IDEAL Systemiser SE Installation And Servicing Manual
2
Systemiser SE - Installation
Systemiser SE:
The condensing system boiler
The Ideal Systemiser SE is a wall mounted, fanned flue condensing system
boiler which serves a home's central heating system. It has been designed to
be 'friendly' to the user, installer and service engineer.
Systemiser SE:
The fit anywhere system boiler
Simple fanned 'go anywhere' flue
The Systemiser SE's flue turret simply rotates through 360° to allow horizontal
outlet in any direction. Options include horizontal flue length extensions or
simple vertical flue kits - and the flue is self-sealing, eliminating the need for
outside assembly - an important benefit in high-rise applications.
Downward or upward connections...
Water and gas connections have been designed to be as simple and fast as
possible. The Ideal Systemiser SE comes complete with a rugged mounting
frame which when fitted with the stand-off brackets can accommodate
downward or upward routed gas, water and electrical connections before the
boiler is fitted.
...and it fits inside a cupboard
Its compact size makes the Systemiser SE ideal for any kitchen. It can be
installed inside a cupboard without any ventilation.
Systemiser SE:
The system boiler you can rely on
The Systemiser SE has been designed and developed with reliability as the
number one priority. But even the finest engineered product may develop a
fault at some stage in its lifetime. To support the Systemiser SE we have
created the Ideal Care Guarantee which sets out our target to repair any fault
next day.
Free Guarantee: 1st Year Ideal Care
The home owner is entitled to 12 months free Ideal Care, which includes both
parts and labour, to restore the boiler to full function. Please encourage the
home owner to complete and return the registration form in their Householder's
pack within 30 days of installation.
Optional Extra Year Cover with Ideal Care
You may wish to offer your own annual service plan or you may wish to advise
the home owner to complete their application form for the appropriate level of
extended Ideal Care - Silver, Gold or Platinum. Full details are available in
the Ideal Care brochure.
3
Systemiser SE - Installation
Gas supply 2H
Gas Supply Connection 22mm copper
Flow Connection Central Heating 22mm copper
Return Connection Central Heating 22mm copper
Flue Terminal Diameter 100 mm
Maximum Working Pressure (Sealed Systems) 2.65 bar
Electrical Supply / Power consumption 230 V ~ 50 Hz. / 126 W
Fuse Rating External : 3A Internal : F2A
Water content Central Heating 2.2 litre
Dry Weight 46.5 Kg
Maximum Installation Weight 38.5 Kg
Boiler Casing Size Height 800 mm
Width 450 mm
Depth 300 mm
Table 1 - General Data
GENERAL
Table 2 - Performance Data - Central Heating
Min. Max.
Boiler Input :
Nett CV kW 10.1 25.1
Btu/h 34 500 85 700
Gross CV kW 11.2 27.9
Btu/h 38 200 95 200
Gas Consumption l/s 0.29 0.72
ft
3
/h 36.8 91.5
Boiler Output :
70
o
C Mean Water Temp kW 9.6 24.0
Btu/h 32 800 81 900
40 oC Mean Water Temp kW 10.9 25.7
Btu/h 37 200 87 700
Burner Setting Pressure mbar 2.0 13.0
(HOT) in. w.g. 0.8 5.2
Seasonal Efficiency
(SEDBUK) * [88.4]%
CAUTION.
To avoid the possibility of injury during the installation, servicing or cleaning of
this appliance, care should be taken when handling edges of sheet steel components.
KEY TO SYMBOLS
IE = Ireland (Countries of
GB = United Kingdom destination)
PMS = Maximum operating pressure of water
C13 = A room sealed appliance designed for connection via
ducts to a horizontal terminal, which admits fresh air to
the burner and discharges the products of combustion
to the outside through orifices which, in this case, are
concentric. The fan is up stream of the combustion
chamber.
I
2H
= An appliance designed for use on 2nd Family gas,
Group H only.
Note. Gas consumption is calculated using a calorific value of
38.7 MJ/m
3
(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different calorific value:
a. FOR L/S - divide the gross heat input (kW) by the gross
C.V. of the gas (MJ/m
3
)
b. FOR FT3/H - divide the gross heat input (Btu/h) by the gross
C.V. of the gas (Btu/ft3)
*The value is used in the UK Government's Standard
Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been
certified by Gastech NV0061.
4
Systemiser SE - Installation
CONTENTS
INTRODUCTION
The Systemiser SE is a wall mounted, low water content,
balanced flue, condensing system boiler.
Note. Due to the high efficiency of the boiler a plume of
water vapour will form at the terminal during operation.
Central Heating (CH) output is fully modulating between
9.6 kW (32 800 Btu/h) minimum and 24 kW (81 900 Btu/
h) maximum.
The boiler is supplied fully assembled with circulating
pump, pressure gauge, safety valve and central heating
(CH) expansion vessel.
A variable CH temperature control is fitted.
The boiler casing is of white painted mild steel with a
dropdown controls door.
The boiler controls are located behind the controls door.
The heat exchanger is of aluminium.
The boiler is suitable for connection to fully pumped,
sealed water systems ONLY. Adequate arrangements for
completely draining the system, by provision of drain
cocks, MUST be provided in the installation pipework.
OPTIONAL EXTRA KITS
Extension Flue Kit - Pack D
Roof Flue Kit - for vertical flue connection
Powered Vertical - for extended vertical flue connection
Flue
Flue Elbow Kits - 90 degree
- 45 degree (2 per box)
Siphon Kit - Pack S
Refer to the separate fitting instructions supplied with
each kit.
Systemiser SE (natural gas only) .......... G.C. Appliance No. 41 349 70
Gastec Certification ............................. P.I. No. 0063 AS 3355 Destination Countries: GB and IE
Air Supply ........................................................................ 6
Boiler Clearances ............................................................ 9
Boiler Exploded Diagram ............................................. 12
Commissioning and Testing ........................................ 33
Condensate Drain ......................................................... 11
Electrical Connections ................................................. 29
Electrical Supply ............................................................. 9
Fault Finding ................................................................. 54
Flow Wiring Diagram .................................................... 30
Flue Extensions ............................................................ 26
Flue Installation ............................................................. 15
Flue Lengths & Types ................................................... 14
Gas Safety ........................................................................ 6
Gas Supply ...................................................................... 7
General Data .................................................................... 3
Installation ..................................................................... 12
Mandatory Requirements ............................................... 6
Safety ............................................................................... 6
Sealed System Requirements ...................................... 10
Servicing ........................................................................ 39
Short List of Parts ......................................................... 56
Water and Systems ......................................................... 7
Water Connections ......................................................... 8
Water Treatment .............................................................. 8
Wiring Diagrams .................................................... 30 - 33
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
5
Systemiser SE - Installation
GENERAL
OPERATION
When there is a call for CH, the heating system is
supplied at the selected temperature of between 40 oC
and 82 oC,
Refer also to Frame 1- 'Boiler Water Circuit Diagram'.
The boiler features a comprehensive diagnostic system
which gives detailed information on the boiler status when
operating, and performance of key components to aid in
commissioning and fault finding.
1
BOILER WATER CIRCUIT DIAGRAM
6
Systemiser SE - Installation
GENERAL
GAS SAFETY
Current Gas Safety (Installation and Use) Regulations,
or rules in force.
It is law that all gas appliances are installed and serviced by a
CORGI registered installer (identified by
) in accordance
with the above regulations. Failure to install appliances
correctly could lead to prosecution. It is in your own interest,
and that of safety, to ensure the law is complied with.
The installation of the boiler MUST also be in accordance with
the latest I.E.E (BS.7671) Wiring Regulations, local building
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 60 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60 kW).
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for domestic
purposes (2nd Family Gases)
BS. 6700 Design, installation testing and maintenance of
services supplying hot water for domestic use.
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891 Low pressure installation pipes.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
SAFE HANDLING OF SUBSTANCES.
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are directly
connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Caradon Plumbing Limited in writing. If in
doubt please enquire.
Any direct connection of a control device not approved by
Caradon Plumbing Limited could invalidate the certification
and the normal appliance warranty. It could also infringe the
Gas Safety Regulations and the above regulations.
LOCATION OF BOILER AND FLUE OUTLET
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be fitted on a combustible wall. Insulation
between the wall and the boiler is not necessary, unless
required by the local authority.
The boiler must not be fitted outside.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
Bathroom Installations
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current I.E.E. (BS.7671) Wiring Regulations and, in Scotland,
the electrical provisions of the building regulations applicable in
Scotland with respect to the installation of the boiler in a room
or internal space containing a bath or shower.
Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains electricity
should be so situated that it cannot be touched by a person
using the bath or shower.
Note. It is not permissible to install a mains socket in a
bathroom.
Where installation will be in an unusual location, special
procedures may be necessary and BS 6798 gives detailed
guidance on this aspect.
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In both cases, details of essential features of cupboard /
compartment design, including airing cupboard installation, are
to conform to the following:
z BS.6798.
z The position selected for installation MUST allow adequate
space for servicing in front of the boiler. Ventilation of the
compartment is not necessary.
z For the minimum clearances required for safety and
subsequent service see the wall mounting template and
Frame 3. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
AIR SUPPLY
It is NOT necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither is
it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of the
boiler casing during operation; therefore the requirements of BS
6798, Clause 12, and BS 5440:2 may be disregarded.
7
Systemiser SE - Installation
GENERAL
5. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard. The minimum
spacing in Table 3, Nos. 2, 3, 4, 5 and 6 would be 75mm, in
order to allow a terminal guard to be fitted.
Terminals guards are available from boiler suppliers - ask
for Tower Flue Guard, Model K1. In case of difficulty seek
advice from:
Tower Flue Components Ltd.,
Vale Rise, Tonbridge, Kent TN9 1TB
Telephone No. 01732 351 555
Ensure that the guard is fitted centrally.
6. Where the terminal is fitted within 850mm (34") of a plastic
or painted gutter or 450mm (18") of painted eaves then an
aluminium shield at least 750mm (30") long should be fitted
to the underside of the gutter or painted surface fitted
centrally above the flue.
7. The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1") to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440: 1990.
8. Where it is essential that the terminal wall plate is fitted, i.e.
wall thicknesses over 610mm (24") or with an inaccurately
cut hole, the minimum spacing in Table 3, Nos. 2, 3, 4, 5
and 6 would be 60mm (2.4") in order to allow the terminal
wall plate to be fitted.
IMPORTANT. It is the responsibility of the installer to ensure, in
practice, that products of combustion discharging from the
terminal cannot re-enter the building or any other adjacent
building through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' until corrective action can be taken.
FLUE LENGTHS
The flue assembly can be adapted to accommodate flue
lengths up to 3 metres. Refer to Frame 10.
WATER CIRCULATION SYSTEM
The boiler is designed for connection to pressurised, fully
pumped, sealed water central heating systems ONLY.
The central heating system should be installed and
commissioned in accordance with BS. 6798 and, in addition, for
smallbore and microbore systems BS. 5449.
The domestic hot water system should be in accordance with
BS. 5546 and BS. 6700.
Copper tubing to BS 2871:1 is recommended for water carrying
pipework and MUST be used for pipework carrying potable
water.
Any soldered joints on potable water pipework MUST NOT be
made with solder containing lead.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by
a registered CORGI installer.
Check that the appliance is suitable for the proposed gas supply.
A working gas pressure of 20 mbar MUST be available at the
boiler inlet.
IMPORTANT.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to the boiler MUST be 22mm O.D.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.
FLUE INSTALLATION
The flue must be installed in accordance with the
recommendations of BS. 5440: Part 1.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is
exposed to external air.
2. It is important that the position of the terminal allows the
free passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in
Table 3.
4. Pluming will occur at the terminal, so where possible,
terminal positions where this could cause a nuisance
should be avoided.
Terminal Position
Minimum Spacing
1. Directly below or alongside an
opening window, air vent or other
ventilation opening 300 mm (12")
2. Below guttering, drain pipes or soil
pipes 25 mm ( 1")
3. Below eaves 25 mm ( 1")
4. Below balconies or a car port roof 25 mm ( 1")
5. From vertical drain pipes or soil pipes 25 mm ( 1")
6. From internal or external corners 25 mm ( 1")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface facing the terminal 600 mm (24")
9. From a terminal facing a terminal 1200 mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling 1200 mm (48")
11. Vertically from a terminal on the
same wall 1500 mm (60")
12. Horizontally from a terminal on the wall 300 mm (12")
Table 3 - Balanced flue terminal position
N.B. These clearances are for horizontal flue only.
Refer to supplementary manual for roof flue kits.
Note (Positions 2-6) : Due to the terminal design, installation is
possible with clearances less than those specified in BS 5440,
Part 1.
8
Systemiser SE - Installation
GENERAL
Ancillary pipework not forming part of the useful heating
surface should be lagged to prevent heat loss and any
possible freezing - particularly where pipes run through roof
spaces or ventilated underfloor spaces.
Draining taps should be at least 1/2" BSP nominal size and be
in accordance with BS 2879.
Maximum recommended system hydraulic losses are given in
within Frame 4.
WATER TREATMENT
The Systemiser SE has an aluminium heat exchanger. If water
treatment is used Caradon Plumbing Limited recommend only
the of Fernox-Copal or Sentinel X100 water treatment products,
which must be used in accordance with the manufacturers'
instructions.
For further information contact either:
Fernox Manufacturing Co. Ltd
Tandem House
Marlowe Way
Croydon, Surrey
CRO 4XS
Tel: 0870 5601 5000
or
Betz Dearborn Ltd.
Widnes
Cheshire
Tel. 0151 424 5351
IMPORTANT.
The application of any other treatment to this product will
render the guarantee of Caradon Plumbing Limited invalid.
The CH flow and return pipe
connections are located at the
bottom of the boiler.
2
BOILER WATER CONNECTIONS
Notes.
1. It is most important that the correct concentration of the
water treatment product is maintained in accordance with
the manufacturers' instruction.
2. If the boiler is installed in an existing system any unsuitable
additives must be removed by thorough cleansing. BS.
7593:1992 details the steps necessary to clean a domestic
central heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary. However, the use of artificially softened water is
not permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
THERMOSTATIC RADIATOR VALVES (TRV)
Caradon Plumbing Limited recommend that heating systems
utilising full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room thermostat
controlling the temperature in a space served by radiators not
fitted with such a valve as stated in BS. 5449.
When thermostatic radiator valves are used a bypass should
be fitted, ensuring it is at least 3m from the boiler. The bypass
should have at least 6m of flow and return pipe of a minimum
22mm diameter.
For further information refer to the 'Good Practice Guide 143', a
publication of the Energy Efficiency Office, available from the
Building Research Establishment, Garston, Watford WD2 7JR.
Tel: 01923 664258.
9
Systemiser SE - Installation
GENERAL
ELECTRICAL SUPPLY
WARNING. This appliance must be efficiently earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply.
The point of connection to the mains should be readily
accessible and adjacent to the boiler, except for bathroom
installations where the point of connection to the mains MUST
be situated outside of the bathroom.
Note. Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains electricity
should be so situated that it cannot be touched by a person
using the bath or shower.
The following minimum clearances must be
maintained for operation and servicing.
Additional space will be required for installation,
depending upon site conditions.
Front clearance: 450 mm from the front of the
boiler casing. The minimum front clearance
when built in to a cupboard is 5mm.
3
BOILER CLEARANCES
For side outlet flues:
Raise the centre line of the hole in
the wall by 5mm +4mm/100mm of
flue length
Dimension y
Boiler only with stand-
off brackets
139mm 219mm
(5 (
7/16") (8 5/8")
10
Systemiser SE - Installation
4
SYSTEM REQUIREMENTS - Central Heating
GENERAL
Notes
a. The method of filling, refilling, topping up or flushing
sealed primary hot water circuits from the mains via a
temporary hose connection is only allowed if acceptable
to the local water authority.
b. Antifreeze fluid, corrosion and scale inhibitor fluids
suitable for use with boilers having aluminium heat
exchangers may be used in the central heating system.
Advice should be sought from a local water treatment
company.
General
1. The installation must comply with all relevant national and
local regulations.
2. The installation should be designed to work with flow
temperatures of up to 82
0
C.
3. All components of the system must be suitable for a
working pressure of 3 bar and temperature of 110
0
C.
Extra care should be taken in making all connections so
that the risk of leakage is minimised.
The following components are incorporated within the
appliance:
a. Circulating pump.
b. Safety valve, with a non-adjustable pre-set lift pressure
of 3 bar.
c. Pressure gauge, covering a range of 0 to 6 bar.
d. A 9-litre expansion vessel, with an initial charge
pressure of 0.75 bar.
4. 'Make-up' Water. Provision must be made for replacing
water loss from the system, either :
a. From a manually filled 'make-up' vessel with a readily
visible water level. The vessel should be mounted at
least 150mm above the highest point of the system
and be connected through a non-return valve to the
system, fitted at least 150mm below the 'make-up'
vessel on the return side of the radiators.
or
Safety valve setting bar 3.0
Vessel charge pressure bar 0.5 to 0.75
System pre-charge pressure bar None 1.0
System volume Expansion vessel
(litres) volume (litres)
25 1.6 1.8
50 3.1 3.7
75 4.7 5.5
100 6.3 7.4
125 7.8 9.2
150 9.4 11.0
175 10.9 12.9
190 11.9 14.0
200 12.5 14.7
250 15.6 18.4
300 18.8 22.1
For other system volumes
multiply by the factor across 0.063 0.074
b. Where access to a 'make-up' vessel would be difficult,
by pre-pressurisation of the system.
The maximum cold water capacity of the
system should not exceed 143 litres, if not
pressurized. However, if the system is to be
pressurized, the efficiency of the expansion
vessel will be reduced and a larger vessel (or
smaller system volume) may be necessary. If
the capacity of the vessel is not considered
sufficient for this, or for any other reason, an
additional vessel MUST be installed on the
return to the boiler.
Guidance on vessel sizing is given above.
11
Systemiser SE - Installation
5
SYSTEM REQUIREMENTS - CH (continued)
GENERAL
5. Filling. The system may be filled by one of the following
methods:
a. Through a temporary hose connection from a 'draw-off'
tap, supplied from a service pipe under mains pressure.
Where the mains pressure is excessive, a pressure
reducing valve must be used to facilitate filling.
i. Thoroughly flush out the whole system with cold
water.
ii. Fill and vent the system until the pressure gauge
registers 1.5 bar, and examine for leaks.
iii. Check the operation of the safety valve by raising
the water pressure until the valve lifts. This should
occur within 0.3 bar of the pre-set lift pressure.
iv. Release water from the system until the minimum
system design pressure is reached; 1.0 bar if the
system is to be pre-pressurised.
Refer to Frame 33.
Refer also to the British Gas document: 'Guidance Notes for
the Installation of Domestic Gas Condensing Boilers'
(1989)
A condensate drain is provided on the boiler. This drain must
be connected to a drainage point on site.
All pipework and fittings in the condensate drainage system
MUST be made of PLASTIC - no other materials may be used.
The boiler does not normally need a bypass but at least some
radiators on the heating circuit, of load of at least 60% of the
boiler output, at minimum rate i.e. 60% of 10.1 kW (34 500
Btu's) equal 6kW (21 000 Btu's) must be provided with twin
lockshield valves so that this minimum heating load is always
available.
Note.
Systems incorporating zone valves which could completely cut
off the flow through the system, must be wired such that the
boiler will not fire or continue to fire when this occurs.
6
SYSTEM BALANCING
BALANCING
1. Set the programmer to ON.
Close the manual or thermostatic valves on all
radiators, leaving the twin lockshield valves (on the
radiators referred to above) in the OPEN position.
Turn up the room thermostat and adjust these
lockshield valves to give boiler flow and return
temperatures not more than 15
o
C apart.
These valves should now be left as set.
2. Open all manual or thermostatic radiator valves and
adjust the lockshield valves on the remaining
radiators, to give around 11 oC temperature drop at
each radiator.
3. Adjust the room thermostat and programmer to
NORMAL settings.
The drain outlet on the boiler is standard 22mm overflow
pipe.
IMPORTANT
External pipe runs must be insulated to prevent possible
freezing.
A Siphon Kit is available see instructions supplied with the
kit.
7
CONDENSATE DRAIN
Water Flow Rate and Pressure Loss
Boiler size 24
System Load 24 kW
Water Flow Rate 0.51 l/s
Temperature Differential 11
O
C
Pressure available 29 kPa
for system 2.9 m
12
Systemiser SE - Installation
8
BOILER ASSEMBLY - Exploded View
INSTALLATION
INSTALLATION
Legend
1. Burner
3. Gas valve
4. Detection electrode
5. Ignition electrodes
13. Fan
26. Boiler flow pipe
27. System flow pipe
30. Gas inlet pipe
35. Heat exchanger
48. Prepiping frame
16. Expansion vessel
17. Pump
18. Automatic air vent
22. System return pipe
25. Pump outlet pipe
50. Control panel
72. Gas injection pipe
13
Systemiser SE - Installation
INSTALLATION
INSTALLATION
Unpack and check the pack contents
9
UNPACKING
HARDWARE PACK
M6 x 10 Pozi pan screw - 4 off
M6 shakeproof washer - 4 off
No. 14 x 50mm slotted rd. hd. screw - 4 off
Wall plug (brown) - 4 off
Condensate drain adaptor - 1 off
1/2" sealing washer - 3 off
3/4" sealing washer - 3 off
15mm olive - 3 off
22mm olive - 2 off
Turret seal - 1 off
PACK CONTENTS
z Complete boiler assembly
z Hardware Pack (listed separately below)
z Wall mounting plate
z Wall mounting template
z These Installation and Servicing Instructions
z User's Instructions
z Stand-off brackets (optional use) (1 pair)
z Concealment panels (optional use) (1 pair)
Stand-off brackets
Concealment panels
The boiler
Piping frame
15mm compression nut - 2 off
22mm compression nut - 2 off
15mm pipe connector - 2 off
22mm - 15mm reducing coupling - 1 off
1/2" - 15mm adaptor - 1 off
15mm street elbow - 1 off
22mm street elbow - 2 off
Pressure relief valve outlet pipe - 1 off
Pressure relief valve nut - 1 off
3-way plug - 1 off
Pack B Contents
No. 8 x 8mm self tapping screws - 2 off.
Flue support cutting aid - 1 off.
No.10 x 2" screws - 4 off.
Rawlplugs - 4 off.
14
Systemiser SE - Installation
Flue length dimension Flue
Rear flue Right hand side Left hand side packs
dimn. X flue dimn. Y flue dimn. Z required
114 - 580 mm 114 - 410 mm 114 - 540 mm Pack B - 1 off
(4
1/2" - 22 3/4") (4 1/2" - 16" ) (4 1/2" - 21 1/4" )
580 - 1530 mm 410 - 1360 mm 540 - 1490 mm Pack B - 1 off &
(22 3/4" - 60 1/4") (16" - 53 1/2") (21 1/4" - 58 1/2") Pack D - 1 off
1530 - 2480 mm 1360 - 2310 mm 1490 - 2440 mm Pack B - 1 off &
(60
1/4" - 97 3/4") (53 1/2" - 90 3/4") (58 1/2" - 96") Pack D - 2 off
2480 - 3000 mm 2310 - 3000 mm 2440 - 3000 mm Pack B - 1 off &
(97 3/4" - 118") (90 3/4" - 118") ( 96" - 118") Pack D - 3 off
INSTALLATION
INSTALLATION
For REAR outlet flue Go to Frame 11
For SIDE outlet flue Go to Frame 21
10
DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
Dimension X - Wall thickness
Dimension Y - Wall thickness plus
boiler spacing
(RHS)
Dimension Z - Wall thickness plus
boiler spacing
(LHS)
Calculate the total length of flue by the following:
Rear flue length = Dim. X + 40mm (1
5/8")
RHS flue length = Dim. Y + 188mm (7 3/8")
LHS flue length = Dim. Z + 61mm (2
3/8
")
Note.
These figures include the length of flue entering the
flue turret socket.
Table. Flue pack requirements
FLUE KITS
Pack B
supplied as standard.
Pack D
optional extension kit for
side flue or rear flue
outlet 1000 mm long.
Refer to 'Flue Extension
Ducts'
Vertical Flue
see optional extras.
IMPORTANT.
The boiler MUST be installed in a vertical position.
Note. The flue duct MUST be inclined at 2.5o to the
horizontal to allow condensate to drain back into the
boiler and out through the condensate drain.
15
Systemiser SE - Installation
INSTALLATION
REAR FLUE OUTLET
11
REAR FLUE ASSEMBLY - Exploded View
1. An optional flue duct extension kit is required
for rear flue lengths greater than 580mm
(22 3/4"). Refer to Frame 11.
2. When cutting the ducts always use the
cardboard support cutting aid provided.
LEGEND
1. Terminal.
2. Weather seal.
3. Duct assembly.
4. No. 8 x 8 self-tapping screw.
12
WALL MOUNTING TEMPLATE
IMPORTANT.
For direct mounting (piping frame on wall) choose one black
circle in each group.
If using the stand-off brackets choose one dotted circle in
each group. Care MUST be taken to ensure the correct
holes are drilled.
1. Tape the template into the selected position.
2. Ensure squareness by hanging a plumbline as shown.
3. Mark onto the wall the following:
a. The 4 wall mounting plate screw positions.
b. The position of the flue duct.
Mark the centre of the hole as well as the
circumference.
4. Remove the template from the wall.
5. Flue Turret.
6. M5 x 10 pozi screw.
7. Turret Clamp.
8. Turret seal.
16
Systemiser SE - Installation
INSTALLATION
REAR FLUE OUTLET
13
PREPARING THE WALL
Note. If the terminal is to be sited within 25-
40mm of a corner or vertical pipe then the hole
MUST be accurately cut and the rubber
weather seal trimmed around the groove
provided.
The terminal wall plate need not be fitted.
1. Cut the flue hole (preferably with a 5" core
boring tool), ensuring that the hole is
square to the wall.
Both wall faces immediately around the
cut hole should be flat.
2. Drill 4 holes with a 7mm (
1/4") masonry
drill and insert the plastic plugs provided,
for the wall piping frame.
WARNING. Ensure that, during the cutting operation, masonry falling
outside of the building does not cause damage or personal injury.
14
FITTING THE PIPING FRAME
Fit the wall mounting frame either:
a. Directly to the wall
zz
zz
z Insert wall plugs.
zz
zz
z Put the screws into the wall plugs and leave
10mm proud
zz
zz
z Hang the frame onto the screws and tighten up.
or
b. Use stand-off brackets
(To allow pipework to be taken upwards).
zz
zz
z Insert wall plugs.
zz
zz
z Put the screws into the wall plugs and leave 10mm
proud.
zz
zz
z Fasten each bracket to the frame with the 6mm screws
and washers provided.
zz
zz
z Hang the brackets and frame onto the screws and
tighten up.
Note. If the clearances above and below the boiler are
less than the length of the pipes it will be necessary to
position the pipes behind the wall mounting plate
BEFORE the plate is screwed to the wall.
17
Systemiser SE - Installation
INSTALLATION
15
WATER CONNECTIONS
REAR FLUE OUTLET
Extend a gas supply pipe of not less than 22mm O.D.
copper or 3/4" BSP iron to the boiler.
A working gas pressure of 20mb (8" w.g) must be
available at the boiler inlet, with the boiler firing at full
rate.
16
GAS CONNECTION
Bottom and top connections
1. Solder the 1/2" connector, street elbow, straight pipe and
reducing coupling together.
2. Remove the gas cock bracket complete with gas cock.
3. Screw the connector into the gas cock in the correct
orientation.
4. Screw the complete assembly back onto the mounting
frame.
For top connections: Reverse elbow
Note.
1. Do not subject any of the isolating valves to heat as the seals may
be damaged.
2. In areas where the mains water pressure is known to be high
(greater than 10 bar) it is recommended that a water governor is
fitted on the cold inlet supply to the boiler.
CH CONNECTIONS TANK CONNECTIONS
Top Connection
18
Systemiser SE - Installation
INSTALLATION
2. Undo the 2 screws and remove the
boiler bottom panel.
3. Lift the boiler on to the wall, locating the
CH flow and return pipes and gas pipe
to the service pipes.
Tighten all pipe connections.
17
MOUNTING THE BOILER
REAR FLUE OUTLET
1. Remove the boiler casing:
a. Undo the securing screw.
b. Disengage the casing from the back panel and lift it
from the boiler.
18
CUTTING THE FLUE Rear Flue Length of 114 to 580mm
Note.
If the optional standoff bracket kit is used
it is essential that 80mm is added to the
measured wall thickness when marking
the flue (to allow for the thickness of the
brackets).
1. Measure and note wall thickness X.
2. Add 40mm (1
5/8") to dimension X and,
measuring from the groove, cut the tube.
IMPORTANT
Measure from the groove marked 'TOP' not
the larger groove.
3. To ensure the tube is cut square, mark the
flue all the way round.
4. Cut to length, using the cardboard support
aid.
5. Remove the cardboard support and any
burrs.
19
Systemiser SE - Installation
INSTALLATION
19
ASSEMBLING THE FLUE
REAR FLUE OUTLET
PROCEED TO FRAME 32
20
CONNECTING THE FLUE TO THE BOILER
1. Fit the 'cut to length' flue on to the flue turret.
Note. Ensure the top groove in the flue aligns with
the top of the turret.
2. Drill a 3.2mm dia. hole through the flue via the hole
present in the turret.
3. Secure the turret to the flue, using the self tapping
screw provided.
Note.
BEFORE fitting the flue turret, fill the
condensate trap within the boiler by pouring a
cupful of water into the flue outlet A.
1. Insert the flue assembly through the
prepared hole in the wall far enough to
allow the rubber seal to unfold completely
and form an adequate seal on the
outside wall.
2. Pull the flue back and locate the flue
turret on the top of the boiler ensuring
that the seal is in place.
3. Secure the flue turret on top of the boiler
by inserting the open ends of the turret
clamp under the 2 studs and fixing it in
the middle with the single M5 x 10mm
pozi-hex screw provided.
4. Now make good the inside wall face
around the flue.
20
Systemiser SE - Installation
INSTALLATION
SIDE FLUE OUTLET
2. When cutting the
ducts always use the
cardboard support
cutting aid provided.
1. An optional flue duct extension kit is
required for flue lengths greater than:
410 mm (16") for RHS flue
540 mm (21 1/4") for LHS flue
(Refer to Frame 11).
21
SIDE FLUE ASSEMBLY - Exploded view
IMPORTANT.
For direct mounting (piping frame on wall)
choose one black circle in each group.
If using the stand-off brackets choose one
dotted circle in each group. Care MUST be
taken to ensure the correct holes are drilled.
1. Tape the template into the selected
position.
2. Ensure squareness by hanging a
plumbline as shown.
3. Mark onto the wall the following:
a. The 4 wall mounting plate screw
positions.
b. The position of the flue duct.
Mark the centre of the hole as well as
the circumference.
Note. Allow for stand-off brackets if
being used. Use the table on the
walling mounting template.
4. Remove the template from the wall.
22
WALL MOUNTING TEMPLATE
LEGEND
1. Terminal.
2. Weather seal.
3. Duct assembly.
4. No. 8 x 8 self-tapping screw.
5. Flue Turret.
6. M5 x 10 pozi screw.
7. Turret clamp.
8. Turret seal.
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