Ideal Boilers Maximiser SE 42 Release note

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
appliance care should be taken when handling edges of sheet steel components.

GENERAL
CONTENTS
Air Supply........................................................................8
Boiler Clearances...........................................................4
Boiler Exploded Diagram ..............................................7
Electrical Connections ................................................18
Electrical Supply.............................................................6
Fault Finding .................................................................29
Flow Wiring Diagram ...................................................18
Flue Installation ..............................................................9
Gas Safety (Installation & Use)
Regulations, 1994 or 1996 .............................................2
Gas Supply......................................................................6
Health & Safety Document No 635...............................3
Installation ......................................................................9
Mandatory Requirements..............................................2
Pump .............................................................................16
Servicing .......................................................................23
Short List of Parts ........................................................34
Water Connections ........................................................4
Water and Systems ........................................................5
Wiring Diagrams...........................................................18
INTRODUCTION
OPTIONAL EXTRA KITS
Roof Flue Kit 80/125 For vertical flue connection.
Roof Flue Kit 100/150 For vertical flue connection.
Pitched and flat roof tiles 125 & 150
For all vertical flue options’.
Vertical Twin Pipe Roof Kit 80/125
For vertical flue connection.
Vertical Twin Pipe Roof Kit 100/150
For vertical flue connection.
Horizontal Wall Flue Kit 80/125
For horizontal flue connection.
Horizontal Wall Flue Kit 100/150
For horizontal flue connection.
Sequence Control MBC 5 For control of more than one boiler.
Remote Indication alarm kit
For volt free contacts
2 Boiler Frame Kit For double boiler application.
3 Boiler Frame Kit For triple boiler application.
GAS SAFETY (INSTALLATION AND USE)
REGULATIONS, 1994 OR 1996 (AS AMENDED)
It is law that all gas appliances are installed and serviced by a
CORGI registered installer 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 l.E.E Wiring Regulations, local building regulations,
bye-laws of the local water authority, the building regulations
and the Building Standards (Scotland) and any relevant requi-
rements of the local authority.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 6891 Low pressure installation pipes.
BS. 6798 Installation of gas fired hot water boilers 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. 6644 Ventilation (for gas appliances of rated input
exceeding 60 kW)
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 70 kW net.)
BS. 5440:1 Flues (for gas appliances of rated input not
exeeding 60 kW)
BS. 4814 Specifications for expansion vessels
Health & Safety document no 635
The Electricity at Work Regulations, 1989
Maximiser SE - Installation 2
Maximiser SE boilers are fully automatically controlled, wall
mounted, low water content, balanced flue, fanned super
efficient condensing gas boiler.
The Maximiser SE condensing boilers can be installed either
on the wall or into a prefabricated floor mounted frame.
The boilers are suitable for use with a room sealed flue or
open flued application.
Through a sophisticated control system combined with premix
burner arrangement the boilers are capable of high operating
efficiencies of 94% and low emissions.
The heat exchanger is manufactured from extruded aluminium
finned tubes sealed into aluminium end plates.
Note. These boilers cannot be used on systems which include
gravity circulation.
The boilers are suitable for connection to fully pumped, open
vented or sealed water systems. Adequate arrangements for
completely draining the system by provision of drain cocks
MUST be provided in the installation pipework.

GENERAL
PERFORMANCE DATA
Table 1 - General Data
Model SE 42 SE 65
Boiler Input (Hs) max kW 45.0 62.7
Btu/h 153,540 213,932
min kW 14.4 24.4
Btu/h 49,133 83,253
Boiler Output (condensing) 50º/30ºC max kW 43.3 60.0
Btu/h 147,740 204,720
min kW 13.9 23.7
Btu/h 47,427 80,864
Boiler Output (non-condensing) 80º/60ºC max kW 40.0 55.1
Btu/h 136,480 188,001
min kW 12.6 21.4
Btu/h 42,991 73,017
*Gas Rate m3/h 4.19 5.83
ft3/h 147.97 205.98
Approx flue gas volume m3/s 0.021 0.029
(non condensing) high rate ft3/s 45 62.7
*Note: The gas rates quoted are for NATURAL GAS and assume a C.V. OF 38.7 (MJ/m3).
Flow tappings mm 28 28
Return tappings mm 28 28
Maximum static m 31 31
water head ft 100 100
Maximum Pressure bar 3 3
psi 44 44
Gas inlet R 1/2 1/2
connection in. BSP 1/2 1/2
Pressure required at the mbar 20 20
boiler inlet for the rated input* in. w.g. 8 8
Electricity supply 230 V 50 Hz 230 V 50 Hz
Nominal flue size / concentric mm 80(100) / 125(150) 80(100) / 125(150)
Nominal flue size / twin pipe mm 80 / 80 80 / 80
Condensate Drain Pipe mm 32 32
NOx emissions mg / kW / hr 33 36
ppm 19 21
Water content Lt 3.6 4.7
gal 0.78 1.02
Weight kg 72 75
lb 159 165
IP Rating IP 44 IP 44
Power Consumption W 180 180
Seasonal efficiency *) (SEDBUK) % 90.4 90.5
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
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 Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Ltd. could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas
Safety Regulations and the above regulations.
Notes.
To obtain the gas consumption:-
a. For l/s divide the gross heat input (kW) by
C.V. of the gas (MJ/m3)
b. For ft/h3 divide the gross heat input (Btu/h)
by C.V. of the gas (Btu/ft3)
3Maximiser SE - Installation
*)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 BG plc 0087.

GENERAL
1 BOILER WATER CONNECTIONS
The boiler flow and return pipes are
suitable for 28 mm compression fitting and
are located at the bottom right hand side
of the boiler.
Note.
This appliance is NOT suitable for use
with a direct hot water cylinder.
LOCATION OF BOILER
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment or on a 2 or 3 boiler frame supplied in kit
form by Caradon Ideal Ltd.
The boiler may be fitted on a combustible wall and 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 Engineers
document IGE/UP/7.
2 BOILER CLEARANCES
The following minimum clearances must be maintained
for operation and servicing.
Front of boiler - 450 mm
Sides of boiler - 50 mm
Above boiler - dependant upon the system
Below boiler - 100 mm
685
55
130
656
731
335
900
110
158
450
46
30
450
152
335
6
A/B
1
CDEF
2
3
A/B
455
Ø80/80
110
100
A
B
Z
x
y
50
80/125
194
166
125
x
y
h
100/150
208
178
125
h
BOILER DIMENSIONS Fig. 2.2
190
75
240
660
65
190
420
42
5
MOUNTING POSITION Fig. 2.1
459137
459138
Maximiser SE - Installation 4
1= Front view
2= Side view
3= Top view
4= Back view
5= Mounting bracket
Key to diagram
A= Flue adapter concentric ø 80/125
B= Flue adapter twin pipe ø 80/80
C= Gas connection ½” B.S.P.
D= Condensate drain ø 32 mm
E= Flow connection ø 28 mm
F= Return connection ø 28 mm
Z= 90º Elbow

GENERAL
3 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.
Note. Combined feed and vent pipes may also be fitted.
There should be a minimum height, 500 mm (20”), of open vent
above the cistern water level. The vertical distance between the
highest point of the system and the feed/expansion cistern
water level MUST not be less than 3 m.
The vertical distance between the pump and feed/expansion
cistern MUST comply with the pump manufacturer’s minimum
requirements, to avoid cavitation. Should these conditions not
apply either lower the pump position or raise the cistern above
the minimum requirement specified by Caradon Ideal Ltd. The
isolation valves should be fitted as close to the pump as
possible.
4 SEALED SYSTEM REQUIREMENTS
Note. The method of filling, refilling, topping up or
flushing sealed primary hot water circuit from the
mains via a temporary hose connection is only
allowed if acceptable to the local water authority.
1. General
a. The
installation
must comply
with the
requirements
of BS. 6798
and BS.
5449.
b. The
installation
should be
designed to work with
flow temperatures of up to 90 ˚C and a
temperature differential of 20 ˚C.
c. All components of the system, including the heat
exchanger of the indirect cylinder, must be
suitable for a working pressure of 3 bar (45 Lbf/in2)
and temperature of 110 °C. Care should be taken
in making all connections so that the risk of
leakage is minimised.
2. Safety Valve
A spring loaded safety valve complying with the
relevant requirements of BS. 6759 must be fitted in
the flow pipe as close to the boiler as possible and
with no intervening valve or restriction. The valve
should have the following features:
a. A non-adjustable preset lift pressure not
exceeding 3 bar (45 Lbf/in2).
b. A manual testing device.
c. Provision for connection of a discharge pipe.
The valve or discharge pipe should be positioned so
that the discharge of water or steam cannot create a
hazard to the occupants of the premises or cause
damage to electrical components and wiring.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4 bar
(0-60 Lbf/in2) must be fitted to the system. The gauge should
be easily seen from the filling point and should preferably be
connected at the same point as the expansion vessel.
459127
459128
5Maximiser SE - Installation

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.
The Ideal Maximiser SE boiler has an aluminium alloy heat exchanger. Therefore it is important that if water treatment
is used it is suitable for the material of the heat exchanger. The ONLY water treatments approved are ‘Fernox Copal’
and ‘Sentinel X 100’ current suitability should be confirmed with the manufacturer direct.
Betzdearborn Ltd. Fernox
Sentinel Division Fry Technology UK,
Foundry Lane Tandem House, Marlowe Way,
Widnes, Cheshire Beddington Farm Road,
Tel [phone] Croydon, CRO 4XS
Tel [phone]
Technical help 01799 550 811
ANY OTHER treatment used will render the guarantee of Caradon Ideal for this product INVALID. The use of artificially
softened water is not permitted.
WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply.
The central heating system should be in accordance with
BS. 6798 and. in addition, for smallbore and microbore systems,
BS. 5449.
WATER TREATMENT - see Frame 5
The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and 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 and ventilated underfloor spaces.
The boiler must be vented.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler and
hot water storage vessel. They should be at least 1/2” BSP
nominal size and be in accordance with BS. 2879.
ELECTRICAL SUPPLY
Wiring external to the appliance MUST be in accordance with
the current l.E.E. (BS7671) Wiring Regulations and any local
regulations which apply.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.
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 engineer.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required. A minimum working gas pressure
of 20 mbar MUST be available at the boiler inlet.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to the boiler MUST be of an
adequate size.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
Maximiser SE - Installation 6

INSTALLATION
CONDENSATE DRAIN - Refer to Frame 18
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.
IMPORTANT.
Any external runs must be insulated.
The drain outlet on the boiler is standard 32 mm
overflow pipe.
6 BOILER ASSEMBLY - Exploded view
1. Frame
2. Heat exchanger
3. Ionisation probe
4. Lower access cover
5. Safety sensor
6. Sight glass
7. Temperature/pressure gauge
8. Display
9. Igniter
10. Control panel
11. Gas inlet pipe 1/2” to valve
12. Condensate drain 32 mm
13. Burner
14. Flow connection
15. Return connection
16. Burner thermostat
17. Gas injector
18. Hand held diagnostic
19. Electrical terminal connection (options)
20. Fan
21. Air/gas connecting piece
22. Gas pipe from valve
23. Fan inlet pipe
24. Pump
25. Gas/air pressure pipe
26. Return sensor
27. Flow sensor
28. Mains connection box
29. Flue sampling point
459129
459129
7Maximiser SE - Installation

INSTALLATION
7 WALL MOUNTING TEMPLATE
Note. The template shows the positions for the fixing holes.
Care must be taken to ensure the correct holes are drilled.
1. Tape template into the selected position.
2. Ensure squareness by hanging a plumbline.
3. Mark onto the wall the screw positions.
4. Remove the template from the wall.
5. Fix the wall bracket into place.
INSTALLATION REQUIREMENTS
The appliance must be installed by a competent person, i.e.
CORGI registered.
The installation of the boiler must be in accordance with the
relevant requirements of the Gas Safety Regulations, current
l.E.E. Regulations, Model Water Bye-laws, local water authority
bye-laws and it should also comply with any relevant
requirements of the local gas supplier, local authority and the
relevant British Standard Codes of practice and building
regulations.
FOR SMALL PIPE INSTALLATIONS;
BS. 6891; Installation of low pressure pipework
8 MOUNTING THE BOILER
1. Remove the jacket:
1 - Pull the door at the front towards you.
2 - Remove the screw (below operating instructions).
3 - Disconnect the fasteners at both sides of the
jacket.
4 - Loosen the jacket by pulling it forwards.
Do not lift the jacket by the fasteners.
2. Attach the adaptor plate for the connection of the flue gas
discharge and the air supply before mounting the unit.
3. Mount the boiler on the wall bracket. Refer to the next
paragraphs for more information about connecting the
central heating, gas and flue gas discharge pipes and the
condensate drain.
9 VENTILATION
Safe, efficient and trouble-free operation of open flued gas
boilers is vitally dependent on the provision of an adequate
supply of fresh air to the room in which the appliance is
installed. Ventilation by grilles communicating directly with
the outside air is required at both high and low levels. The
minimum free areas of these grilles must be according to the
following scale:
Table 2 - Ventilation Requirements
Position ventilation grilles to avoid the risk of accidental
obstruction by blockage or flooding. If further guidance on
ventilation is required then consult BS 5440:2.
Room Sealed Applications
Boilers in this instance will require no additional air for
combustion. It may be necessary to ventilate the boiler house
in order to remove any additional heat generated by the boiler
and pipework. Reference should be made to BS 5440:2 and
the requirements for boiler room temperatures.
open-flued appliancesMinimum air vent
free area for
compartments:
Roomsealed appliances
Vent Position
High level
Low level
Compartment ventilated:
to room or direct to
internal space outside air
cm2per kW (net.) cm2per kW (net.)
of appliance of appliance
maximum maximum
rated input rated input
10 5
20 10
Compartment ventilated:
to room or direct to
internal space outside air
cm2per kW (net.) cm2per kW (net.)
of appliance of appliance
maximum maximum
rated input rated input
10 5
10 5
3
3
4
2
1
214079
Maximiser SE - Installation 8

INSTALLATION
10 FLUE INSTALLATION
Caution : To avoid the possibility of injury during the use
or cleaning of this appliance, care should be taken when
handling edges of sheet steel components.
The flue kits are suitable for use with the Ideal Maximiser SE
boiler only.
These kits and the associated options are suitable for both
roof and wall mounting applications.
The roof kit is suitable for both flat and pitched roof
termination, using a concentric flue (tube within tube) to run
vertically from the top of the boiler and terminating above the
roof level.
Connection to the top of the boiler is made using a
separately supplied vertical connector in both concentric and
twin pipe configurations.
Additional information covering the selection and installation
can be found with this booklet.
WEATHER PROOFING
Where the flue passes through the roof line an adequate seal
must be made. This can be achieved by using either:
●Flat roof tile 125 or 150 mm
●Pitched roof tile 125 mm or 150 mm
Concentric flue duct extension kits are available for flue
lengths extending beyond 1 metre. These packs contain
additional 1 metre ducts and may be cut to the desired
length.
If obstructions prevent direct flue routing then both 90° and
45° elbows can be provided to offset the flue system.
TERMINAL POSITION
Due to the high efficiency of the boiler in certain weather
conditions pluming will occur. Therefore, where possible,
terminal positions which could cause problems should be
avoided.
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’ and corrective action taken.
TERMINAL POSITION
Where the lowest part of the terminal is fitted less then 2 m
(80”) 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 between the balcony and the terminal should be 75
mm, in order to allow a terminal guard to be fitted.
Terminal guards are available from boiler suppliers and
merchants- 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.
Where the terminal is fitted within 850 mm (34”) of a plastic
or painted gutter or 450 mm (18”) of painted eaves then an
aluminium shield at least 750 mm (30”) long should be fitted
to the underside of the gutter or painted surface.
The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25 mm (1”) to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440: 1990.
9Maximiser SE - Installation
ASSEMBLING THE FLUE
All Concentric flue packs provided contain locking collars for ease of installation (see Frame 11).
Extension duct kits are available in 1 metre lengths. These can be cut to suit the required application.
The outer duct should be cut to the required length. However, the inner duct MUST be 20 mm greater in length to allow
connection to the remainder of the flue.
Important : Only the plain end of the ducts should be removed when cutting to length.
Note : Care should be taken to support the inner duct pipe when cutting the flue.

11 FLUE KITS
Table 3
KEY TO DIAGRAM DESCRIPTION CODES
80/125 mm 100/150 mm
Fig. 11.1 Vertical Roof Kit 152394 152 395
Fig. 11.2 Vertical Twin PipeRoof Kit 152396 152 397
Fig. 11.3 Horizontal Wall Kit 152398 152 399
Fig. 11.4 90º Elbow (shown) 152616 152617
Fig. 11.4 45º Elbow 152618 152619
Fig. 11.5 Flat Roof Tile (shown) 152611 152612
Fig. 11.5 Pitched Roof Tile 152609 152610
Fig. 11.6 Locking Collar Supplied within wall & roof kits
Fig. 11.7 Concentric Flue Adaptor Supplied within wall & roof kits
Fig. 11.8 Twin Pipe Adaptor 152403 N/A
Fig. 11.9 1 m Extension kit 152400 152401
Not Shown Increaser 80/100 152404 N/A
Not Shown Air inlet grille 152402 N/A
The Vertical and Horizontal flue kits are supplied with all the necessary components to allow the connection
of the concentric flue system from the boiler to the outside atmosphere. The kits are supplied with a
maximum length of 1 metre. For lengths greater than 1 metre extension kits will need to be obtained.
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
Maximiser SE - Installation 10

12 FLUE RESISTANCE’S
11 Maximiser SE - Installation
IMPORTANT : The boiler MUST be installed in a vertical
position.
The pressure available at the boiler outlet is sufficient to
overcome the resistance of approximately 40 metres of 100
mm smooth straight flue pipe. However, this pressure will
be significantly reduced dependant upon the type of flue
system used and the number of bends.
The table below provides the individual resistance’s for a
number of pipes and bends available.
The maximum pressure drop allowed in the flue length
is approximately:-
70 Pa for the Maximiser SE42
90 Pa for the Maximiser SE65
Table 4 - Flue Gas Resistance
Pressure drop per component Pa Pa SE42 SE65
SE42 SE65 Straight pipe Ø 80 mm per m 2.2 5.3
Ducts Straight pipe Ø 90 mm per m 1.8 4.4
Roof duct 80/125 mm 34.0 75.2 Straight pipe Ø 100 mm per m 0.8 1.7
Roof duct 100/150 mm - 37.0 Straight pipe Ø 110 mm per m 0.3 0.7
Wall duct 80/125 mm 22.0 -
Wall duct 100/150 mm - 43.3 Air supply system
Concentric pipe 45º bend Ø 80 mm 2.3 5.3
45º bend Ø 80/125 mm 3.7 - 45º bend Ø 90 mm 1.7 4.1
45º bend Ø 100/150 mm 1.8 2.7 45º bend Ø 100 mm 0.7 1.6
90º bend Ø 80/125 mm 6.0 - 45º bend Ø 110 mm 0.2 0.5
90º bend Ø 100/150 mm 2.7 4.5
Straight pipe Ø 80/125 mm per m 4.0 - 90º bend Ø 80 mm 7.2 16.0
Straight pipe Ø 100/150 mm per m 1.8 3.6 90º bend Ø 90 mm 5.4 12.5
90º bend Ø 100 mm 2.2 4.4
Flue gas discharge system 90º bend Ø 110 mm 0.3 0.6
45º bend Ø 80 mm 3.7 8.9
45º bend Ø 90 mm 2.8 6.7 Straight pipe Ø 80 mm per m 1.5 3.6
45º bend Ø 100 mm 0.9 2.0 Straight pipe Ø 90 mm per m 1.3 3.1
45º bend Ø 110 mm 0.4 0.9 Straight pipe Ø 100 mm per m 0.6 1.4
Straight pipe Ø 110 mm per m 0.1 0.2
90º bend Ø 80 mm 11.7 26.6
90º bend Ø 90 mm 9.0 20.0
90º bend Ø 100 mm 3.5 7.2
90º bend Ø 110 mm 0.5 1.1
The above table provides approximate resistance information for the optional flue kits (concentric pipe) and propriety
fittings, available from the flue companies mentioned below.
Purpose designed flue and air systems can be provided with the boiler (concentric systems) at the time of purchase, or can
be purchased from either of the following:
Rite Vent Ltd [phone]
Selkirk Manufacturing [phone]
FLUE DESIGNS
Flue designs are calculated against the maximum available resistance using the resistance table above. The examples
following are given as a guide only, therefore a greater number of variations can be obtained.

Maximiser SE - Installation 12
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 100/150 80/125 100/150 100/150
Standard flue 152398 152399 22 22 43.3
+ 2 x Extension packs 152400 152401 8 3.6 7.2
+ 1 x 90° elbow 152616 152617 6 2.7 4.5
approximate length - right 2300mm; left 2000mm; rear 2500mm
Note: lengths are from side/back of boiler
horizontal flue with 1x90° elbow
13 EXAMPLES OF POSSIBLE FLUE INSTALLATIONS
Fig.13.1
horizontal flue with 2x90° elbows
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 100/150 80/125 100/150 100/150
Standard flue 152398 152399 22 22 43.3
+ 2 x Extension packs 152400 152401 8 3.6 7.2
+ 2 x 90° elbows 152616 152617 12 5.4 9
approximate length - right 2300mm; left 2000mm; rear 2300mm
Note: lengths are from side/back of boiler
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 80/125 80/125
Twin pipe adaptor 152403 n/a n/a
Air inlet grille 152402 5 5
6m of 80mm pipe n/a 13.2 31.8
approximate length - 6000mm
Note: * Flue system supplied by proprietary flue manufacturers. This flue
design layout would be used where greater flue travel is required. By utilizing the
twin pipe adaptor and air inlet grille, as shown in the diagram, proprietary flue
lengths can be used to take the flue gases to the external atmosphere.
It should be noted that in this example the combustion air is drawn from the room
the boiler is situated in, therefore the boiler will need to be positioned
in a purpose built boiler room with additional air inlet grilles
open flue
152402
152403
*
Fig.13.2
Fig.13.3
NOTE: FOR MAXIMUM PRESSURE DROPS SEE FRAME 12

Maximiser SE - Installation 13
13 EXAMPLES OF POSSIBLE FLUE INSTALLATIONS (CONT)
Fig.14.1
roof flue system
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 100/150 80/125 100/150 100/150
Standard flue 152394 152395 34 34 37
approximate length - 1000mm
Standard flue 152394 152395 34 34 37
+ Extension pack 152400 152401 4 1.8 3.6
approximate length - 2000mm
Standard flue 152394 152395 34 34 37
+ 3 x Extension packs 152400 152401 12 5.4 10.8
approximate length - 4000mm
Standard flue 152394 152395 34 34 37
+ 6 x Extension packs 152400 152401 24 10.8 21.6
approximate length - 7000mm
Note: * The twin pipe adaptor is supplied within the standard flue pack for
connection to the boiler
152394/5
152611/2
152400/1
*
roof flue system with 2x45° elbow
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 100/150 80/125 100/150 100/150
Standard flue 152394 152395 34 34 37
+ 2 Extension packs 152400 152401 8 3.6 7.2
+ 2 x 45° elbows 152618 152619 7.4 3.6 5.4
approximate length - 3500mm
Standard flue 152394 152395 34 34 37
+ 3 x Extension packs 152400 152401 12 5.4 10.8
+ 2 x 45° elbows 152618 152619 7.4 3.6 5.4
approximate length - 4500mm
Part No. Resistance Pa
SE 42 SE 65
Flue diameter 80/125 100/150 80/125 100/150 100/150
Standard flue 152398 152399 22 22 43.3
approximate length - right 300mm; left n/a; rear 500mm
Standard flue 152398 152399 22 22 43.3
+ Extension pack 152400 152401 4 1.8 3.6
approximate length - right 1300mm; left 1000mm; rear 1500mm
Standard flue 152398 152399 22 22 43.3
+ 3 x Extension packs 152400 152401 12 5.4 10.8
approximate length - right 3300mm; left 3000mm; rear 3500mm
Note: items * are provided with the standard flue pack
horizontal flue
152398/9
152400/1
*
*
Fig.13.4
Fig.13.5
Fig.13.6

Maximiser SE - Installation 14
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. Below balconies or car port roof 25 mm 1 in
5. Above adjacent ground, roof, or balcony level 300 mm 12 in
6. From vertical drain pipes or soil pipes 25 mm 1 in
7. From internal or external corners 25 mm 1 in
8. From a surface facing the terminal 600 mm 24 in
9. From a terminal facing the terminal 1200 mm 48 in
10. From an opening in the car port
(eg door, window) into dwelling 1200 mm 48 in
11. Vertically from a terminal on the same wall 1500 mm 60 in
12. Horizontally from a terminal on the same wall 300 mm 12 in
roof terminal positions
13. Directly below an opening, air brick, windows, etc 300 mm 12 in
14. Below plastic/painted gutters 500 mm* 20 in
15. Below painted surface 500 mm* 20 in
16. Below eaves or balcony 500 mm 20 in
17. From wall 1000 mm
*Note: may be reduced to 300mm if a shield fitted
Note: the flue must be installed in accordance with BS 5440: Part 1

INSTALLATION
15 CASCADE FRAME KITS
16 INSTALLATION OF MULTIPLE BOILERS
In installations where the heat load is greater than the boiler
capacity an ideal solution is to use multiple boiler arrange-
ments.
There are many variations available to suit most commercial
applications.
Multiple boiler layout incorporating room sealed application.
Modular flue arrangements using a single combined header can be used.
For further advice or additional information on multiple arrangements contact Caradon Ideal Ltd.
KEY
1. Non-return Valve
2. Relief Valve
3. Service Valve
4. Expansion Vessel
5. Mixing Header
6. Flow Sensor
7. System pump
8. By-pass
9. Flow control
10.Outdoor Sensor
11.MBC 5
12.Flue gas Terminal
459140
499004
15 Maximiser SE - Installation
12
3
33 4
5
6
7
8
KEY
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
2 and 3 Boiler Frame Kits, shown above, are available as options to mount the boilers remote from the wall of the boiler house.

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.
If this pressure is not sufficient an additional pump to overcome system resistance must be fitted. (see frames 3 & 4 for pump
positions)
Fig. 17.1 Automatic air-vent.
Central heating circuit
The connections for the return pipe and the flow pipe of the
central heating circuit are located at the bottom rightside of
the unit. The return pipe has a blue mark, the supply pipe a
red mark. It is recommended to connect the unit to the pipe
system by means of valves.
If applicable select the size of the expansion vessel,
depending on the central heating water temperature, the total
water volume of the installation and the static water pressure.
The boiler has been equipped with an automatic air-vent.
This vent is located in the left top side wall of the heat
exchanger. (Refer to Fig. 17.1).
A pressure safety device is necessary, too. The pressure
safety device has to be installed in the flow pipe.
In installations at which all radiators have been provided with
thermostatic radiator valves, you need to ensure that the
water circulation through the unit is guaranteed. This can be
done by means of a differential pressure valve, that is
installed between the supply pipe and the return pipe at
about 6 meters distance from the unit. The pipe diameter has
to be at least 22 mm for an installed capacity of 22 and 30
kW and 28 mm for an installed capacity of 42 kW or over.
(Refer to Fig 17.2).
The Ideal Maximiser is not suited for installations with a
natural water circulation (gravity installations).
Important information:
Corrosion in the central heating system depends on:
- the water quality,
- not flushing old installations when installing a new boiler,
- intrusion of oxygen through leakages or open valves,
- diffusion in synthetic (floor) heating systems.
The changing temperature and pressure in the system can
also accelerate the corrosion.
If the Ideal Maximiser is to be installed in an existing installa-
tion, the central heating water has to be checked in advance.
If this water is contaminated, the whole installation has to be
drained and flushed before the unit can be mounted and the
system filled.
Do not use system additives.
(refer to frame 5, page 6)
Fig. 17.2 Schematic diagram of installation, with remote
shunt pipe and differential pressure valve.
2
3
14
1. Valves
2. Relief valve
3. Expansion vessel
4. Differential pressure valve
211084
216034 UK
459141
200 4000 600 800 16001000 1200 1400
0
100
200
300
400
600
litre/hour
mbar
UPUP25-5525-55
1800
500
∆T=20KT=20K
Availiable for
installation
lift pump
200 4000 600 800 16001000 1200 1400
0
100
200
300
400
600
litre/hour
mbar
UPUP25-5525-55
1800
500
∆T=20KT=20K
Availiable for
installation
lift pump
20002200 24002600
MaximiserMaximiser SE42SE42 MaximiserMaximiser SE65SE65
∆T=25KT=25K
Maximiser SE - Installation 16

INSTALLATION
18 CONDENSATE DRAIN
Note.
The drain connection is located at the bottom left of the
casing.
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.
Any external runs must be insulated.
In order to defer the onset of freezing of the condensate
drain when the pipe is run externally the pipe should be run
as far as possible within the building.
Excessive external pipe runs should be avoided in order to
prevent possible freezing.
All pipework and fittings in the condensate drain system
must be made of plastic. No other materials may be used.
The drain outlet on the boiler is standard 32 mm overflow
pipe. This size must not be reduced in any part of its length.
The boiler condensate drain connection should be sealed to
the tubing, using a suitable plastic tube adhesive.
The use of an open tundish is recommended to prevent
condensate building up inside the boiler.
19 ELECTRICAL CONNECTIONS
WARNING. This appliance MUST be efficiently earthed.
A mains supply of 230 V ~ 50 Hz is required.
The supply wiring MUST be suitable for mains voltage.
Wiring should be 3 core PVC insulated cable NOT LESS
than 0.75 mm2(24 x 0.2 mm) and to BS. 6500, Table 16.
Wiring external to the boiler MUST be in accordance with the
current l.E.E. Wiring Regulations and any local regulations.
The supply connection is intended to be made via a double
pole switch, having a 3 mm (1/8”) contact separation in both
poles, serving only the boiler and system controls.
The fuse rating should be 3 A.
20 EXTERNAL WIRING
External wiring MUST be in accordance with the current l.E.E.
Wiring Regulations.
The wiring diagrams illustrated in Frames 22 to 23 cover the
systems most likely to be used with this appliance.
For wiring external controls to the boiler, reference should be
made to the systems wiring diagram supplied by the relevant
manufacturer in conjunction with the wiring diagrams shown in
Frames 22 to 23.
Difficulty in wiring should not arise, providing the following
directions are observed:
1. It is advised that the appliance is wired with an unswitched
(permanent) live supply.
2. External controls should NOT be wired in series with the
boiler mains input. Controlling teh mains input in this way
prevents the internal pump from performing its over-run
sequence and may cause damage to the heat exchanger.
3. Caradon Ideal Ltd. Recommend the use of the iRT30
programmable room thermostat or the MBC5 sequence
controllers.
4. However, if alternative external timers/controllers are to be
used, volt free contacts should be wired across terminals 1&2.
5. DO NOT connect mains voltage across terminals 1&2.
6. If no external controls are fitted, a link must be used to replace
the factory fitted ‘loop’ across terminals 1 & 2.
6. Contols that override an on/off control, e.g. a frost thermostat,
Must be wired in parallel with the controls to be overridden.
8. SYSTEM DESIGNS FEATURING CONTROLS OR WIRING
ARRANGEMENTS WHICH ALLOW THE BOILER TO FIRE
WHEN THERE IS NO PUMPED CIRCULATION TAKING
PLACE MUST NOT BE FITTED.
Advice be obtained from the component manufacturers.
N.B. All secondary controls, such as room thermostats, programmers etc., used with this boiler MUST be volt free or 24 volt.
Do not connect mains voltage via the boiler secondary control connections.
open connection 2 cm
siphon
to the drain
built-in siphon
21105 UK
459139
17 Maximiser SE - 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 & 2.
I
J
M
G
Connector for
external 3 way valve
(optional)
EF
M
12 12 123
LN
1234
24VAC
0V
- max 6 VA
0
12 34 56 78 9 1110
Weather
compensation
(optional)
24VAC
output
Volt free
alarm kit
(optional)
34
MBC 5
12
On/Off
'Loop'not conducting
(remove when used)
'Loop'conducting
(remove when used)
Ionisation electrode
Hot surface
ignitor
AC
B
Control panel
18 pin. connector
Fan
Circulation pump
(max. 2A)
MAINS
230V 50Hz
Fuses, main switch, safety switch
and/or further safety precausions,
follow local regulations
When used remove
bridge connector
20 pin. connector
20
16 17 18 1910 12 13 14 15
11
4
35678912
H
16 17 18
10 12 13 14 15
11
4
35678912
yellow/blue pink pink black yellow purple blue brown pink purple/red green/black white red/white black/white grey/white blue/white
pink
purple/white black/red black/white pink brown/red red blue/red grey/red yellow/red green/red
F Safety sensor
G Supply sensor
H Boiler identification module
I ignition gas valve
J main gas valve
K hot water tank sensor kit
Note!
1) Only 1 external controller may be connected.
2) Only 1 controller MBC5
may be connected.
A Flue gas temperature limiter (optional)
B Potential free connection (bridge connector)
C Burner safety protection
D Not present
E Return sensor
Terminal
connection
box
Colour codes:
1 white
2 red/white
3 green/red
4/5 green/red
6 grey/red
7 green/black
8 black/white
9 red/white
10 pink
11 yellow/red
L
N
K
22 PICTORIAL WIRING
1
2
3
1
2
3
4
5
6
ON/OFF
Roomthermostat
MBC5
volt free alarm kit
211090 UK / 211093 UK 211292
219053 [Caradon]
Maximiser SE - Installation 18

INSTALLATION
23 FROST PROTECTION
Central heating systems fitted wholly inside the building do
not normally require frost protection as it acts as a storage
heater.
The Maximiser SE boiler has built into its control system the
facility to protect the boiler against freezing. The frost
protection will be actioned when the boiler thermostat drops
below 7 ˚C. This will result in the boiler switching on until its
temperature raises to 17 ˚C.
If a frost protection thermostat is to be fitted, remove plastic
link across 1 & 2 and connect wires to terminals 1 & 2. This
must be a Normally Open thermostat!
24 PUMP OPERATION (INTERNAL)
The Maximiser SE is provided as standard with an internal
circulation pump manufactured by Grundfos.
The pump has been preset and therefore should not be
adjusted as this could have a detrimental effect on the
operation of the boiler.
The control system built into the boiler provides the facility
for pump overrun which can be adjusted between continuous
or 4 minutes after the boiler has ceased firing. If the unit has
not operated for long periods the control system will operate
both the pump and the fan for 5 minutes once every 24
hours.
Pump overrun adjustment is shown in the diagram
1 = 4 minutes
2 = Continuous
25 COMMISSIONING AND TESTING
A. Electrical Installation
1. Checks to ensure electrical safety should be carried out
by a competent person.
2. ALWAYS carry out the preliminary electrical system
checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable test meter.
B. Gas Installation
1. The whole of the gas installation, including the meter,
should be inspected and tested for soundness an purged
in accordance with the recommendations of BS. 6891.
2. Purge air from the gas installation by loosening the gas
cock union and purge until gas is smelt.
3. Retighten the union and test for gas soundness.
WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation, open all windows and
doors, extinguish naked lights and DO NOT SMOKE
26 GAS CONNECTION
Refer to Frame 2 for details of the position of the gas
connection.
A MINIMUM working gas pressure of 20 mbar (8”w.g.) must
be available at the boiler inlet with the boiler firing. Refer to
Frame 31 or ‘Servicing’for details of the pressure test point
position.
Extend a gas supply pipe NOT LESS THAN 15 mm O.D. to
the boiler and connect to a gas service cock (not supplied),
situated at the bottom left hand side of the boiler.
Ensure that the gas supply pipe does not foul the boiler casing.
Note. If the pipe run from the meter to the boiler is greater
than 3 m (10’) it is recommended that 22 or a 28 mm O.D.
pipe is used.
A 1/2”BSP x 15 mm connector, pre-fitted with a short stub
connection, should be screwed into the cock, using a
suitable sealant.
IMPORTANT. The gas service cock may contain a non-
metallic seal so must not be overheated when making
capillary connections.
display
service
reset
pump
Type UBA 4000
Max. safety time: 10 sec.
230 Vac 50 Hz
DIN DVGW nr: 93.01bNF "S"
12
reset
pump
12
211079
19 Maximiser SE - Installation