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IDEAL Systemiser SE Installation And Servicing Manual

Wall mounted, gas fired, fanned flue condensing system boiler boiler
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  • Page 2 ...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.

  • Page 3: General Data

    The test data from which it has been calculated have been certified by Gastech NV0061. 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. Systemiser SE - Installation...

  • Page 4: Table Of Contents

    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 INTRODUCTION CONTENTS The Systemiser SE is a wall mounted, low water content, Air Supply ................ 6 balanced flue, condensing system boiler.
  • Page 5 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. BOILER WATER CIRCUIT DIAGRAM Systemiser SE - Installation...

  • Page 6: Air Supply

    BS 6798, Clause 12, and BS 5440:2 may be disregarded. Systemiser SE - Installation...

  • Page 7: Gas Supply

    1500 mm (60") 12. Horizontally from a terminal on the wall 300 mm (12") Note (Positions 2-6) : Due to the terminal design, installation is possible with clearances less than those specified in BS 5440, Part 1. Systemiser SE - Installation...

  • Page 8: Water Connections

    In hard water areas, treatment to prevent limescale may be WATER TREATMENT necessary. However, the use of artificially softened water is The Systemiser SE has an aluminium heat exchanger. If water not permitted. treatment is used Caradon Plumbing Limited recommend only...

  • Page 9: Boiler Clearances

    5mm. Dimension y Boiler only with stand- off brackets 139mm 219mm (5 ( ") ") 7/16 For side outlet flues: Raise the centre line of the hole in the wall by 5mm +4mm/100mm of flue length Systemiser SE - Installation...

  • Page 10: Sealed System Requirements

    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. Systemiser SE - Installation...

  • Page 11: Condensate Drain

    All pipework and fittings in the condensate drainage system A Siphon Kit is available see instructions supplied with the MUST be made of PLASTIC - no other materials may be used. kit. Systemiser SE - Installation...

  • Page 12: Boiler Exploded Diagram

    Control panel Expansion vessel Boiler flow pipe Gas valve Gas injection pipe Pump System flow pipe Detection electrode Gas inlet pipe Automatic air vent Ignition electrodes System return pipe Heat exchanger Pump outlet pipe Prepiping frame Systemiser SE - Installation...
  • Page 13 1 off Turret seal 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. Systemiser SE - Installation...

  • Page 14: Flue Lengths & Types

    Pack B - 1 off & " - 118") " - 118") ( 96" - 118") Pack D - 3 off For REAR outlet flue Go to Frame 11 For SIDE outlet flue Go to Frame 21 Systemiser SE - Installation...

  • Page 15: Flue Installation

    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. Remove the template from the wall. Systemiser SE - Installation...
  • Page 16 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. Systemiser SE - Installation...
  • Page 17 Screw the connector into the gas cock in the correct A working gas pressure of 20mb (8" w.g) must be orientation. available at the boiler inlet, with the boiler firing at full rate. Screw the complete assembly back onto the mounting frame. Top Connection Systemiser SE - Installation...
  • Page 18 Measure from the groove marked 'TOP' not the larger groove. To ensure the tube is cut square, mark the flue all the way round. Cut to length, using the cardboard support aid. Remove the cardboard support and any burrs. Systemiser SE - Installation...
  • Page 19 2 studs and fixing it in the middle with the single M5 x 10mm pozi-hex screw provided. Now make good the inside wall face around the flue. PROCEED TO FRAME 32 Systemiser SE - Installation...
  • Page 20 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. Systemiser SE - Installation...
  • Page 21 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. Systemiser SE - Installation...
  • Page 22 A working gas pressure of 20mb (8" w.g) must be 3. Screw the connector into the gas cock in the correct available at the boiler inlet, with the boiler firing at full orientation. rate. Top Connection Systemiser SE - Installation...
  • Page 23 Cut to length, using the cardboard support aid. Remove the cardboard support and remove any burrs. FOR FLUE LENGTHS GREATER THAN 600mm REFER TO FRAMES 34, 35 & 36 - FLUE EXTENSION DUCTS Systemiser SE - Installation...
  • Page 24 For standard installations use the short wood screw. If the stand-off option is used, secure the support bracket using the spacer bracket and long wood screw. Now make good the inside wall face around the flue. Systemiser SE - Installation...
  • Page 25 Marley 'Terrain' tubing, which is slightly larger. This adaptor should be sealed to the Marley 'Terrain' tubing and to the boiler condensate drain, using a suitable plastic tube adhesive. Systemiser SE - Installation...

  • Page 26: Flue Extensions

    Flue extensions of greater length than 1m (39") should be supported with the bracket provided, suitably adjusted - refer to Frame 34. Note. Side flue shown Systemiser SE - Installation...
  • Page 27 Cut to length using the cardboard support aid. 10. Remove the cardboard offcuts and deburr the metal edges. Appliances fitted with a REAR outlet flue; please refer to Frame 11 Appliances fitted with a SIDE outlet flue; please refer to Frame 21 Systemiser SE - Installation...
  • Page 28 Boiler heat exchanger Gas valve Safety valve Condensate & safety drains CH flow Gas inlet CH return Pump CH expansion vessel Automatic air vent Flue sensing point Front elevation layout of boiler components (control panel open) Systemiser SE - Installation...

  • Page 29: Electrical Connections

    3mm (1/8") contact separation in both poles, or a plug and socket, serving only the boiler and system controls. All external controls and wiring must be suitable for mains The means of isolation must be accessible to the user after voltage. installation. Systemiser SE - Installation...

  • Page 30: Flow Wiring Diagram

    3. If a room thermostat is fitted wire across the 5-way remote plug terminals 1 & 2 in place of link wire. 4. Secure the mains lead with the cable clamp in the plug. Note. Room thermostat connections 41 FLOW WIRING DIAGRAM Systemiser SE - Installation...
  • Page 31 INSTALLATION 42 PICTORIAL WIRING DIAGRAM Systemiser SE - Installation...
  • Page 32 Switchmaster 'Midi' is similar in operation, but the wiring supply. differs slightly; see manufacturer's literature. LEGEND LEGEND white blue yellow g/y green/yellow blue bk black white orange bk black brown g/y green/yellow brown violet orange pk pink yellow violet Systemiser SE - Installation...

  • Page 33: Commissioning And Testing

    INSTALLATION 45 EXTERNAL WIRING For wiring external controls to the Systemiser SE boiler, WARNING. This appliance must be efficiently earthed. reference should be made to the system wiring diagrams A mains supply of 230 V ~ 50 Hz is required.

  • Page 34: Initial Lighting

    Remove the screw in the burner pressure test point (C) and connect a gas pressure gauge via a flexible tube. Swing the control panel into its working position. Systemiser SE - Installation...
  • Page 35 15. Operate the boiler for 20 minutes to stabilise the burner temperature. 16. The boiler central heating control is fully modulating, operating between burner pressures of: 13.0 mbar (± 0.2 mbar) MAXIMUM 2.0 mbar (± 0.2 mbar ) MINIMUM These are factory set. Systemiser SE - Installation...
  • Page 36 00 = CH OFF requirement. 01 = CH ON Balance the system. Refer to Frame 6. Max CH temp ( 20 to 82 Check the condensate drain for leaks and check that it is discharging correctly. Systemiser SE - Installation...

  • Page 37: Handing Over

    Emphasise that if a fault is indicated, the boiler should be contract your self or alternatively offer to the customer turned off and a registered local heating installer the benefits of the Ideal Care Scheme, details of consulted. which are outlined in the householder pack supplied with this boiler.

  • Page 38: Servicing Schedule

    If not, proceed to Step 3. contract yourself or, alternatively, to the customer the benefits of the Ideal Care scheme, details of which are Clean the main burner. outlined in the Householder pack supplied with this boiler.

  • Page 39: Servicing

    Lift to disengage the casing from the back panel and withdraw it from the boiler. 55 BOILER SEALING PANEL REMOVAL 1. Release the 2 retaining clips. 2. Swing the panel open to the left and disengage it from the boiler. Systemiser SE - Installation...

  • Page 40: Burner Removal And Cleaning

    Check that the spark and detection leads are in good heat exchanger. condition ,and renew as necessary. 3. Brush off any deposits that may have collected on the burner, ensuring that the flame ports are unobstructed. Note. Brushes with metallic bristles must NOT be used. Systemiser SE - Installation...

  • Page 41: Cleaning The Heat Exchanger

    Reconnect the fan electrical lead. Turn on the gas supply at the gas service cock. Refit the fan, engaging it in the bayonet fixing. Ensure that the 'O' ring seal is in place. 10. Reconnect the electrical supply. Systemiser SE - Installation...

  • Page 42: Replacement Of Components

    5. Unscrew the thermostat from the side of the heat exchanger. Remove the boiler casing. Refer to Frame 54. 6. Fit the new flue thermostat ,and re-assemble in reverse Remove the boiler sealing panel. Refer to Frame 55. order. Disconnect the flue thermostat electrical leads. Systemiser SE - Installation...
  • Page 43 Undo the 3 fixing screws securing the burner assembly. mounting Withdraw the burner assembly downward and out of the Note. Check the spark and detection flange is in heat exchanger. gaps. Refer to Frame 39. place. Systemiser SE - Installation...
  • Page 44 1. Refer to Frame 61. 5. Fit the new injector, using a suitable jointing compound 2. Remove the boiler casing. Refer to Frame 54. sparingly. 3. Remove the boiler sealing panel. Refer to Frame 55. 6. Re-assemble in reverse order. Systemiser SE - Installation...
  • Page 45 Disconnect the electrical leads from the valve solenoids, as required. Undo the securing screws as required and remove the solenoid. Fit the new solenoid and re-assemble in reverse order. Check the operation of the new solenoid. Systemiser SE - Installation...
  • Page 46 Fit the new board and re-assemble in reverse order. Ensure that all electrical connections are correctly Undo the 3 securing screws and unclip the plastic cover remade. from the back of the control panel. Check the operation of the boiler. Display board shown Systemiser SE - Installation...
  • Page 47 6. Pull off the trap from the bottom of the boiler. 7. Withdraw the trap from the boiler. 8. Fit the new trap and re- assemble in reverse order. Systemiser SE - Installation...

  • Page 48: Draining The Boiler

    Pull the electrical lead off the sensor. Unscrew the sensor from the boss. Fit the new sensor, using a suitable jointing compound, and re-assemble in reverse order. Systemiser SE - Installation...
  • Page 49 The new seals (provided) are fitted. b. The electrical connections are correctly remade. c. The pump selector switch is set at position 3. 10. Check the operation of the new pump. Systemiser SE - Installation...
  • Page 50 Unscrew the air vent from the boiler flow boss. Fit the new air vent, complete with 'O' ring provided, and re- assemble in reverse order. IMPORTANT. Ensure that the vent cap (A) is loose. Systemiser SE - Installation...
  • Page 51 5. Undo the top retaining bracket screw and remove. 6. Slide the expansion vessel out of the support rails. 7. Fit the new vessel and re-assemble in reverse order. 8. Check the operation of the boiler. Systemiser SE - Installation...
  • Page 52 'O' ring seals for damage and replace, if necessary. 22. Lower the heat exchanger to disengage from the flue connector tube, and withdraw it from the boiler. 23. Fit the new heat exchanger and re- assemble in reverse order. Systemiser SE - Installation...
  • Page 53 Fit the new self adhesive seals to the panel. Re-assemble in reverse order. Note. Ensure that the boiler sealing panel is correctly seated, compressing the sealing strip to make an airtight joint. Systemiser SE - Installation...

  • Page 54: Fault Finding

    Note. The Gasmodul control unit is fitted with 3 fuses. If the boiler fails to operate, check these first. To gain access to the fuses, refer to Frame 69. IMPORTANT. At the end of any fault finding always refit the control buttons cover plate. Systemiser SE - Installation...
  • Page 55 Fan not running / no tacho signal Fan keeps turning / no tacho signal Water pressure switch or flue thermostat failure Maximum temperature Flow temperature T too high Return temperature T too high Flow temperature T increase too fast Systemiser SE - Installation...

  • Page 56: Safety

    Flue thermostat - ELMWOOD 138 097 Condensate trap 075 095 Boiler casing, painted white, with controls dropdown door 075 076 Control panel 075 092 Control valve solenoid - SIT 075 205 Control valve solenoid - SIT 075 206 Systemiser SE - Installation...
  • Page 57 SHORTS LIST OF PARTS 86 SHORT PARTS LIST Systemiser SE - Installation...
  • Page 58 43. 'O' ring 44. 'O' ring 45. Gasket (rubber) 46. Gasket (Cork) 54. EV1 solenoid 55. EV2 solenoid 60. 'O' ring 61. Burner gasket 70. Gas valve mounting bracket 71. Gas valve support bracket 72. Gas injection pipe Systemiser SE - Installation...
  • Page 59 SHORT LIST OF PARTS 88 CONTROL PANEL ASSEMBLY - Exploded View Legend Gasmodul control 12. Rocker switch Display board 50. Control panel Fan speed control board 58. Relay 11. CH pressure gauge Systemiser SE - Installation...
  • Page 60 SHORT LIST OF PARTS 89 BOILER CASING ASSEMBLY Systemiser SE - Installation...
  • Page 61 Systemiser SE - Installation...
  • Page 62 No. London 322 137. Registered Office: National The right is therefore reserved to vary Avenue, Kingston upon Hull, HU5 4JN. A specification without notice. subsidiary of Caradon p.l.c July 2000 151415 A06 Ideal Installer/Technical Helpline: 01482 498663 Systemiser SE - Installation...
  • Page 63 YOUR FEEDBACK AND YOUR CHANCE TO WIN A FREE BOILER At Ideal we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service.

  • Page 64: Further Information

    Further information If you would like information about Ideal Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Installer details...

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