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41 FAULT FINDING - CAUSES (CONT)

Too high resistance in the central heating circuit, e.g. because of blocked thermostatic radiator valves or because of

blockage by dirt.

The test switch on the control panel is switched on; put it back in off position.

Too few radiators are open or the differential pressure switch is not properly adjusted.

Defective safety sensor.

Defective/polluted supply sensor.

The pump is dead; loose contact in the connecting wires or the plug is incorrectly mounted in the control panel.

Pump stuck or defective.

Water level is too low in the central heating system because of a leakage or because of air in the installation. Check

the pressure gauge, eventually fill up to 2 bar and open the air separator one full turn (provided that it was closed).

The 11 kW jumper has been removed from the control panel or the partial load potentiometer is set at an insufficient

value. If the fan only operates at low speed, the fan or control panel is defect.

Too much resistance or dirt in the air circuit; check the air supply/combustion gas discharge system, the burner, and

the heat exchanger.

The fan is not functioning properly; check the connectors and the fuse of the transformer and check the voltage on

the control panel connector.

Return sensor is defective or not properly connected.

Burner thermostat is open or not connected; check the thermostat for the switching point 107˚C. Check the burner

cover for defects, it is possible that the flame will extend to the rear-side of the burner cover. Check the sealing

between the mixing chamber and the heat exchanger and check the connection of the burner housing to the heat

exchanger.

The fuse F2 in the control panel is blown, caused by a short-circuit in the gas valve-circuit. Check the electrical

connection of the gas valve for a proper functioning.

Disconnect the connector of the sensor and press “reset”. When the same fault remains, short-circuiting in the cable

loom has occurred or the control panel is defect, otherwise the sensor is defect.

Sensor defect or improper contacts and connections.

The connecting wires of the igniter do not make contact or the igniter is defective or the fuse F1 is defective.

Control panel should supply 120 V to connector.

Improper gas/air ratio. Check the air restriction and the gas injector for the correct diameter, mounting, and pollution.

The first and/or second gas valve does not open, check for a 24 V supply during the ignition phase. Check the

resistance of the burner thermostat (unit electrically disconnected) maximum resistance of 3

Ω

The burner is supplied with too little gas or air is present in the gas pipe; check the pre-pressure. If the control pipe is

not blocked, the gas/air

∆

P should be checked at minimum and maximum load.

Check the connection of the ionisation pin, use the pin to measure the ionisation current in series (this current should

amount to at least 2 µAC).

Check the mains supply during operation.

Short-circuiting in the 24 V circuit (three-way valve or connector); check for a short-circuit and replace the F3 fuse in

the control panel.

Press “reset” until “r” appears on the display.

Gas inlet-pressure too low; check the inlet-pressure during operation at maximum load. Inlet-pressure should amount

to at least 20 mbar (25 mbar -17%).

Gas valves do not close; check the voltage on the gas valve. If a voltage is measured on both the gas valves (> 20 V),

the control panel should be replaced. When ionisation occurs while the unit is not operational, the ionisation circuit

should be checked. If the control panel and the ionisation function properly, the gas valve has to be replaced.

Cause

No.

Cause description

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.

FAULT FINDING

Maximiser SE

- Installation

Содержание Maximiser SE 42

Страница 1: ...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 ...

Страница 2: ......

Страница 3: ...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 wa...

Страница 4: ...r 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 fl...

Страница 5: ...he 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 3...

Страница 6: ...ty 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 take...

Страница 7: ...ecommended 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...

Страница 8: ...iew 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 connect...

Страница 9: ...raphs 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 requi...

Страница 10: ...t 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 ter...

Страница 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 ki...

Страница 12: ...º 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 45...

Страница 13: ... 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 require...

Страница 14: ...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 ...

Страница 15: ...rners 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 m...

Страница 16: ... 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 1 2 3 3 3 4 5 6 7 8 KEY 1 2 boiler basic frame 2 additional single frame 3 support foot 4...

Страница 17: ...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...

Страница 18: ... 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 F...

Страница 19: ...7 18 19 10 12 13 14 15 11 4 3 5 6 7 8 9 1 2 H 16 17 18 10 12 13 14 15 11 4 3 5 6 7 8 9 1 2 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 va...

Страница 20: ...cks 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...

Страница 21: ...rried out on the boiler These adjustable potentiometers are located behind the control panel cover Adjustment of these meters to the desired value will be dependant upon the type of installation Supply temperature Hot water storage temperature Partial load Test switch 1 Supply temperature Using the upper trimming potentiometer indicated with a radiator to adjust the central heating water temperatu...

Страница 22: ...grammer and all other system controls should be proved Operate each control separately and check that the main burner or circulating pump as the case may be responds 2 Water circulation system a With the system HOT examine all water connections for soundness b With the system still HOT turn off the gas water and electricity supplies to the boiler and drain down to complete the flushing process c R...

Страница 23: ...suring the differential pressure The differential pressure should be 5 Pa 0 05 mbar with a tolerance of 5 Pa 0 05 mbar Because of this the measured value should be between 10 and 0 Pa The differential pressure can be corrected by turning the adjustment screw of the gas pressure on the gas valve By turning it to the right the differential pressure will decrease Note The adjustment screw is protecte...

Страница 24: ... and that the flue system is sealed correctly h If the appliance has been installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 33 and 34 and MUST be carried out in sequence Note In order to carry out either servicing or replacement of components the boiler casing must removed Refer to frame 8 IMPORTANT After completing the ...

Страница 25: ... and inspect the heat exchanger refer to Fig 32 3 If the heat exchanger is polluted major maintenance should be carried out Note The lower access cover plate has to be cleaned with a steel brush before remounting it If the seal is dirty it should be cleaned with a cloth or a soft brush The servicing procedures are covered more fully in Frames 33 to 34 and MUST be carried out in sequence WARNING Al...

Страница 26: ...ed with 120 V AC The mains supply MUST therefore always be isolated before removing the burner dangerous voltage above 50 V AC 5 After cleaning the burner the silicone burner sealing gasket can be re used provided it shows no damage If it is damaged it should be replaced Reassemble the burner in reverse order 6 Remove the fan by loosening it from the lower access cover plate refer to Fig 33 3 Insp...

Страница 27: ...h 4 lnspect the heat exchanger 4a Remove the lower access cover plate by detaching the quick acting closures at the foot of the heat exchanger refer to Fig 34 1 Subsequently clean the cover plate with a steel brush Clean the gasket with a cloth or a soft brush Remove and check the ionisation electrode Fig 34 2 the igniter Fig 34 4 Note the igniter is very fragile the guide plate Fig 34 3 Never tou...

Страница 28: ...replacement 2 Swing the control panel away from the fan 3 Unplug the two electrical connectors from the front of the fan by squeezing the retainers and pulling forwards 4 If fitted remove the retaining block from the top fitting point of the fan 5 Remove the air hose to the heat exchanger by pushing it upward to clear the fan body 6 Pull fan assembly forwards to clear the rear location points lowe...

Страница 29: ...assembly and reassemble in reverse order 5 Check the operation of the boiler Lower Access Cover Seal refer to fig 43 3 key 28 1 Follow steps 1 7 of Fan replacement 2 Disconnect siphon from lower access cover plate see fig 33 4 3 Spring open the upper and lower retaining clips of the lower access cover plate and pull downwards to remove 4 Remove the damaged seal from the groove in the cover plate a...

Страница 30: ...e UBA 4000 Max safety time 10 sec 220 240 Vac 50 Hz DIN DVGW nr 93 01bNF S CE REG NR 63 A05280 1 2 pump service display reset 211077 35 replacement of components REFER TO FRAME 43 CONT Heat Exchanger refer to fig 43 3 key 19 1 Disconnect the electricity supply 2 Where possible isolate the boiler from the heating system 3 Drain the system water from the heat exchanger 4 Isolate the gas supply at th...

Страница 31: ...appear if the unit adjusts itself to the small amount of water in the installation H Unit is in operation for hot water 39 FAULT DIAGNOSIS By combining the display and service codes that are shown with the unit and or installation behaviour the cause of the malfunction can be found Normally the operating code is indicated on the display By pressing the Service button the service code will appear I...

Страница 32: ...on is not sufficiency heated The central heating water temperature is higher than the set value Unit in anti fast cycle time Connection for flue gas thermostat not closed Safety sensor of the heat exchanger is overheated The difference in heat between the safety sensor and the supply sensor is too large or the supply and return sensor have been interchanged Temperature of safety sensor is rising t...

Страница 33: ...9 37 39 39 39 39 37 39 39 39 40 41 FAULT FINDING CAUSES Cause No Cause description 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 The room thermostat is not properly connected ensure a proper connection of the poles The room thermostat does not switch off D...

Страница 34: ...set When the same fault remains short circuiting in the cable loom has occurred or the control panel is defect otherwise the sensor is defect Sensor defect or improper contacts and connections The connecting wires of the igniter do not make contact or the igniter is defective or the fuse F1 is defective Control panel should supply 120 V to connector Improper gas air ratio Check the air restriction...

Страница 35: ...nce of this appliance The full list is held by Caradon Ideal distributors and merchants When ordering spares please quote 1 Boiler model 2 Description 3 Quantity FAULT FINDING Maximiser SE Installation 34 Key No 7 6 1 3 4 5 41 89 72 73 52 56 50 99 104 35 36 25 39 28 30 63 105 G C No E58 940 E58 942 E58 941 E58 954 E58 952 E58 956 E58 962 E58 993 E58 998 E59 737 E59 000 E59 705 E59 005 E59 008 E59 ...

Страница 36: ...43 Casing Control panel 43 Heat exchanger 35 Maximiser SE Installation 7 6 1 5 4 3 30 25 28 35 36 41 99 39 21 19 22 31 fig 43 1 fig 43 2 fig 43 5 fig 43 4 fig 43 3 105 104 ...

Страница 37: ...43 Fan Gas control 43 Pump Burner Maximiser SE Installation 36 63 72 73 52 53 89 49 56 50 fig 43 6 fig 43 7 57 59 fig 43 8 fig 43 9 ...

Страница 38: ......

Страница 39: ......

Страница 40: ...g Solutions Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring Technical Training 01482 498432 Caradon Plumbing Solutions pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary s...

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