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Maximiser SE 42 & SE 65
Installation & Servicing instructions
Wall Mounted, Fanned, Super Efficient Gas Boilers
Natural Gas Models Only
Maximiser SE 42
Maximiser SE 65
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.
G.C. Appliance No. 41-349-85
G.C. Appliance No. 41-349-86
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Table of Contents
Related Manuals for Ideal Boilers Maximiser SE 42
Summary of Contents for Ideal Boilers Maximiser SE 42
- Page 1 Maximiser SE 42 & SE 65 Installation & Servicing instructions Wall Mounted, Fanned, Super Efficient Gas Boilers Natural Gas Models Only Maximiser SE 42 G.C. Appliance No. 41-349-85 Maximiser SE 65 G.C. Appliance No. 41-349-86 CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this...
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Page 3: Table Of Contents
GENERAL OPTIONAL EXTRA KITS Roof Flue Kit 80/125 For vertical flue connection. CONTENTS Roof Flue Kit 100/150 For vertical flue connection. Air Supply................8 Pitched and flat roof tiles 125 & 150 For all vertical flue options’. Boiler Clearances............4 Vertical Twin Pipe Roof Kit 80/125 Boiler Exploded Diagram ..........7 For vertical flue connection. - Page 4 GENERAL PERFORMANCE DATA Table 1 - General Data Model SE 42 SE 65 Boiler Input (Hs) 45.0 62.7 Btu/h 153,540 213,932 14.4 24.4 Btu/h 49,133 83,253 Boiler Output (condensing) 50º/30ºC 43.3 60.0 Btu/h 147,740 204,720 13.9 23.7 Btu/h 47,427 80,864 Boiler Output (non-condensing) 80º/60ºC 40.0 55.1...
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Page 5: Boiler Clearances
GENERAL LOCATION OF BOILER BOILER WATER CONNECTIONS The boiler must be installed on a flat and vertical wall, capable The boiler flow and return pipes are of adequately supporting the weight of the boiler and any suitable for 28 mm compression fitting and ancillary equipment or on a 2 or 3 boiler frame supplied in kit are located at the bottom right hand side form by Caradon Ideal Ltd. - Page 6 GENERAL OPEN VENT SYSTEM REQUIREMENTS The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150 mm (6”) away from the vent connection.
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Page 7: Electrical Supply
GENERAL 5 WATER TREATMENT The Maximiser boiler has an ALUMINIUM alloy heat exchanger Corrosion will always occur within a heating/hot water system to a greater or lesser degree irrespective of water characteris- tics, unless the initial fill water from the mains is treated. For these reasons Caradon Ideal strongly recommends that when necessary the system be thoroughly cleaned prior to the use of a stable inhibitor wich does not require continual topping up to combat the effects of hardness, salts, and corrosion on the heat exchanger and its associated systems. - Page 8 INSTALLATION CONDENSATE DRAIN - Refer to Frame 18 A condensate drain is provided on the boiler. This drain must IMPORTANT. be connected to a drainage point on site. All pipework and Any external runs must be insulated. fittings in the condensate drainage system MUST be made of plastic - no other materials may be used.
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Page 9: Air Supply
INSTALLATION INSTALLATION REQUIREMENTS WALL MOUNTING TEMPLATE The appliance must be installed by a competent person, i.e. Note. The template shows the positions for the fixing holes. CORGI registered. Care must be taken to ensure the correct holes are drilled. The installation of the boiler must be in accordance with the Tape template into the selected position. -
Page 10: Flue Installation
INSTALLATION 10 FLUE INSTALLATION Caution : To avoid the possibility of injury during the use IMPORTANT or cleaning of this appliance, care should be taken when handling edges of sheet steel components. It is the responsibility of the installer to ensure, in practice, that products of combustion discharging from the terminal The flue kits are suitable for use with the Ideal Maximiser SE cannot re-enter the building or any other adjacent building... - Page 11 11 FLUE KITS Fig. 11.1 Fig. 11.2 Fig. 11.3 Fig. 11.4 Fig. 11.5 Fig. 11.6 Fig. 11.7 Fig. 11.8 Fig. 11.9 Table 3 KEY TO DIAGRAM DESCRIPTION CODES 80/125 mm 100/150 mm Fig. 11.1 Vertical Roof Kit 152394 152 395 Fig.
- Page 12 12 FLUE RESISTANCE’S IMPORTANT : The boiler MUST be installed in a vertical The table below provides the individual resistance’s for a position. number of pipes and bends available. The maximum pressure drop allowed in the flue length is approximately:- The pressure available at the boiler outlet is sufficient to 70 Pa for the Maximiser SE42 overcome the resistance of approximately 40 metres of 100...
- Page 13 13 EXAMPLES OF POSSIBLE FLUE INSTALLATIONS NOTE: FOR MAXIMUM PRESSURE DROPS SEE FRAME 12 horizontal flue with 1x90° elbow Part No. Resistance Pa SE 42 SE 65 Flue diameter 80/125 100/150 80/125 100/150 100/150 Standard flue 152398 152399 43.3 + 2 x Extension packs 152400 152401 + 1 x 90°...
- Page 14 13 EXAMPLES OF POSSIBLE FLUE INSTALLATIONS (CONT) roof flue system 152394/5 Part No. Resistance Pa SE 42 SE 65 Flue diameter 80/125 100/150 80/125 100/150 100/150 152611/2 Standard flue 152394 152395 approximate length - 1000mm 152400/1 Standard flue 152394 152395 + Extension pack 152400 152401...
- Page 15 14 FLUE TERMINATION POSITION wall terminal positions minimum spacing 1. Directly below, or adjacent to, an openable window or any other ventilation opening 300 mm 12 in 2. Below guttering, drain pipes, or soil pipes 25 mm 1 in 3. Below eaves 25 mm 1 in 4.
- Page 16 INSTALLATION 15 CASCADE FRAME KITS 1. 2 boiler basic frame 2. additional single frame 3. support foot 4. main return pipe 5. main flow pipe 6. main gas supply pipe 7. boiler connection kit 8. hydraulic header 499004 2 and 3 Boiler Frame Kits, shown above, are available as options to mount the boilers remote from the wall of the boiler house. 16 INSTALLATION OF MULTIPLE BOILERS In installations where the heat load is greater than the boiler There are many variations available to suit most commercial...
- Page 17 INSTALLATION 17 PUMP SPECIFICATION The boiler is fitted with a Grundfos UP 25/55 circulating pump, wich provides circulation through the boiler heat exchanger. Some pump pressure remains available for the system and is shown on the graphs below. Maximiser Maximiser SE42 SE42 Maximiser Maximiser SE65...
- Page 18 INSTALLATION 18 CONDENSATE DRAIN The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building. The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length. IMPORTANT.
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Page 19: Installation
INSTALLATION 21 INTERNAL WIRING A pictorial wiring diagram is shown. 1. Route the mains cable into the bottom of the casing. 2. If an on/off roomsthermostat is to be fitted remove plastic link across 1 & 2 and connect wires to to terminals 1 &... -
Page 20: Pump
INSTALLATION 23 FROST PROTECTION Central heating systems fitted wholly inside the building do If a frost protection thermostat is to be fitted, remove plastic not normally require frost protection as it acts as a storage link across 1 & 2 and connect wires to terminals 1 & 2. This heater. -
Page 21: Maximiser Se - Installation
INSTALLATION 27 INITIAL LIGHTING To burner Honeywell gas 1. Check that the system has been filled and that the boiler is not air locked - air in the system could trip the overheat control valve thermostat. 2. Check that all the drain cocks are closed and any valves in the flow and return are open. -
Page 22: Maximiser Se - Installation
INSTALLATION 29 ADJUSTMENT PARAMETERS Table 5 Table 6 Hot water tank temperature adjustment Capacity (kW) partial load adjustment at 80/60˚C (only in case of an external hot water tank) Potentiometer Water temperature Potentiometer adjustment in hot water tank (˚C) adjustment SE42 SE 65 12.6... -
Page 23: Maximiser Se - Installation
INSTALLATION 31 BOILER ADJUSTMENTS General The Maximiser constantly controls the gas/air mixture. In Fig. 31.1 order to maintain the correct output and low emissions it is important to have the initial adjustment correct, thus avoiding high/low operation and/or bad emissions. Although the boiler has been factory set, starting problems can be caused by a variation of the gas/air pressure ratio. -
Page 24: Servicing
SERVICING 32 SERVICING SCHEDULE WARNING. BEFORE SERVICING always turn OFF the gas supply at the gas service cock and switch OFF and DISCONNECT the electrical supply to the appliance. To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. -
Page 25: Maximiser Se - Installation
SERVICING 32 SERVICING SCHEDULE (CONT) Fig. 32.2 2. Siphon inspection. Inspecting the siphon of the lower access cover plate in the unit. Remove the siphon located under the lower access cover plate in the unit (refer to Fig. 32.2). The contents of the siphon will indicate whether or not aluminium oxide has been formed. -
Page 26: Maximiser Se - Installation
SERVICING 33 MINOR MAINTENANCE Fig. 33.1 Preparing the burner detachment Minor maintenance involves the following activities: 1. Isolate the electricity supply. 2. Successively remove or detach (refer to frame 6): the jacket of the unit (refer to frame 8) the gas pipe from the valve the gas/air pressure pipe the plugs of the burner safety thermostat the air supply hose of the fan. -
Page 27: Maximiser Se - Installation
SERVICING 34 MAJOR MAINTENANCE Fig. 34.1 Removing the lower access cover plate Major maintenance includes all minor maintenance activities. However, major maintenance also includes complete cleaning of the heat exchanger at the combustion gas side: Isolate the electricity supply. 1. Successively remove or detach (refer to frame 6): the jacket of the unit (refer to page 8) the upper union connection on the gas pipe from the gas valve... -
Page 28: Maximiser Se - Installation
35 replacement of components (REFER TO FRAME 43) Casing Door (refer to fig. 43.1, key 7) Fan (refer to fig. 43.6, key 63) 1. Open the casing door. 1. Follow steps 1-2 of Burner Thermostat replacement. 2. Carefully continue to hinge the door outwards until the 2. -
Page 29: Maximiser Se - Installation
35 replacement of components (REFER TO FRAME 43) Gas Valve (refer to fig. 43.7, key 72) 3. Spring open the upper and lower retaining clips of the 1. Follow steps 1-2 of Burner Thermostat replacement. lower access cover plate and pull downwards to remove. 2. - Page 30 35 replacement of components (REFER TO FRAME 43) (CONT) Heat Exchanger (refer to fig. 43.3, key 19) 5. Disconnect the flue system from the boiler and remove 1. Disconnect the electricity supply. the adapter plate fixed to the back panel. 2.
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Page 31: Maximiser Se - Installation
FAULT FINDING 37 FAULT FINDING During normal operation (no fault having occured) one of the indicated on the display panel of the Maximiser SE following codes with the corresponding service code, will be condensing boiler. display code service code unit operating condition Starting up the Control panel sequence Restart of the Control panel sequence after a reset Control panel sequence checks the unit data when starting up... -
Page 32: Maximiser Se - Installation
FAULT FINDING 40 FAULT FINDING - CODES Display Service Unit and/or installation behaviour Causes code code 0 or =. The central heating installation is not heated, but the hot water tank (if present) is. The central heating installation is overheated; the hot water tank is not heated. Unit is constantly fired for the central heating and does not modulate in reverse direction. -
Page 33: Maximiser Se - Installation
FAULT FINDING 40 FAULT FINDING - CODES (CONT) Display Service Unit and/or installation behaviour Causes code code Mains supply failure during locking error or reset button released too soon. 30/32 Defective control panel or blown F3 fuse. 31/39 Defective control panel. Defective control panel. -
Page 34: Maximiser Se - Installation
FAULT FINDING 41 FAULT FINDING - CAUSES (CONT) Malfunction causes and remedies The table shown below gives the possible cause of the malfunction described in frame 40. The table also provides instructions of how to remedy the malfunction. Cause Cause description Too high resistance in the central heating circuit, e.g. -
Page 35: Short List Of Parts
FAULT FINDING 41 FAULT FINDING - CAUSES (CONT) Malfunction causes and remedies The table shown below gives the possible cause of the malfunction described in frame 40. The table also provides instructions of how to remedy the malfunction. Cause Cause description BIM is defective or not properly connected, when started, the fan will rotate for a moment and then stops. - Page 36 43 Casing / Control panel fig. 43.1 fig. 43.2 43 Heat exchanger fig. 43.4 fig. 43.5 fig. 43.3 Maximiser SE - Installation...
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Page 37: Maximiser Se - Installation
43 Fan / Gas control 72/73 fig.43.6 fig.43.7 43 Pump / Burner 52/53 fig.43.8 fig.43.9 Maximiser SE - Installation... - Page 40 Caradon Plumbing Solutions Technical Training pursues a policy of continuing improvement in the design and The Caradon Plumbing Solutions Technical Training Centre performance of its products. The offers a series of first class training courses for domestic, right is therefore reserved to vary commercial and industrial heating installers, engineers and specification without notice.
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