As mentioned above there are two types of faults burner faults and the control device and heating system faults. Whenever there is a burner fault, the lamp located on the burner will flash. Control device and heating system fault finding is included in the section above. To remedy burner faults you should remove the burner hood, if the boiler has an integral burner. Next you should press the burner reset button as shown on the picture below.
Buderus boilers are able to work in two systems: sealed and open. Nowadays sealed system boilers are commonly used, and open systems are usually boilers that were commissioned years go.
Therefore, a sealed system is used as an example of how you can check the water pressure. The pressure gauge marker in case of sealed systems must be within the green field. Ensure that the red pressure gauge needle is set to the required operating pressure. Set the over-pressure to at least 1 bar. Check the heating system operating pressure. If the operating pressure is too low the pressure gauge needle indicates below the green field top the system up with water. Top up with water.
Bleed the heating system. Re-check the operating pressure. You can damage the system if you re-fill it too frequently due to water quality or by corrosion and scaling. You should contact your installer or service engineer if you need to regularly re-fill the system as there may be a leakage in the system and leak testing should be performed, because pressure, control and safety equipment may be damaged through excessive pressure.
If you carry out a leak test, you need to make sure that no pressure, control or safety equipment is fitted which cannot be isolated from the boiler water chamber. Shut off the pressure expansion vessel from the system by closing the cap valve. Then verify the connections and pipework for leaks. After this the mixing valve should be opened as same as the shut-off valves- both on the primary side- hot water.
At the end system should be re-filled with water. Each heating system need to contain proper amount of water to function correctly. Make-up water should be added into the heating circuit when the system pressure is not high enough. In most cases make-up water loses much of its volume in the first few days because of gases release. If you are a new system owner we would recommend to check your heating system water pressure first on a daily basis, and thereafter at increasing intervals.
Otherwise system pressure should be checked pressure monthly, if the heating system still loses volume. Sometimes you can experience air pockets accumulation caused by re-filling and therefore the whole system should be air-vented through the radiators. One of the most unique features of the Buderus iron cast boilers is the thermo-stream technology. The main idea of this technology is that the water that comes to the combustion chamber is first preheated and then mixing within the appliance.
Thanks to this there is a sustainable temperature distribution and there is no condensate built int he combustion chamber. This way thermal stress is highly reduced. The minimal appliance operating temperature is always maintained- no need for a pump, n risk of its breaking. The minimum appliance operating temperatures are listed in the table below.
Those temperatures should be reached within maximum 10 min period of time. Fuel operating condition can be easily achieved by the controls monitoring the boiler temperature and reducing the flow rate through the boiler until the required temperature is reached. This is can be kept by controlling flow comparing to temperature of the boiler. Flow rate can be reduced by modulating the boiler primary pumps, closing the valves on the mixed heating circuits.
Normally it can be managed by the Buderus control panel, but that can also be achieved by simple BMS usage. In those cases where it is difficult to regulate the proper flow, fitting a shunt pump circuit is recommended. In the most the cases the shunt pump circuit can be controlled normally by Buderus fitted with a ZM module or Buderus control.
Carry out a leak test at a test pressure of 5. Slowly fill the boiler block. Bleed at the highest point of the system, until water flows out of the air vent valve. Then remove the water pipes and the the feed pipe. After this release and remove the anchor rods. Separate the leaking boiler by driving flat wedges or chisels into the leaking part. Attention Pressure gauge class 1. Remember that system may get damaged through over-pressure. You need to make sure that no pressure, control or safety equipment is fitted.
Hubs need to be cleaned before re-assembly. New nipples shouldbe used and and new packing cord. Your appliance should be compressed block again. The feed pipe and the anchor rods need to be re-fitted and at the end the leak test should be repeated. Loosen the fastening screw of the UBA 3 by turning it counterclockwise as shown on the picture below.
Remove the UBA 3 once the fastening screw is fully loosened by pulling it forward carefully as indicated by the arrow. Check the circuit continuity through the fuse using the volt-ohm multimeter. Do not push or force the UBA 3 in place by hand!
To clean your boiler properly you should first open the door by removing the two lateral hexagon bolts. First you should write down the position of the hot gas baffle plates to ensure their correct re-installation later. Next you should remove the hot gas baffle plates from the hot gas flues.
Now you should clean the hot gas baffle plates using one of the two cleaning brushes as shown on the picture below. The hot gas flues should be cleaned by rotating the round cleaning brush. Combustion chamber should however be cleaned with a flat brush. All loose combustion residues need to be removed from the combustion chamber, the flue outlet and the hot gas flues.
Now the hot gas baffle plates need to be installed as same as in their original position. Verify position of the packing cord on the burner door. Hardened or damaged packing cord must be replaced! The burner door should be closed with both hexagon bolts. Tighten the hexagon bolts evenly to properly seal the burner door. When wet-cleaning, proper cleaning agent level should be used appropriate to the level of contamination- soot level and encrusted residues.
While wet-cleaning you should follow the same steps in the same order as described for cleaning with brushes, but you need to pay attention to the cleaning agent functionality, in some instances you will need to cover the control device with plastic to prevent spray from entering the control device.
The cleaning agent should be spayed evenly into the hot gas flues. The burner door should be closed the burner plug should be plugged and now you should start the heating system. Once achieved you can shut down the heating system and brush out the hot gas flues.
Before you start the boiler make sure that: the system water pressure is at the proper level, emergency stop switch of the the heating system is ON and the fuel supply to the main fuel shut-off valve is open. In order to reset the boiler you need to simply press the burner reset button. Remember that you can damage the system through frequent activation of the reset button.
The burner ignition transformer may get damaged once you press the reset button more than three times in one after another if burner refuses to start. Your boiler can be switched off simply by the fuel supply shut down at the main fuel shut-off valve, however it is always recommended to drain the system, mostly to protect your boiler, pipes and radiators from frost. The air vent valve should be opened at the highest system point. The system can freeze up if it is not in use, e.
It is advice to protect your system against frost damage, where temperatures below zero are expected. This switches the boiler and all its components OFF for example the burner as shown on the picture below. The main shut-off fuel valve should be closed. In other dangerous circumstances, isolate the main fuel shut-off valve and the electrical power supply of the system. This can be done at the appliance main fuse or alternatively by the the emergency stop switch. Troubleshooting Manual.
Wall clearances Where possible install the boiler with the recommended wall clearances values shown table below. Safety first! Inappropriate operation of Buderus boilers may lead to material losses, heath and life danger: Life danger- through the explosion of volatile gases. If you can smell gas then there is a risk of explosion. Then you should close the mains gas, and that can be achieved by closing off the mains valve, immediately open all doors and windows.
Warn all people being at the property and leave the building. Contact your gas supplier by using a phone minimum m away from your property. If necessary, notify police or fire services. Leave the danger zone immediately when you hear gas streaming out Life danger- through poisoning. Ventilation not good enough can lead to dangerous flue gas leaks.
Make sure that the ventilation and exhaust air openings are not closed and not restricted. You should switch off the boiler immediately and call for help Life danger- through the explosion of volatile gases. Make sure that the installation, fuel gas and oil connections, the initial start-up, the power connection, repair and maintenance work are carried out by licensed specialists Life danger and material losses- through the fire of the combustible material or liquids.
Never store flammable materials or liquids next to heat generator Material losses- through boiler damage caused by contaminated combustion air. Never use chlorinated cleaning agents or halogenated hydrocarbons as, for example paints and adhesives, solvents or cleaning agents, contained in spray cans.
Avoid atmospheres which are frequently very dusty. Never hang washing to dry in the boiler room Material losses- through system damage caused by frost. Have your system inspected, cleaned and maintained annually by a specialist.
Annual service record should be entered into operating manual book provided with your boiler Remember to: 1. Page 3 7. Under no circumstances should mineral oils be taken internally. Before using your new Boiler, we ask that you carefully read the following information.
Page 6 Boiler has been installed it is first commissioned by a competent and preferably an O. 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 commissioning and servicing engineers from their register.
Page 9 Your Installer should give guidance on this. Page 10 Flue Terminal Pluming Due to the high efficiency of the Camray 5 range white water vapour from 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. Note: The nozzle on this appliance is only covered by a 1 year guarantee. Page 13 This appliance must be effectively earthed and connection to the supply must be through a double pole isolating switch fused 5 amp.
Page 16 6. The boiler requires a level hearth on which to stand which should comply with the Building Regulations. Page 17 Page 17 of 67 The boiler requires a minimum stable draught of 0. If the chimney exceeds 6m 20 feet in length, it may produce a draught exceeding 0.
Page 18 When the Boiler is installed in a basement or low level boiler house where air can enter only from high level, the incoming air supply for Combustion and Ventilation should be ducted to low level.
A high level outlet should be provided for ventilation. Page 19 50mm thick garden slabs or a concrete base. As there is only one tapped outlet they are more suited to single pipe feed as gravity supply or with a Boulter 3K Oil Loop Deaerator where suction lift is required.
Page 20 The Flexible Oil Pipes are fitted inside the Boiler casing and are of adequate length to enable the Burner to be removed without disconnecting.
Page 25 The Control Panel is pre-wired and fitted to the Boiler ready for connection to the system wiring. Page 26 Page 26 of 67 2. Page 28 Page 28 of 67 4. Remove the plate and carefully cut through the overlay with a sharp knife. Feed the pre-wired terminal block and wires through the hole now exposed in the Control Panel. Click the Programmer in place from the front.
Fitting Instructions for the programmer are included in the Programmer Kit. These may be as required but can be easily changed if not. Press and release once. Press and release once to answer. The Day on the Display will flash. Page 31 pm pm 4. Page 32 Test enables a quick review of the 7 day programme.
Page 33 When the Holiday Period is over the Programmer reverts back to the normal programme. Page 35 It must be removed for fully pumped systems. Balanced Flues permit considerable choice of siting of the Boiler. Boilers may be installed in situations where no chimney exists, where the chimney is unsatisfactory or in outhouses.
Page 37 see BS Care should be taken to ensure that there is clearance between the outer surface of the flue and any combustible material. The Terminal must be slightly angled down to ensure correct operation of the boiler. Due to the efficiency levels of Camray 5 pluming from the terminals may occur under certain conditions. Page 40 3. Ensure that the boiler to offtake gasket is fitted foil face upwards and the clamp is made with four nuts and washers securely fixed.
The illustration shows a typical rear outlet flue. Assemble the flue generally as follows: 1. Secure the terminal to the flange using the four screws. Fit an approved terminal guard if in an accessible position. Available from Boulter Buderus. Inside: Using the clips supplied fix the flexible air duct to the burner spigot and flue offtake securely.
Position boiler check that all water connections and proposed flue position are according to clearances specified. Mark the flue position on the wall.
Page 45 NB. Fit an approved terminal guard if in accessible position.
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