Eurocal SENATOR Technical data
Contents
1. INTRODUCTION WARRANTY 2 WHAT IS A CONDENSING BOILER 2 AMBASSADOR KITCHEN COUNTRYMAN OUTDOOR amp CONSUL BOILERHOUSE CONSENSING BOILERS USER INSTRUCTIONS 3 BOILER OPERATION 3 SWITCHING THE BOILER ON 3 BOILER CONTROLS 4 SWITCHING THE BOILER OFF BURNER LOCKOUT RESTARTING AFTER LOCKOUT 5 RESTART 6 INSTALLATION REGULATIONS WATER CONNECTIONS 7 BOILER LOCATION 8 CONNECTING OIL SUPPLY 9 10 ELECTRICAL CONNECTION WIRING DIAGRAM 11 TECHNICAL DATA BOILER SPECIFICATIONS 12 14 SERVICING INSTRUCTIONS 15 BAFFLE ASSEMBLY BURNER 16 BURNER SETTINGS 17 SENATOR KITCHEN amp COUNTRYMAN OUTDOOR COMBI CONSENSING BOILERS USER INSTRUCTIONS BOILER OPERATION SWITCHING THE BOILER ON 18 BOILER CONTROLS 19 BUILT IN TIME SWITCH SENATOR COMBI ONLY 20 SWITCHING THE BOILER OFF BURNER LOCKOUT RESTARTING AFTER LOCKOUT 21 RESTART 22 INSTALLATION REGULATIONS PROTECTION OF DOMESTIC HOT WATER WATER CONNECTIONS 23 BOILER LOCATION 8 SERVICE REQUIREMENTS THE HEARTH CONTROL PANEL 24 PREFORMED PIPEWORK SEALED SYSTEM PLASTIC PIPE 25 CAPACITIES OF EXPANSION VESSEL EXPANSION VESSEL SIZING FILLING SYSTEM 26 SENATOR CONVENTIONAL FLUE INSTALLATION 27 CONNECTING OIL SUPPLY 9 10 ELECTRICAL CONNECTION SENATOR 28 ELECTRICAL CONNECTION COUNTRYMAN 29 WIRING DIAGRAM SENATOR amp COUNTRYMAN 30 TECHNICAL DATA BOILER SPECIFICATIONS 31 32 COMMISSION INSTRUCTIONS 33 SER2. A flexible oil pipe is supplied to connect the burner to the incoming oil supply pipe IMPORTANT NOTES Tf sitting oil tank above burner height use single supply pipe only If sitting oil tank below burner height use twin pipe supply or Tiger loop Please refer to Burner Manual for conversion to oil pump for two pipe system Issue No 1 Combined Manual 24 10 07 10 ELECTRICAL ENTRY The electrical supply to the boiler must be wired using a double pole isolating switch 230v 50hz fused 5 amps The mains supply must be connected with the boiler dual stat the supply will then continue down to the burner control box The burner is supplied with a three wire cable plug which allows disconnection for maintenance WIRING DIAGRAM HIGH LIMIT STAT CONTROL STAT Q BROWN BLUE YELLOW GREEN CONNECTOR MAINS INTO TWIN STAT THEN CONTINUING DOWN TO BURNER PLUG IMPORT ANT ELECTRIC SUPPLY SHDULD BE FUSED 5 AMP Issue No 1 Combined Manual 24 10 07 11 BOILER SPECIFICATIONS FOR AMBASSADOR KITCHEN DIMENSION 15 21 Kw 21 27 Kw 27 38 Kw 35 50 Kw LEFT HAND VIEW FRONT VIEW RIGHT HAND VIEW General Data Electrical Supply 240w 50hz Supply Connection 1 4 BSP Fuel 28 Second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 Maximum Operating Pressure 3 Bar 45psi 28m Static head room 92ft Draught Limit Min 12 5 Nm 0 05 WG Max 33 0 Nm 0 12 WG Issue No 1 Combi
3. BS5410 Part 1 installations up to 45kw BS7593 Water treatment of hot water central heating systems BS7671 Electrical Regulations Building Regulations Part 1L and J 2002 England and Wales Part F Scottish Regulations and Technical Booklet L Northern Ireland OFTEC Codes of Practice Published or Recommended After installing the system it needs to be flushed with a cleanser like Fernox Heavy Duty Restore for fast acting removal of lime scale black sludge magnetite and other deposits from the boiler and the central heating system Then add a Fernox protector to give long term protection of the central heating system against internal corrosion lime scale formation PROTECTION OF DOMESTIC HOT WATER WE recommend that appropriate water softening equipment is fitted in hard water areas Check with local water authority if in doubt WATER CONNECTIONS The following connections are required Heating Flow Heating Return Mains Overflow Hot Water PVC Condensate Pipe HEATING FLOW HEATING RETURN MAINS OVERFLOW HOT WATER COUNTRYMAN OUTDOOR MAINS OVERFLOW HOT WATER HEATING HEATING RETURN SENATOR KITCHEN Issue No 1 Combined Manual 24 10 07 23 INSTALLATION SERVICE REQUIREMENTS The boilers are serviced through an access panel at the front A service access space of at least 700mm should be made available at the front of the boiler THE HEARTH The temperature of the surface below the boiler is less
4. Spring Safety Valve 3 bar Conventional Size 100 125mm Thermostatic Mixer Valve 30 C 70 C LEFT HAND VIEW FRONT VIEW RIGHT HAND VIEW Issue No 1 Combined Manual 24 10 07 COMBI COUNTRYMAN OUTDOOR MODELS TECHNICAL SPECIFICATION DIMENSIONS 15 21 KW 21 27 KW 27 38 KW A 645 645 645 B 260 260 260 C 681 681 681 D 868 868 868 E 684 684 684 F 880 880 880 G 827 827 827 DIMENSIONS ARE IN mm General Data Electrical Supply 240w 50hz Oil Supply Connection 1 4 BSP Fuel 28 Second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 C Maximum Operating Pressure Expansion Vessel Capacity 12 Litres Spring Safety Valve 3 bar Thermostatic Mixer Valve 30 70 Issue No 1 Combined Manual 24 10 07 32 COMMISSIONING amp SERVICING INSTRUCTIONS A competent service engineer OFTEC registered should be appointed on an annual basis PLEASE NOTE Reducing the air supply into the burner air inlet shutter decrease the flue gas temperature and increases the Isolate Power to the boiler De pressurise heating system and check expansion vessel pre charge is the same as the cold fill pressure of the heating system Expansion vessel pre charge must not exceed 1 5 bar Remove inspection door burner and baffle assembly Brush down the inside of the heat exchanger and vacuum out debris Clean baffle assembly Pu
5. or damaged Check and rectify Fan slipping on shaft Check and retighten Pump coupling loose or worn Check and replace Burner starts violently Delayed ignition Check the electrode adjustment see diagram Check electrodes for damage Check H T leads for damage and disconnection Issue No 1 Combined Manual 24 10 07 34 NO HEATING OR HOT WATER Check there is power to the boiler has fuse blown If yes replace and test if fuse continues to blow check circulation pump is not passing heating water into circulation pump electrical box Is the system pressure below 1 bar on black needle on pressure gauge If yes recharge system pressure by opening the filling loop valve slowly until black needle indicator reads approx 1 bar Green neon NOT illuminated Place rocker switch to the ON position located on the control panel Check system is pressurised Green and orange neon illuminated Reset start by pushing red button in next to the On Off rocker switch on the control panel Vent air from the system Re check system pressure charge Orange neon illuminates regularly when in heating mode check calibration of control stat and replace if out of range Green and red neon illuminated refer to Burner Locked Out Page 5 NO D H W BUT SOME WHEN HEATING ON Turn time switch to the off position and open hot tap If boiler doesn t fire up when Temp drops approximately 1 2 minutes remove micro switch from diverter valve by remo
6. than 85 If the floor under the boiler is of combustible material then protection such as steel should be fitted between the boiler and the floor Consideration should be given to the weight of the filled boiler the floor must provide adequate support Please consult the building regulation for safe floor loadings CONTROL PANEL The boiler control panel is factory fitted prior to despatch The phials of the Control and High Limit Thermostat are inserted into the pockets situated on the left hand side of the boiler heat exchanger HIGH LIMIT STAT ELECTRICAL ENTRY The electrical supply to the boiler must be 230v 50hz fused at 5 amps Connection of the appliance and any system controls to the mains supply must be a common isolator and must be fused at 5A maximum This must be fixed wired to a double pole isolating switch that has a maximum contact separation of 2mm in both poles The isolator should be clearly marked showing it s purpose and preferably positioned close to the boiler Issue No 1 Combined Manual 24 10 07 24 PREFORMED PIPEWORK 1 of 22mm section labelled Heating Flow 1of 15mm section labelled Mains 1 15 section labelled Hot Water 1ofi5mm section labelled Overflow 1 of 22mm section labelled Heating Return Preformed pipes on the senator Combi can exit on the left or right hand side of the casing Please ensure that if flueing low level balanced flue from the side of the casing of
7. IR VENT 8 SAFETY RELIEF VALVE 9 PRESSURE GAUGE 10 GATE VALVES 11 GRUNFOSS PUMP 12 DIVERTER VALVE DIAPHRAGM 13 MIRCO SWITCHES 14 PLATE HEAT EXCHANGER 15 LOW PRESURE SWITCH 16 FILLING LOOP 17 THERMOSTAT MIXER VALVE 18 EXPANSION VESSEL HOSE 19 12 LITRE EXPANSION VESSEL 20 BURNER 21 DOOR INSULATION KIT NOT SHOWN 22 BASE INSULATION KIT NOT SHOWN 23 CONDENSATE TRAP 24 SNORKEL TUBE Issu 10 1 Combined Manual 24 10 07 36
8. VICING INSTRUCTIONS 33 FAULT FINDING COMBUSTION 34 FAULT FINDING COMBI 35 PARTS LIST 36 BAFFLES ASSEMBLY BURNER 16 BURNER SETTINGS 17 Issue No 1 Combined Manual 24 10 07 INTRODUCTION Thank you for choosing our condensing oil boiler please read the following carefully To the installer This manual must be left with the householder by the installer who will instruct the user on the boiler operation To the user Please read the user section of this manual to familiarise yourself with the boiler operation WARRANTY WARRANTY FOR YOUR BOILER MUST MEET THE FOLLOWING CONDITIONS OR YOUR WARRANTY MAY BE INVALID Warranty on the Heat Exchanger 5 Years Excludes labour Warranty on Burner and Controls 2 Years CONDITIONS OF WARRANTY 1 Boiler MUST BE installed by an OFTEC registered engineer if not permission will be required by building control 2 Boiler MUST BE commissioned after installation by an OFTEC registered engineer 3 Boiler MUST BE serviced every 12 months after installation by an OFTEC registered engineer 4 Installer MUST COMPLETE an Installation Commission Form which will be found along with your manual and this must then be returned to the address on the warranty form Failure to return this form may invalidate your warranty WHAT IS A CONDENSING BOILER AND HOW DOES IT WORK On all standard boilers the flue gases that go up the chimney have quite a high temperature 200 C 2609 and are made up of a f
9. c hot water function is permanently on and controlled by a heating control thermostat INSTALLATION OF A ROOM THERMOSTAT Connect a room thermostat to terminal 3 and 4 on the 8 way connect strip inside the boiler control panel and discard link wire If neutral wire is required for room thermostat connect neutral wire to terminal 6 on the 8 way connect strip INSTALLATION OF A TIME CLOCK OR PROGRAMMABLE ROOM STAT Connect a remote time clock or programmable room stat to 3 and 4 on the 8 way connect strip inside the boiler control panel and then disregard link wire The internal time clock can be switched to continuously on or a link wire can be connected to 4 and 5 on the 8 way connect strip to disable integral time clock INSTALLATION OF FROST THERMOSTAT Connect a frost thermostat to terminal 5 and 3 on the 8 way connect strip inside the boiler control panel If neutral wire is required for frost thermostat connect to terminal 6 on the 8 way connect strip Issue No 1 Combined Manual 24 10 07 28 ELECTRICAL CONNECTION COUNTRYMAN OUTDOOR COMBI The electrical supply to the boiler must be wired to a double pole isolating switch 240v 50hz fused at 5 amps A multi 6 pin plug is included with the boiler which connects with the boiler control panel The burner is supplied with 4 wire cable plug which allows disconnection for maintenance CONTROL OPTIONS A Room Thermostat must be fitted for the boiler to work correctly A Frost The
10. ce excessive draught over 4mm w g Draught stabilisers may be required 7 Length Before bends are applied length of flue must be at least 600mm COMBUSTION AIR SUPPLY CONVENTIONAL FLUE CONVENTIONAL FLUES MUST BE SUITABLE FOR CONDENSING BOILERS INFORMATION SUPPLIED BY OFTEC Conventional Flue Typical Arrangement 2 550mm kw OPEN FLUE BOILER IN ROOM NX Ia LE P wi N 1 Soot gt N kw i f Door Mias 12 Rue Pipe me 11 00mm kw OPEN FLUE BOILER COMPARTMENT VENTILATED FROM OUTSIDE Seo 55 AXATITITTETTTE i x L nomm Li 550mm kw 1 1650mrmm KW OPEN FLUE BOILER COMPARTMENT ECT CR ead ca T ran VENTILATED FROM ROOM Issue No 1 Combined Manual 24 10 07 27 ELECTRICAL CONNECTION SENATOR KITCHEN COMBI The electrical supply to the boiler must be wired to a double pole isolating switch 240v 50hz fused at 5 amps A multi 3 pin plug is included with the boiler which connects with the boiler control panel The burner is supplied with 4 wire cable plug which allows disconnection for maintenance CONTROL OPTIONS A Room Thermostat must be fitted for the boiler to work correctly A Frost Thermostat may be required this should be assessed when installing the boiler INTEGRAL TIME CLOCK SENATOR KITCHEN COMBI ONLY The integral time clock controls the heating function The domesti
11. d can be attributed to following examples interruption of the fuel supply Electrical Supply Fault e g Extreme low voltage Failure of a burner component A fault within the heating system Burner combustion not being correct The Burner Reset button on the Control Box illuminates to indicate that a lockout has occurred In the event of the Burner locking out do not attempt to restart the Burner by pressing the Reset Button on the Burner Control Box for at least 2 minutes A Bi metallic timer within the Control Box has a minimum cooling time of 45 seconds thus the 2 minute interval will ensure that this Bi metallic timer has cooled and is therefore in a position where it may be reset RESTARTING AFTER LOCKOUT When lockout has occurred inspect for any obvious causes e g oil leaks Also check the fuel line from the tank to the boiler and that any oil shut off valve has not been inadvertently closed Issue No 1 Combined Manual 24 10 07 RESTART Check there is adequate oil in the storage tank Check oil supply valves are open Switch on heating system e g Time Clock Press the Burner Reset Button on the burner Control Box which will be illuminated The Burner Reset Button illuminated Fig 1 will go out and the burner will commence the ignition start sequence After 15 seconds the Burner should fire normally PLEASE NOTE Should the Burner not start the lockout indicator on the Control Box Burner Reset B
12. d on Issue No 1 Combined Manual 24 10 07 20 SWITCHING THE BOILER OFF The boiler can be switched off by turning the rocker switch located on the underside of the control panel to the OFF position PLEASE NOTE For longer periods of shutdown e g while away on holiday switch OFF the mains electrical supply and turn OFF the OIL supply If shutdown occurs during cold weather ensure boiler is protected against frost damage BURNER LOCKOUT The burner has an independent control system Burner Control Box this includes a flame detector Photocell which senses the presence of a flame In the event of a flame failure the burner control box activates a second re ignition sequence Should the photocell not detect a flame presence within 15 seconds the burner goes to LOCKOUT and shuts down Continued LOCKOUTS are a result of a fault in the operation of the boiler and can be attributed to following examples interruption of the fuel supply Electrical Supply Fault e g Extreme low voltage Failure of a burner component A fault within the heating system Burner combustion not being correct The Burner Reset button on the Control Box illuminates to indicate that a lockout has occurred In the event of the Burner locking out do not attempt to restart the Burner by pressing the Reset Button on the Burner Control Box for at least 2 minutes A Bi metallic timer within the Control Box has a minimum cooling time of 45 seconds t
13. dary facing the terminal From a terminal facing the terminal Vertically from q terminal on the same wall Horizontally from a terminal on the same wall Above the highest point of an intersection with the roof From vertical structure on the side of the terminal Above a vertical structure less than 750mm From ridge terminal to vertical structure on the roof uO 2 rn GC OD nm oO wa gt Issue No 1 Combined Manual 24 10 07 OIL SUPPLY REMOTE FIRE VALVE MUST BE OUTSIDE THE OIL LOWEST LEVEL OIL TANK 4 Plastic tank shown FIRE VALVE L BURNER Steal tank also suitable PAPER ELEMENT FILTER J i L ALTERNATIVE Single Pipe Oil System ALTERNATIVE TYPICAL SYSTEM SHOWN Issue No 1 Combined Manual 24 10 07 OIL SUPPLY Diagrams of twin pipe oil supply systems p BOILER je FIRE VALVE SENSOR ALTERNATIVE FILTER POSITION FILL p ENT SAW CUT INSIDE TANK TO PREVENT SYPHON ru PAPER ELEMENT FILTER OILTANK Plastic tank shown steel tank also suitable r BOILER FIRE VALVE SENSOR TIGER LOOP MUST BE r 1 UPRIGHT 2 OUTSIDE RESIDENCE Can be above or below burner f VALVE 222292 eem VENT EUM Fx E EN Iu OIL FULL LEVEL 2 e 2 PAPER ELEMENT FILTER FIRE VALVE OIL TANK Plastic tank shown steel tank also suitable
14. er on including time clock and then set the boiler control thermostat to recommend setting Ensure condensate trap is filled with water before operation Issue No 1 Combined Manual 24 10 07 18 NEONS GREEN POWER ORANGE HIGH LIMIT STAT RED LOCKOUT TIME SWITCH Senator only BOILER CONTROL STAT BOILER CONTROLS BOILER CONTROL THERMOSTAT The temperature of the water within the boiler and the store is controlled and maintained by the Boiler Control Thermostat located on the boiler control panel Mixer Valve the mixer valve can be adjusted to the desired hot water temperature setting which the householder requires The valve is graduated between 1 to 5 the greater the number the hotter the water TEMPERATURE SETTINGS The Boiler Control Thermostat has a range of 50 to 80 BUT THE BOILER CONTROL THERMOSTAT MUST BE SET AT 80 C AT ALL TIMES PLEASE NOTE A ROOM STAT MUST BE FITTED MAINS INDICATOR GREEN The mains indicator will illuminate when the mains supply to the boiler is on and system charge is above 0 5 bar the boiler is protected by a low pressure cut off switch HIGH LIMIT STAT INDICATOR ORANGE The high limit indicator will illuminate when the water within the boiler is or has overheated e g reached a temperature above that set on the high limit thermostat THIS INDICATES THAT THE THERMOSTAT NEEDS TO BE RESET TO START THE BOILER When the boiler has had time to cool the manual reset button colou
15. ermostat BOILER OPERATION The Boiler Control Thermostat responds to the temperature of the water within the boiler and switches power to the burner when heat is required The burner has an independent control system which regulates the firing and shut off of the burner Automatic firing of the burner will occur when the water temperature within the boiler falls below the control thermostat set point which will continue to run until the water temperature rises to the temperature set on the boiler control thermostat SWITCHING THE BOILER ON Check there is water in the system Check radiator valves are on Turn on oil supply Switch electrical supply to the boiler on including time clock and then set the boiler control thermostat to recommend setting Issue No 1 Combined Manual 24 10 07 3 BOILER CONTROLS BOILER CONTROL THERMOSTAT The temperature of the water within the boiler is controlled and maintained by the Bo er Control Thermostat located on the boiler control panel TEMPERATURE SETTINGS The Boiler Control Thermostat has a range of 50 to 80 The recommended setting for the boiler control thermostat is WINTER Heating and hot water supply 80 C SUMMER Domestic hot water supply 65 C It is not recommended to operate the boiler with a thermostat setting of less than 60 as this will precipitate corrosion thus reducing the life of the boiler HIGH LIMIT STAT The high limit lockout will occur when t
16. ew different types of gases condensing boiler is designed so that these flue gases pass through a stainless steel heat exchanger connected to the boiler These flue gases transfer heat to the water contained in the secondary heat exchanger This results in a increasing the temperature of the water returning to the main boiler b Converting some of the flue gases into condensate Lowers the exit flue gas temperatures considerably Less than 85 This all results in increased efficiency in the boiler and therefore a saving on oil IMPORTANT CHANGES TO BOILER MANAGEMENT Annual Service This is very important in order to keep the flue ways clean and ensure the boiler is correctly set Quarterly Check empty and clean the condensing trap Fig 4 Always ensure that the condensate is flowing freely through the outlet into the drain This can get dirty and block flow or it can freeze in extreme conditions Plume a condensing boiler which produces a white plume from the flue into the air This is caused by the low flue gas temperatures mixing with the colder air outside Best performance Radiator Heating System Flow Temperature 70 C Return Temperature 50 Underfloor Heating System Flow Temperature 50 Return Temperature 40 C Note return temperature should never be less than 40 Issue No 1 Combined Manual 24 10 07 2 USER INSTRUCTIONS Reset Button Remove Black Cap To Reset Thermostat Control Th
17. he water within the boiler is or has overheated e g reached a temperature above that set on the high limit thermostat TO RESET THE BOILER When the boiler has had time to cool unscrew black cap and press button on the control panel to reset LOCKOUT INDICATOR RED The lock out indicator will illuminate when the burner has failed to fire e g No fuel or an electrical fault Wait for two minutes then press the manual reset button coloured red Fig 1 on the control box to reset Fig 1 Issue No 1 Combined Manual 24 10 07 SWITCHING THE BOILER OFF The boiler can be switched off at anytime using one of the following Turn the boiler control thermostat to the OFF position Switch the mains electrical supply to OFF Setthe control system to OFF e g Time Clock PLEASE NOTE For longer periods of shutdown e g while away on holiday switch OFF the mains electrical supply and turn OFF the OIL supply If shutdown occurs during cold weather ensure boiler is protected against frost damage BURNER LOCKOUT The burner has an independent control system Burner Control Box this includes a flame detector Photocell which senses the presence of a flame In the event of a flame failure the burner control box activates a second re ignition sequence Should the photocell not detect a flame presence within 15 seconds the burner goes to LOCKOUT and shuts down Continued LOCKOUTS are a result of a fault in the operation of the boiler an
18. hus the 2 minute interval will ensure that this Bi metallic timer has cooled and is therefore in a position where it may be reset RESTARTING AFTER LOCKOUT When lockout has occurred inspect for any obvious causes e g oil leaks Also check the fuel line from the tank to the boiler and that any oil shut off valve has not been inadvertently closed Issue No 1 Combined Manual 24 10 07 21 RESTART Check there is adequate oil in the storage tank Check oil supply valves are open Switch on heating system e g Time Clock Press the Red Burner Reset Button on the burner Control Box which will be illuminated Both burner reset button illuminated and the lockout indicator on the Control Panel will go out and the burner will commence the ignition start sequence After 15 seconds the Burner should fire normally PLEASE NOTE Should the Burner not start the lockout indicator on the Control Panel and Burner Reset Button will illuminate again Wait at least 3 minutes and press the Burner Reset Button again Failure to start a second time indicates a fault requiring attention In the event of a second failure to start Switch off electrical supply Call service engineer Burner Reset Button Issue No 1 Combined Manual 24 10 07 22 REGULATIONS The installation of oil fired boilers should comply with the following standards and codes of practice BS5449 Forced circulation hot water heating systems for domestic use
19. l 6 on the 8 way connect strip Issue No 1 Combined Manual 24 10 07 29 WIRING DIAGRAM SENATOR COMBI HI LIMIT CUTOUT STAT MAINS HI LIMIT LOCKOUT NOTE WHEN ROOK STAT 15 REQUIRED DISCONNECT LOOP BETWEEN amp AND CONNECT RDDM STAT SWITCH BURNER CONNECTOR FLOW SWITCHES COUNTRYMAN COMBI HI LIHIT HEATING CUTOUT STAT CONTROL STAT MAINS HI LIMIT LOCKDUT BURNER COMMECTOR FLOW SWITCHES LOW PRESSURE SWITCH a u s z BOILER EARTH MAINS INPUT SOCKET NOTE IF ROOM STAT REDUIRED DISCONNECT LOOP BETMEEN 3 amp AMD CONNECT STAT foe PIN EARTH PIN 2 mapy 3 Live VS SUPPLY IO BIN LIVE pin 5 SWITCHED LIVE PIN WOT USED MULTI PIN Issue No 1 Combined Manual 24 10 07 SOCKET PANEL 30 COMBI SENATOR KITCHEN MODELS TECHNICAL SPECIFICATION DIMENSIONS 15 21 KW 21 27 KW 27 38 KW A 741 741 741 B 293 293 293 C 140 140 140 D 423 423 423 E 589 589 589 F 641 641 641 G 589 589 589 H 577 577 577 I 614 614 614 J 645 645 645 K 670 670 670 L 705 705 705 M 854 854 854 N 140 140 140 O 240 240 240 DIMENSIONS ARE IN mm General Data Electrical Supply 240w 50hz Oil Supply Connection 1 4 BSP Fuel 28 Second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 Maximum Operating Pressure Expansion Vessel Capacity 12 Litres
20. ld be appointed on an annual basis Remove inspection door burner and baffle assembly Brush down the inside of the heat exchanger and vacuum out debris Clean baffle assembly Pull out inserts from stainless steel heat exchanger and clean before replacing Ensure stainless steel heat exchanger is thoroughly cleaned Empty and clean condensing trap Fig 4 Inspect and clean burner assembly and replace with new nozzle see burner manual Renew any insulation e g inspection door or inside base of heat exchanger Reassemble baffles and replace inspection door Replace paper oil filters Test oil pressure and test combustion CIAR 7 Issue No 1 Combined Manual 24 10 07 15 BAFFLE ASSEMBLY AA NN VAN L H STACK NA 2 SET OF BAFFLES 27 38 KW BOILER 35 50 KW BOILER 1 SET OF BAFFLES 2 SET OF BAFFLES 15 21 KW R H STACK 8 NO L H STACK amp 7 NO R H STACK 21 27 KW BOILERS BOILER SIZE NO OF INSERTS FROM L H SIDE OF CONDENSER REMAINING TUBES WITHOUT INSERTS 15 21 KW 10 6 21 27 KW 15 9 27 38 KW 21 2 35 50 KW 28 cnn AIR REGULATION RESET BUTTON PUMP ELECTRICAL CONNECTION SIGHT GLASS FROM STAT Issue No 1 Combined Manual 24 10 07 16 BURNER SETTINGS BOILER MODEL 15 21 21 27 27 38 35 50 Btu hr 72000 92000 130000 170000 MAXIMUM OUTPUT Kw hr 21 27 38 50 B
21. ll out inserts from stainless steel heat exchanger and clean before replacing Ensure stainless steel heat exchanger is thoroughly cleaned Empty and clean condensing trap Inspect and clean burner assembly and replace with new nozzle see burner manual Renew any insulation e g inspection door or inside base of heat exchanger Reassemble baffles and replace inspection door Replace paper oil filters Turn electrical supply to the boiler to ON Set central heating controls so they are calling for heat Set burner pump pressure Allow time for the boiler to reach normal operating temperature Check the smoke reading Measure the Co Measure net flue gas temperature Check domestic hot water flow and hot temperature is acceptable to the householder Condensing Trap Issue No 1 Combined Manual 24 10 07 33 BOILER WILL NOT START Check if mains electricity supply is reaching boiler control panel making sure control thermostat is turned on and time clock is calling for heat Mains indicator green should be illuminated If green light is not illuminated and fuse has been checked then heating system charge may be low check black needle on pressure located inside boiler cabinet top right hand side is reading 1 bar or more If not depressurised refer to fault diagnosis FAULT LOCATION Possible causes Remedies Flame instabillity Check nozzle to burner head dimension and electrode position Burner pre purges Incorrec
22. ly total system water content BAR GUAGE However in practice it is often not possible to calculate the system water contents with any LITRES LITRES LITRES LITRES certainty and therefore estimates must be 5 24 2 7 3 9 made 50 4 2 5 4 7 8 75 63 82 11 7 The following volume approximations can be j used to give a reasonable estimate of total 125 10 4 13 6 19 5 COMBI 61 5 LITRES 150 12 5 16 3 23 4 KW RATING 21 27 175 14 6 19 1 273 SMALL BORE PIPEWORK 1 Litre Per Kw of 200 16 7 21 8 312 System Output 225 18 7 24 5 35 1 STEEL PANEL RADIATORS _ 8 Litre Per Kw of 250 20 8 27 2 39 0 System Output 275 22 9 30 0 42 9 LOW WATER CAPACITY 2 Litre Per Kw of 300 25 0 32 7 46 8 RADIATORS MODERN TYPE System Output 325 27 0 35 7 50 7 HOT WATER CYLINDER 2 Litres 350 29 1 38 1 54 6 375 31 2 40 9 58 5 Note As an approximation BS7074 Part1 400 33 3 43 6 62 4 suggests that figures of 12 litres kw of boiler 425 35 4 46 3 66 3 output could be used to estimate total system water content this would be generous for 450 37 5 49 0 70 2 most systems 500 41 6 54 5 78 0 EXPANSION VESSEL SIZING Multiplying Having determined the total system water factor for content expansion vessel sizing can be other systems considered Taking into account the other Volumes 0 0833 0 109 0 156 system design factors Full details of expansion vessel sizing and models available are given in the expansion vessel data sheet However expansion vessels are supplied
23. ned Manual 24 10 07 12 BOILER SPECIFICATION FOR COUNTRYMAN OUTDOOR DIMENSIONS 15 21 Kw 21 27 Kw 27 38 Kw A 521 521 521 868 868 868 750 750 750 D 894 894 894 E 880 880 880 F 485 485 485 DIMENSIONS ARE IN mm General Data Electrical Supply 240w 50hz Supply Connection 1 4 BSP Fuel 28 Second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 Maximum Operating Pressure 3 Bar 45psi 28m Static head room 92ft Draught Limit Min 12 5 Nm 0 05 WG Max 33 0 Nm 0 12 WG Note 28 sec fuel must only be used on Countryman boiler Issue No 1 Combined Manual 24 10 07 13 BOILER SPECIFICATION FOR CONSUL BOILERHOUSE DIMENSION 15 21 KW 21 27 KW 27 38 KW A 436 440 440 B 402 402 402 568 568 568 D 385 453 453 E 559 527 527 F 694 694 694 G 138 142 142 H 352 357 357 DIMENSIONS ARE IN mm LEFT HAND VIEW FRONT VIEW RIGHT HAND VIEW General Data Electrical Supply 240w 50hz Supply Connection 1 4 BSP Fuel 28 Second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 Maximum Operating Pressure 3 Bar 45psi 28m Static head room 92ft Draught Limit Min 12 5 Nm 0 05 WG Max 33 0 Nm 0 12 WG Issue No 1 Combined Manual 24 10 07 14 SERVICING INSTRUCTIONS A competent service engineer OFTEC registered shou
24. pre charges at 1 bar suitable for system static heads up to 15 metres and the safety valve normally pre set at 3 bar British Specification For standard conditions therefore the above table can be used to select the required expansion vessel volume NB Please note the above information EXPANSION VESSEL SIZING is only a guide therefore we do not accept responsibility for sizing of systems and this does not over rule British Standards always refer back to BS7074 Part1 if in doubt FILLING THE SYSTEM Prior to filling the system must be thoroughly flushed using a cleaning agent The system must then be vented of all air and recharged to maximum of 1 5 bar Issue No 1 Combined Manual 24 10 07 26 CONVENTIONAL FLUE INSTALLATION The boiler is supplied as standard for use with conventional flue The chimney must comply with building regulations and BS 5410 Factory made insulated chimneys are covered by BS 4543 Parts 2 amp 3 Notes on Conventional Flue 1 Liner A stainless steel flue liner of diameter to suit the boiler is recommended 2 Flue Pipe can be of vitreous enamel or stainless steel 3 Bends Bends in the flue pipe should not be greater than 135 degrees 4 Insulation Insulation between the flue pipe and brick chimney is recommended to minimize the occurrence of condensation 5 Cowls Cowls and pots that may restrict the flue should not be used 6 Draught Stabilisers Chimneys over 6 metres high may produ
25. rap in side the boiler casing which should be plumbed to an external source ensuring one of the following options Internal waste drainage system Soil vent stack External Drainage system External condensate absorption point NOTE condensate pipe work must fall at least 50 per metre towards the outlet ensuring all joints are leak proof WARNING the condensate trap must be filled with water prior to starting the boiler to stop flue gases escaping Retum 4 Condensation Pipe Fig 2 Fig 3 Issue No 1 Combined Manual 24 10 07 7 BOILER LOCATION Sound levels should be discussed with the householder as some people may be sensitive to low noise levels in a small room as is may appear more annoying than in larger rooms Please Note installation should take into account of flue position see diagram RECOMMENDED FLUE POSITION Please Note where the terminal is within 1 metre of any plastic material such material should be protected from the effects of the combustion products of the fuel IMPORTANT 35 SECOND CLASS D GAS OIL MUST NOT BE USED FOR BALANCED FLUES Min Position Directly below an opening air brick opening window etc Horizontally to an opening air brick opening window etc Below gutter eaves or balcony with protection Below a gutter or a balcony without protection From vertical sanitary pipework From an intemal or external corner Above ground or balcony level From a surface or a boun
26. red red on the control panel will need to be pressed in to reset If the high limit thermostat continues to trip contact your installer as there may be a fault with the central heating system LOCKOUT INDICATOR RED The lock out indicator will illuminate when the burner has failed to fire e g No fuel or an electrical fault PLEASE NOTE The reset button on the burner will illuminate on the burner control box at the same time Reset by pressing the reset button on the burner control box ON OFF SWITCH BOILER CONTROL STAT NEONS GREEN POWER ORANGE ON OFF SWITCH MIXER VALVE COUNTRYMAN SENATOR Issue No 1 Combined Manual 24 10 07 19 BUILT IN TIME SWITCH SENATOR COMBI ONLY Tappets position antika Out On SAADAN Arrow Manual switch position 1 On Top Position Clock symbol Timed centre position 0 Off bottom position Tappets position In Off SETTING TIME SWITCH UP The outer dial should be set to the current time Rotate the dial slowly in a clockwise direction until the correct hour is approaching the arrow marked on the dial MANUAL SWITCH OPERATION The manual switch will provide On Timed Off Control thereby allowing manual control of the heating without disrupting the timed tappet settings PROGRAMME SWITCH TIMES One tappet is equal to 15 minutes set the number of tappets to the outer edge of the dial equal to the duration of time heating is required to be switche
27. rmostat may be required this should be assessed when installing the boiler INSTALLATION OF A TIME CLOCK OR PROGRAMMABLE ROOM STAT COUNTRYMAN OUTDOOR COMBI ONLY Installation of external time clock or programmable room thermostat to Countryman Combi The boiler comes with a multi 6 pin plug The electrical supply must be sent directly to the boiler off the fused spur and not interrupted by any forms of control i e time switch or programmable room thermostat The electrical supply to the time switch or programmable room thermostat is supplied from the boiler The connections to the muti pin plug are as follows PIN1 Earth PIN2 Neutral PIN3 Live PIN4 Electrical supply out from boiler to time switch or programmable room thermostat PIN5 Switch supply back from the time switch or programmable room thermostat The External Time Clock controls the heating function The domestic hot water function is permanently on and controlled by Heating Control Thermostat INSTALLATION OF A ROOM THERMOSTAT Connect a room thermostat to terminal 3 and 4 on the 8 way connect strip inside the boiler control panel and discard link wire If neutral wire is required for room thermostat connect neutral wire to terminal 6 on the 8 way connect strip INSTALLATION OF FROST THERMOSTAT Connect a frost thermostat to terminal 5 and 3 on the 8 way connect strip inside the boiler control panel If neutral wire is required for frost thermostat connect to termina
28. t head settings Low oil pressure Check oil pressure Flame occurs Adjust air damper Burner locks out Photocell not seeing light Check that photocell is clean and unobstructed Pnotocell failed Confirm with new photocell rm will NB it is advisable to change th n Control faulty Check that photocell is not seeing ambient light Burner pre purges False light Check that H T leads are sound and are not f No flame occurs arcing other than at electrode gap Check oil supply to burner check that pump Burner locks out is not airlocked Check operation of magnetic valve BURNER FAILS TO START AFTER NORMAL OPERATION heck or replace fuse if necessary Check Fuse has own Heset overheat device Find reason for its Appliance overheat device has operated operation and rectif Control relay or photocell defective Check by replacement Check that tank oil lines fire valve pump and nozzle are all in good order Rectify condition Check ignition transformer Check electrode gap and porecelains DELAYED IGNITION BURNERS STARTS VIOLENTLY Burner pulsates on start up only with hot flue Excessive draught Burner pulsates on start up Nozzle partly blocked Oil pressure too low Burner fails to start Lamp not lit No oil being delivered Excessive flue draught is preventing flame establishment Burner runs to lockout No spark Recommission burner Replace nozzle Check and recommission Flue blocked
29. the boiler that the preformed pipes are exiting on the opposite side to which the flue is exiting The preformed pipe on the Countryman Combi exits at the rear of the casing Base SEALED SYSTEM This boiler operates on a sealed system A pressure relief valve operating at 3 bar is fitted The overflow pipe must terminate in compliance with current building regulations The boiler is supplied with a 12 litre expansion vessel It is the installer s responsibility to ensure adequate provision is made for expansion within the heating system and to install extra capacity if required Damage to components caused by over expansion may not be covered by warranty Unsuitable pipe work and fittings and factors such as sediment or residue left in the system may cause damage to your boiler and it s components and may not be covered by warranty PLASTIC PIPE PLEASE NOTE When using plastic pipe on heating system a minimum of 2 metres of copper pipe must be used off the boiler before connecting to plastic pipe PLASTIC PIPE MUST NOT IN ANY CIRCUMSTANCES BE CONNECTED DIRECTLY TO THE BOILER Issue No 1 Combined Manual 24 10 07 25 CAPACITIES OF EXPANSION VESSELS EXPANSION VESSEL SIZING Bs7074 Part1 1989 gives full details of Safety valve setting O 3 3 3 accurate method of calculating the required expansion vessel capacity assuming that full Vessel charge and and accurate design information is available Initial System Pressure 0 5 1 1 5 particular
30. tu hr 63000 82000 113000 160000 FACTORY SETTING Kw hr 18 5 24 33 46 NOZZLE SIZE 0 55 80 deg H 0 65 80 deg H 0 85 80 deg H 1 2 80 deg H OIL PRESSURE Bar 8 8 8 8 BURNER AIR SETTING 7 12 15 3 5 SMOKE 0 0 0 0 co 11 5 12 12 11 FLUE 29 87 d id RETURN 2 ee j 26 WATER OUTLET FLOW mm 22 22 22 28 CONDENSATE FLOW mm 22 pvc rigid pipe 22 pvc rigid pipe 22 pvc rigid pipe 22 pvc rigid pipe ELECTRICAL POWER 230 240 volt 50 Hz fused at 5 amp ee Bar 25 25 2 5 2 5 BOILER EFFICIENCY 98 99 100 99 SEDBUK A RATING 93 5 93 5 94 93 2 Please Note Boiler Efficiency Schedule 2 of Rules Efficiency Regulation 1993 Issue No 1 Combined Manual 24 10 07 USER INSTRUCTIONS CONDENSING COMBI BOILERS BOILER CONTROL THERMOSTAT BOILER OPERATION The Boiler Control Thermostat responds to the temperature of the water within the boiler and switches power to the burner when heat is required The burner has an independent control system which regulates the firing and shut off of the burner Automatic firing of the burner will occur when the water temperature within the boiler falls below the control thermostat set point which will continue to run until the water temperature rises to the temperature set on the boiler control thermostat SWITCHING THE BOILER ON Check there is water in the system Check radiator valves are on Turn on oil supply Switch electrical supply to the boil
31. utton will illuminate again Wait at least 3 minutes and press the Burner Reset Button again Failure to start a second time indicates a fault requiring attention In the event of a second failure to start Switch off electrical supply Call service engineer Issue No 1 Combined Manual 24 10 07 REGULATIONS The installation of oil fired boilers should comply with the following standards and codes of practice BS5449 Forced circulation hot water heating systems for domestic use BS5410 Part 1 Cil installations up to 45kw BS7593 Water treatment of hot water central heating systems BS7671 Electrical Regulations Building Regulations Part 1L and J 2002 England and Wales Part F Scottish Regulations and Technical Booklet L Northern Ireland OFTEC Codes of Practice Published or Recommended After installing the system needs to be flushed with a cleanser like Fernox Heavy Duty Restore for fast acting removal of lime scale black sludge magnetite and other deposits from the boiler and the central heating system Then add a Fernox protector to give long term protection of the central heating system against internal corrosion lime scale formation WATER CONNECTIONS Only two connections for the heating and hot water system on a standard condensing boiler 1 Flow from top of boiler Fig 2 and return to top of stainless steel heat exchanger Fig 2 2 The PVC pipe fig 3 is 21 5mm and should continue from the condensate t
32. ving circlip located at the bottom of the switch if micro switch is not attached to the diverter valve it could be damaged this would prevent the burner and circulation pump coming on If not check electrical connection to switches to check that burner and circulation pump are coming on If not check electrical connection to switches and replace if faulty If micro switches are working correctly check that cap is on plunger If cap is not and has been dislodged refit cap and check that plunger is moving out when tap is open if not replace diaphragm NO D H W HEATING FUNCTION CORRECTLY Check 15mm pipe coming off plate heat exchanger that goes to mixer valve is hot If not there could possibly be a blockage in the plate heat exchanger i e lime scale If this is the case descale if possible or replace and check appropriate water softening equipment has been fitted E Check 15mm pipe coming off plate heat exchanger going to mixer valve is hot But 15mm coming out of the mixer valve is not hot Rotate mixer valve control knob in and out as valve may have stuck If this does work remove clean and replace if faulty Issue No 1 Combined Manual 24 10 07 35 SENATOR KITCHEN COMBI PARTS LIST 1 LJ 8 2 9 4 6 19 10 18 11 16 23 13 17 15 12 14 20 ITEM DESCRIPTION 1 INTERNAL TIME SWITCH 2 CONTROL THERMOSTAT 3 GREEN NEON ORANGE NEON RED NEON 4 ROCKER SWITCH 5 HIGH LIMIT THERMOSTAT 6 FLOW REGULATOR 7 A
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