filling the System.
Should be checked to be in accordance with the cold design pressure of the system. 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. Replace control box. Electric cell circuit faulty Flame instability Check combustion setting out and reset if necessary. CAMRAY 5 COMBI PAGE 58 Burner starts but will not This can be due either to light up absence of oil ignition.
Oil pump air locked (repeat. Checked and replace with correct size and type nozzle (see Technical Data) Air supply inadequate Check fan operation and cleanliness. CAMRAY 5 COMBI PAGE 59 Burner pulsates Worn nozzle with excess Replace with nozzle of correct type and size (a) continuously throughout or uneven. High flue gas temperature Check: air shutter, nozzle size (see Technical Data), clean heat exchanger surfaces. Oil odour Leaking joints Break all leaking joints and re-make CAMRAY 5 COMBI PAGE 60 High operating Control stat failed and Replace control stat and reset Limit Thermostat temperature operating on limit stat.
Bleed air from pipe and repressurise if required CAMRAY 5 COMBI PAGE 62 10:4 FAULT FINDING SYSTEM WINTER MODE (DHW & CH) SYMPTOM FAULT REMEDY. Free off or replace circulating pump. Thermostat is tripped, no heat to tank or heating CAMRAY 5 COMBI PAGE 63 10:5 PARTS REPLACEMENT INSTRUCTIONS Note: Before attempting any parts replacement ALWAYS isolate appliance from mains electricity supply. 1) To remove/replace circulating pump.
Remove cable grip and ease cable from control panel e) Reassemble in reverse order, reinstate cold mains supply and test correct functioning of flow switch. CAMRAY 5 COMBI PAGE 65 11 INSTRUCTIONS FOR CONNECTING AN EXTERNAL PROGRAMMER 1) These instructions are ONLY for suitably qualified personnel. Boulter Boderus Limited, Magnet House, 30 White House Road, Ipswich IP1 5JA Tel:55 Fax:21 Boulter Boderus policy is one of continuous research and development and this may necessitate alterations to this specification from time to time.
Hearthstone H-3 Oil Boiler
Boulter Boderus reserve the right to do this without prior notification.