Eurocal SENATOR Operation manual

Installation & Users Guide
SENATOR
and
COUNTRYMAN
System- Boilers

1
INTRODUCTION Page
- WARRANTY 2
USER INSTRUCTIONS
- BOILER OPERATION 3
- SWITCHING THE BOILER ON 3
- BOILER CONTROLS 4
- SWITCHING THE BOILER OFF 5
- BURNER LOCKOUT 5
- RESTARTING AFTER LOCKOUT 5
- RESTART 6
INSTALLATION
- REGULATIONS 7
- WATER CONNECTIONS 7
- BOILER LOCATION 8
- SERVICE REQUIREMENTS 9
- THE HEARTH 9
- CONTROL PANEL 9
- PREFORMED PIPE WORK 10
- SEALED SYSTEM 10
- PLASTIC PIPE 10
- CAPACITIES OF EXPANSION VESSEL 11
- EXPANSION VESSEL SIZING 11
- WARNING SEALED SYSTEM 11
- FILLING SYSTEM 11
- SENATOR CONVENTIONAL FLUE INSTALLATION 12
- BALANCED FLUE INSTALLATION (INTERNAL) 13-21
- CONNECTING OIL SUPPLY 21-22
- ELECTRICAL CONNECTION (INTERNAL & EXTERNAL) 23
- WIRING DIAGRAM (INTERNAL) 23
TECHNICAL DATA
- BOILER SPECIFICATIONS 24-25
- COMMISSIONING INSTRUCTIONS 26
- SERVICING INSTRUCTIONS 27
- FAULT FINDING COMBUSTION 28
- PARTS LIST 29
- BURNER SETTINGS 30
Issue No.1 12/11/04

INTRODUCTION
Thank you for choosing the INTERNAL or EXTERNAL COUNTRYMAN COMBI 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 familiarize 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
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/Commissioning 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.
2

USER INSTRUCTIONS
3
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 (recommended) 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 recommended setting.
Boiler Control
Thermostat

BOILER CONTROLS
BOILER CONTROL THERMOSTAT
The temperature of the water within the boiler is controlled and maintained by the Boiler
Control Thermostat located on the boiler control panel.
TEMPERATURE SETTINGS:
The Boiler Control Thermostat has a range of 50˚C to 80˚C. 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˚C,
as this will precipitate corrosion, thus reducing the life of the boiler.
HIGH LIMIT STAT INDICATOR:
The high limit lockout will occur when the 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, the manual reset button (coloured 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.
4
Reset Button
Burner Control Box

SWITCHING THE BOILER OFF
The boiler can be turned off by turning the rocker switch, located on the underside of
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 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:
- An 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 and the red Lockout Indicator on the boiler
control panel 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.
5

RESTART
- Check there is adequate oil in the storage tank.
- Check oil supply valves are open.
- Switch on heating system (e.g. Time clock).
- Depress 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, both lockout indicator, on the Control Panel and
Burner Reset Button will illuminate again.
- Wait at least 3 minutes and depress the Burner Rest 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.
6
Burner Reset Button

Heating
Return
option
Left or Right
Pipes routed out through rear of External Pipes routed out through rear of Internal
Heating Return
Heating Flow
Cold Mains
Discharge Pipe
Heating Return
Heating Flow
Cold Mains
Discharge Pipe
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-Part1 Oil installations up to 45kw.
- BS7593 Water treatment of hot water central heating systems.
- BS7671 Electrical Regulations.
- BS7074 Code of practice for sealed systems
- Building Regulations Part L1 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 and lime scale
formation.
WATER CONNECTIONS
The boiler is supplied with one flow and two return connections. Diagrams below show pipe
configurations.
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 it may appear more annoying than in a larger room.
Please Note installation should take into account of flue position (see diagram).
RECOMMENDED FLUE POSITION
8
RefMin. Position mm
ADirectly below an opening, air brick, opening window etc. 600
BHorizontally to an opening , air brick, opening window etc. 600
CBelow a gutter, eaves or balcony with protection. 75
DBelow a gutter or a balcony without protection. 600
EFrom vertical sanitary pipework. 600
FFrom an internal or external corner. 600
GAbove ground or balcony level. 600
HFrom a surface or a boundary facing the terminal. 600
JFrom a terminal facing the terminal. 1200
KVertically from a terminal on the same wall. 1500
LHorizontally from a terminal on the same wall. 750
MAbove the highest point of an intersection with the roof. 600
NFrom a vertical structure on the side of the terminal. 750
OAbove a vertical structure less than 750mm. 600
PFrom a ridge terminal to a vertical structure on the roof. 1500
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.

INSTALLATION
SERVICE REQUIREMENTS
The boilers are serviced though an access panel at the front. A service access space of
least 700mm should be made available at the front of the boiler.
THE HEARTH
The temperature of the surface below the boiler is less than 85˚C. 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 regulations 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 horizontal pocket situated on the left hand side
of the boiler heat exchanger.
9
DIAGRAM OF
PHIAL POSITIONS
ON BOILER HEAT
EXCHANGER
ELECTRICAL ENTRY
The electrical supply to the boiler must be 230 volts, 50 Hz, fused at 5A. 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 its
purpose, and preferably positioned close to the boiler.
Control & High
Limit Thermostat

PREFORMED PIPE WORK
- 1 Of 22 mm section label Heating Flow
- 1 Of 22 mm section label Heat Return
- 1 Of 15 mm section label Cold Mains
- 1 Of 15 mm section label Over Flow
Preformed pipes, on the Internal system exit on the right hand side of the boiler. from
the front view of the boiler.
The preformed pipe on the External combi exits at the rear of the casing.
For diagrams on pipe layout go page 7.
The heating return pipe (22mm) can be connected to either the left or right hand
side with the tapping at the bottom rear of the boiler. The unused tapping must be
blanked off.
These tappings are 1” B.S.P.
SEALED SYSTEM
This boiler operates on a sealed system. A pressure relief valve operating at 3 bar is
fitted.
The over flow pipe must terminate in compliance with current building regulations.
This boiler is supplied with a 12 litre expansion vessel. It is the installers 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 pipework and fittings and factors such as sediment or residue left in the
system, may cause damage to your boiler and its components and may not be
covered by warranty.
PLASTIC PIPE
PLEASE NOTE: When using plastic pipe on heating system, a minium 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
10

CAPACITIES OF EXPANSION VESSELS
Safety Valve Setting @ 3 3 3
Vessel charge and
Initial System Pressure 0.5 1 1.5
(BAR GAUGE)
LITRES LITRES LITRES LITRES
52.1 2.7 3.9
50 4.2 5.4 7.8
75 6.3 8.2 11.7
100 8.3 10.9 15.6
125 10.4 13.6 19.5
150 12.5 16.3 23.4
175 14.6 19.1 27.3
200 16.7 21.8 31.2
225 18.7 24.5 35.1
250 20.8 27.2 39.0
275 22.9 30.0 42.9
300 25.0 32.7 46.8
325 27.0 35.7 50.7
350 29.1 38.1 54.6
375 31.2 40.9 58.5
400 33.3 43.6 62.4
425 35.4 46.3 66.3
450 37.5 49.0 70.2
500 41.6 54.5 78.0
Multiplying
Factors for
other system
Volumes 0.0833 0.109 0.156
11
EXPANSION VESSEL SIZING
Bs7074:Part1:1989 gives full details of accurate
method of calculating the required expansion
vessel capacity, assuming that full and accurate
design information is available, particularly total
system water content.
However, in practice, it is often not possible to
calculate the system water contents with any
certainty, and therefore estimates must be made.
The following volume approximations can be used
to give a reasonable estimate of total system
volume.
50/70 SYSTEM 20 Litres
KW RATING 14.65-20.5
SMALL BORE PIPEWORK 1 Litre Per Kw of
System Output
STEEL PANEL RADIATORS 8 Litres Per Kw of
System Output
LOW WATER CAPACITY 2 Litres Pre Kw of
RADIATORS MODERN TYPE System Output
HOT WATER CYLINDER 2 Litres
Note: As an approximation, BS7074: Part 1
suggests that figure of 12 litres/kw of boiler output
could be used to estimate total system water
content-this would be generous for most systems.
EXPANSION VESSEL SIZING
Having determined the total system water
content, expansion vessel sizing can be
considered. Taking into account the other system
design factors.
Full details of expansion vessel sizing and Altecnic models available are given in the expansion
vessel data sheet.
However, Altecnic expansion vessels are supplied pre-charged at 1bar (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 following 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: Part 1 if in doubt.
WARNING SEALED SYSTEM
This boiler operates on a sealed system up to a maximum pressure of 3 bar. It is the responsibility
of the installer to ensure all pipework and fittings are suitable for use under these circumstances.
This boiler is supplied with a 12 litre expansion vessel. It is the installers responsibility to ensure
adequate provision is made for expansion within the system and to install extra capacity if
required.
Damage to components caused by over expansion may not be covered by warranty. Unsuitable
pipework and fittings and factors such as sediment or residue left in the system, may cause
damage to your boiler and its components this will not be covered by warranty.
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.

SENATOR CONVENTIONAL FLUE INSTALLATION
The boiler is supplied as standard for use with conventional flue.
The chimney must comply with building regulations and B S 5410. Factory made insulated
chimneys are covered by B S 4543 Parts 2 & 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 Stabiliser Chimneys over 6 metres high may produce excessive draught (over
4mm w.g.). Draught stabilizers may be required.
7. Length Before bends are applied, length of flue must be at least 600mm.
COMBUSTION AIR SUPPLY -CONVENTIONAL FLUE
12
INFORMATION SUPPLIED BY OFTEC Conventional Flue - Typical Arrangement
550mm2/kw
1100mm2/kw
1650mm2/kw
550mm2/kw
1100mm2/kw
OPEN FLUE BOILER IN ROOM
OPEN FLUE BOILER COMPARTMENT
VENTILATED FROM OUTSIDE
OPEN FLUE BOILER COMPARTMENT
VENTILATED FROM ROOM
550mm2/kw
Terracotta Pot
Liner
Soot
Door
Soot
Door
Flue Pipe
Insulation
Bends135˚

BALANCED FLUE INSTALLATION
VENTILATION AIR SUPPLY
Air ventilation for balanced flue boilers is only required if the boiler is installed in a confined
space e.g. a cupboard. This is to prevent over heating of components.
13
COMBUSTION AIR SUPPLY
25MM M IN
WALL
TERMINAL LENGTH
COMBUSTION AIR SUPPLY
BALANCED FLUE BOILERS
550mm /kW
2
550mm /kW
2
BOILER IN COMPARTMENT
VENTED FROM OUTSIDE
1100mm /kW
2
1100mm /kW
2
180 TO 450
B
C
SIDE OUTLET LEFT
180 TO 450
B
REAR OUTLET
LOW LEVEL BALANCED FLUE
NOTE If flueing from the side of the boiler. Combi preformed pipes must go opposite to the side on which the flue is
flueing from.
NOTE If flueing from the right hand side of the boiler when looking from the front of the boiler, then a flue extension
maybe required.

LOW LEVEL BALANCED FLUE
A
D
14
REMOVE FOIL REMOVE FLUE RING FIT SQUARE GASKET
RETAIN BOLTS FOR
FITTING FLUE FIT SEALS AND LUBRICATE
LOW LEVEL BALANCED FLUE SIDE AND REAR ASSEMBLY INSTALLATION
1. Cut hole in wall. Remember measure, mark, CHECK then cut.
2. Remove Conventional Flue ring from top of boiler.
3. Fit Red inner seal and Black out Seal to flue connector and
extension if required.
4. Apply lubricant included in kit. To the inner and outer seal taken
care to only lubricant the lip of the seal.
MODEL Flue A B C D
50/70 3” 125 176 765 130
70/90 3” 125 176 765 130
REMOVE CASING LID
TEST POINT
TERMINAL GUARD
A Terminal Guard must be fitted to low
level Flue Terminal below 2 metres and
where persons or animals could come into
contact with the terminal or if it could be
subject to damage.

1
2
5
3
4
6
9
10
8
7
5. With boiler in position pass the flue assembly
through the wall and bolt the bottom section of the
flue to the boiler, insuring that square gasket is in
between the boiler and the flue.
6. Attached the snorkel tube with clips to the flue.
7. Make sure that flue terminal protrudes through the
wall a minimum of 176mm.
FLUE EXTENSION
The maximum horizontal flue level is 1450mm this
can be achieved using the following extension kits:
3 x kit 3 300mm extension
OR
1 x kit 6 950mm extension
8. Remove CF adaptor from burner and discard.
9. Fit the gasket and B F adaptor and connect snorkel
Tube.
N.B. Kit 8 45 degree bends must not be used on low
level balanced flue kits.
15
HORIZONTAL FLUE
FIT BOLTS
FIT SNORKEL TUBE
FIT CLIP
INTERNAL VIEW
ITEM DESCRIPTION PART No.
1Control Thermostat COTHCS
2High Limit Thermostat COTHHL
3Safety Relief Valve COMPRES
4Gate Valves COMGATE
5Grunfoss 25-50 GRUN50
6Filling Loop COMLOOP
7Expansion Vessel Hose COMHOS
812 Litre Expansion Vessel COM12L
9Door Insulation Kit INSKIT
50/70 Baffle
70/90 Baffle
10 Burner
See Burner Parts List

16
HIGH LEVEL ROOM SEALED BALANCED FLUE DIMENSIONS
INSTALLATION OF HIGH LEVEL BALANCED FLUE
1. Position boiler and Cut Hole in wall. Remember
measure, mark, CHECK then cut.
2. Remove Conventional flue ring from top of boiler.
REMOVE CASING LID REMOVE FOIL
REMOVE FLUE RING
FIT SEALS AND
LUBRICATE BOLT BOTTOM SECTION
TO BOILER
TEST POINT
MODEL Flue A B C
50/70 3” 125 176 200
70/90 3” 125 176 200
50/115
700-
1100 mm

3. Fit Red inner seal and Black outer seal to flue
connectors and extensions if required.
4. Apply lubricant to the inner and outer seals. Taken
care to only lubricant the lip of the seals.
5. Bolt bottom section of the flue to the boiler
insuring the square gasket is fitted in between the
boiler and the flue.
6. Attached snorkel to the flue with the clip.
7. Refit boiler top panel insure the knock out in the
panel has been removed.
8. Assemble second vertical flue section and any
vertical extension.
9. Assemble horizontal section and pass through the
wall. Making sure that the terminal protrudes
through the wall a minimum of 176mm.
10. Connect vertical and horizontal section together.
11. Secure vertical section with the screws provided.
12. Seal around the flue terminal in wall using mastic.
13. Remove CF adaptor from burner and discard.
14. Fit BF adaptor connect snorkeltube with clip.
NOTE: Expanding foam can be used to fill/insulate
the gap between flue parts and wall.
FLUE EXTENSIONS
Please note a maximum of one kit 6
950mm or 3 x kit 3 300mm extension
can be used on the high level.
Kit 8 45 degree bends must not be used
on low level balanced flue kits.
17
FIT SNORKEL TUBE
FIT HORIZONTAL SECTION
FIT CLIP
FIT LID
INTERNAL VIEW

18
VERTICAL BALANCED FLUE
2.4
METRE
MINIMUM 600MM
VERTICAL BALANCED FLUE DIMENSIONS
50/70
70/90
125MM
FLASHING NOT
SUPPLIED
The vertical flue is telescopic as supplied.
The flue has a range of 1020-2400mm
from the top of the boiler to the flashing.
Extension kits of 300 and 950mm
are available.
The maximum vertical length is 4800mm.
Also available are 45 degree bends.
For further information contact our sales office.
N.B. Every 45 degree elbow is equivalent to
500mm of flue.

INSTALLATION OF VERTICAL FLUE
1. Position boiler and cut hole/s in ceiling and roof.
Remember measure mark ,CHECK then cut.
2. Remove conventional flue ring from top of boiler.
3. Fit Red inner seal and Black outer seal to flue
connectors and extensions if required.
4. Apply lubricant to the inner and the outer seals.
Taking care to only lubricant the lip of the seals.
5. Bolt bottom section of the flue to the boiler
insuring the square gasket is fitted in between the
boiler and the flue.
6. Attached snorkel to the flue with the clip.
7. Refit boiler top panel insure the knock out in the
panel has been removed.
8. Assemble second vertical flue section and any
vertical extension.
9. Fit the roof flashing and flue terminal.
10. Secure the terminal to a roof joist with clamps
provided.
11. Fit flue elbows if required and secure vertical
section with the screws provided
12. Seal around the flue terminal in wall using mastic
13. Remove CF adaptor from burner and discard
14. Fit BF adaptor connect snorkel tube with clip.
NOTE: Expanding foam can be used to
fill/insulate the gap between flue parts and wall.
19
Remove lid
Remove flue ring
Bolt bottom section
Fit Clip
Fit Snorkel Tube
Vertical Terminal Internal View
Fit seals and
lubricant
Remove lid