GB24 ErP & GB30 ErP
Series II
User & Installation Instructions
off
e
max
reset
mode
min
preheat
min
max
status
burner
preheat
GB24 Series II
BOILER OUTPUT
To Domestic Hot Water:
To Central Heating:
GB24/30 Minimum 8.0 kW (27,296 Btu/h)
GB24 Maximum 24.2 kW (82,570 Btu/h)
GB30 Maximum 30.3 kW (103,384 Btu/h)
GB24/30 Minimum 8.0 kW (27,296 Btu/h)
GB24/30 Maximum 24.2 kW (82,570 Btu/h)
Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD
Morco Products Ltd
Tel: 01482 325456 Fax: 01482 212869
Website: www.morcoproducts.co.uk
UIN 212134 A05
April 2017
ERP DATA
MODEL
Condensing Boiler
Low Temperature Boiler
B1 Boiler
Cogeneration Space Heater
Equipped with a Supplementary Heater
Combination Heater
Nominal Heat Output for Space Heating
Full Load
Part Load
Auxiliary Electricity Consumption
Full Load
Part Load
Standby
Seasonal Space Heating Energy Efficiency
Full Load
Part Load
Standby Loss
Ignition
Emissions
Annual Energy Consumption
Sound Power Level, Indoors
Domestic Hot Water
2
SYMBOL
n/a
n/a
n/a
n/a
n/a
n/a
UNITS
n/a
n/a
n/a
n/a
n/a
n/a
24
yes
no
no
no
no
yes
30
yes
no
no
no
no
yes
P4
P1
kW
kW
24.3
8.0
24.3
8.0
elmax
elmin
PSB
kW
kW
kW
0.042
0.012
0.005
0.031
0.013
0.005
ƞ4
ƞ1
Pstby
Pign
%
%
kW
kW
90.0
98.7
0.050
0
90.0
98.7
0.050
0
NOx
QHE
LWA
mg/kWh
GJ
dB
26
75
45
26
75
46
AEC
AFC
kWh
GJ
16
6
16
6

PRODUCT FICHE
MORCO COMBINATION BOILER
Morco Products Ltd
ERP DATA SYMBOL
Condensing boiler
Seasonal Space heating efficiency class
Rated heat output
Seasonal space heating energy efficiency
UNITS
GJ
dB
QHE
LWA
MODEL
30
Yes
A
24
94*
kW
%
ƞs
Annual energy consumption
Sound power level, indoors
Water heating energy efficiency class
24
76
45
46
A
Seasonal Space Heating Energy Efficiency of the Boiler
*%
A
Temperature control (from fiche of temperature control)
%
Class I
Class II
Class III
Class IV
Class V
Class VI
Class VII
Class VIII
1%
2%
1.5%
2%
3%
4%
3.5%
5%
B
Solar Contribution (from fiche of solar device)
Tank Volume
(in m3)
Collector Size
(in m2)
= (‘III ’x
+ ‘IV ’ x
Collector
Efficiency
(in %)
) x 0.9 x (
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
/ 100 x
%
=
%
TOTAL: A+B+C=
Seasonal Space Heating Energy Efficiency of Package
C
Seasonal Space Heating Energy Efficiency Class of Package
G

< 30%
F
E
≥ 30%
≥ 34%
D
≥ 36%
C
≥ 75%
B
≥ 82%
A
≥ 90%
A+
A++
A+++
≥ 98%
≥ 125%
≥ 150%
The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a
building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics
3
4
Morco GB24 & GB30 Series II
Combination Boiler
Destination Country:
BE= Belgium
CH= Switzerland
CZ= Czech Republic
DE = Germany
ES= Spain
FR= France
GB= UK
GR= Greece
IE = Ireland
IT = Italy
NL= Netherlands
PL= Poland
PT= Portugal
SI = Slovenia
CONTENTS
SECTIONPAGE
1
Users Instructions...........................................................................................................................................6
2
General Specifications....................................................................................................................................10
3
Technical Data................................................................................................................................................12
4
General Installation Requirements.................................................................................................................14
5
Installation Instructions...................................................................................................................................16
6
Commissioning Instructions............................................................................................................................25
7
Routine Servicing Instructions........................................................................................................................27
8
Fact Sheets.....................................................................................................................................................33
9
Fault Codes....................................................................................................................................................34
10
Combustion Ratio Check................................................................................................................................36
11Warranty.........................................................................................................................................................38
5
SECTION 1 - USERS INSTRUCTIONS
FOR ANY QUERIES PLEASE RING THE
MORCO CONSUMER HELPLINE : 01482 325456
NOTE. BOILER RESET PROCEDURE To reset boiler, turn mode control knob to reset position and immediately turn knob back to required setting.
Introduction
Minimum Clearances
Due to the high efficiency of the boiler, condensate is produced from
the flue gases and this is drained to a suitable disposal point through
a plastic waste pipe at the base of the boiler. A condensate ‘plume’
will also be visible at the flue terminal.
Bottom clearance
Bottom clearance after installation can be reduced to 5mm.
The Morco GB Series II is a wall mounted, room sealed, condensing
combination boiler, featuring full sequence automatic spark ignition
and fan assisted combustion.
The Morco GB Series II is a combination boiler providing both central
heating and instantaneous domestic hot water.
Safety
Current Gas Safety (Installation & Use)
Regulations or rules in force.
Clearances of 165mm (6 1/2”) above, 100mm (4”) below,
2.5mm (1/8”) at the sides and 450mm (17 3/4”) at the front of
the boiler casing must be allowed for servicing.
This must be obtained with an easily removable panel, to
enable the consumer to view the system pressure gauge, and
to provide the 100mm clearance required for servicing.
To light the boiler. Refer to Boiler Controls
1. CHECK THAT THE ELECTRICITY SUPPLY TO BOILER IS
OFF.
In your own interest, and that of safety, it is the law that this boiler
must be installed by a Gas Safe Registered Engineer, in accordance
with the above regulations.
2. Set the mode knob control (A) to ‘Off’.
In other countries the installation must be carried out by a qualified
and competent Gas Installer. In the approved country the boiler is
installed, this must be in accordance with their current rules in force.
4. Ensure that all hot water taps are turned off.
It is essential that the instructions in this booklet are strictly followed,
for safe and economical operation of the boiler.
3. Set the Domestic Hot Water temperature control (B) and
Central Heating temperature control (C) to ‘max’.
5. Switch ON electricity to the boiler and check that all
controls, e.g. timer and room thermostat, are ON (refer to
mechanical timer instructions - Page 8).
6. Set the mode knob control to winter (
).
Electricity Supply
If there is a central heating demand the boiler will commence
the ignition sequence.
Supply: 230 V ~ 50 Hz. The fusing should be 3A.
Note. In normal operation the boiler status display (D) will
show codes:
This appliance must be earthed.
Important Notes
 This appliance must not be operated without the casing correctly
fitted and forming an adequate seal.
 If the boiler is installed in a compartment then the compartment
MUST NOT be used for storage purposes.
 If it is known or suspected that a fault exists on the boiler then it
MUST NOT BE USED until the fault has been corrected by a Gas
Safe Registered Engineer or in other countries a qualified and
competent Gas Installer.
Standby - no demand for heat.
CH being supplied.
DHW being supplied.
DHW preheat.
During normal operation the burner on indicator (E) will remain
illuminated when the burner is lit.
 Under NO circumstances should any of the sealed components on
this appliance be used incorrectly or tampered with.
Note : If the boiler fails to light after five attempts the fault
 This appliance can be used by children from 8 years and above
code
will be displayed.
and persons with reduced physical, sensory or mental capabilities
RESET PROCEDURE
or lack of experience and knowledge if they have been given
supervision or instruction concerning use of the appliance in a safe To reset boiler, turn the mode control knob (A) to reset position
way and understand the hazards involved. Children shall not play and immediately turn knob back to required setting. The boiler
with the appliance. Cleaning and user maintenance shall not be
will repeat the ignition sequence if a heat demand is present.
made by children without supervision.
If the boiler still fails to light consult a Gas Safe Registered
 Children should be supervised to ensure that they do not play with Engineer, or in other countries a qualified and competent Gas
Installer.
the appliance.
In cases of repeated or continuous shutdown a Gas Safe Registered
Engineer, or in other countries a qualified and competent Gas Installer,
should be called to investigate and rectify the condition causing this
and carry out an operational test. Only the manufacturers parts are to
be used for replacement.
6
SECTION 1 - USERS INSTRUCTIONS
To shut down the boiler
Operation
Set the mode knob control to OFF
Winter conditions - i.e. CH and DHW required.
Ensure the mode knob control (A) is set to winter (
To relight the boiler
)
Repeat the procedure detailed in ‘To light the boiler’.
The boiler will fire and supply heat to the radiators but will give
priority to DHW on demand.
Frost protection
If the holiday home or park home is to be left unoccupied during
cold periods when there is a threat of freezing, the domestic hot
and cold water circuits must be drained as follows:
Summer conditions - i.e. DHW only required.
Set the mode knob control to Summer (
).
Set the CH external controls to OFF.
Note. The pump will operate briefly as a self-check once every 24
hours, regardless of system demand.
- Turn off the cold water supply
- Open all hot and cold water taps
Pre-heat is enabled if the pre-heat indicator (F) is lit. To switch
pre-heat on or off move the DHW/Pre-heat control knob (B) fully
clockwise and then return it to the required DHW temperature
setting.
- Open all drain plugs in the hot and cold water system (do not
drain the central heating circuit, which should have been filled
with antifreeze if installed in a caravan holiday home or park
home).
Control of water temperature
Refer to the Holiday Home or Park Home owner’s handbook for
the drain plug positions and further instructions on draining down.
The DHW temperature is limited by the boiler controls to
64oC maximum at low draw-off rate, adjustable via the DHW
temperature control (B).
Please note there are no drain plugs on the boiler. Leave all taps
and drain plugs open until next use to allow any residual water to
continue to drain.
Due to system variations and seasonal temperature fluctuations
DHW flow rates/temperature rise will vary, requiring adjustment
at the draw off tap : the lower the rate the higher the temperature,
and vice versa.
Approx. flow temperatures for the boiler thermostat settings are:
When installed in a Caravan Holiday Home or Park Home the
heating circuit and radiators should be filled with an approved
antifreeze (see section 4.8). The level of antifreeze should be
checked annually by a competent person. If the home is occupied
during very cold and freezing weather, the central heating should
be run continuously and the room stat or thermostatic radiator
valves set at a minimum of 15ºC.
Domestic Hot Water
Knob Setting
Flow Temperature
Minimum40o C (104oF)
Maximum64o C (147oF)
If the home is unoccupied for even a short period, the hot and
cold water system must be drained down. This is the only way to
guarantee against frost damage.
Central Heating
ALL FROST DAMAGE IS OUTSIDE OF THE WARRANTY.
The boiler controls the central heating radiator temperature to a
maximum of 80oC and a minimum of 45ºC, adjustable via the CH
temperature control (C).
Boiler Overheat Protection
The boiler controls will shut down the boiler in the event of
overheating. Should this occur, a fault code
will be displayed.
The boiler is a high efficiency combination boiler which is most
efficient when operating in condensing mode.
Refer to fault chart.
Flame Failure
The boiler will operate in this mode if the CH temperature control
(C) is set to the ‘e’ position (economy mode). This control should
be set to maximum for very cold periods
Should this occur a fault code
chart.
will be displayed. Refer to fault
continued . . . . . .
BOILER CONTROLS
off
Legend
reset
min
min
preheat
max
preheat
mode
A
B
C
20 19 18 17
22
21
0
23
I
D
16
3
2
1
24
14 13 12 11
F
E
GB24 Series II
10
9
8
7
6
5
4
Mode Control Knob
DHW/Preheat Control Knob
CH Control Knob
Boiler Status
Burner ‘on’ Indication
Pre Heat on/off Indication
Mechanical Timer
Pressure Gauge
Condensate Drain
Gas Isolation Valve
(on position shown)
burner
15
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
status
e
max
G
H
J
K
7
SECTION 1 - USERS INSTRUCTIONS
Loss of system water pressure
The pressure gauge indicates the central heating system
pressure. If the pressure is seen to fall below the original
installation pressure of 1-2 bar over a period of time then a water
leak may be indicated. In this event re-pressurise the boiler.
If unable to do so or if the pressure continues to drop a Gas
Safe Registered Engineer, or in other countries a qualified and
competent Gas Installer should be consulted.
off
e
max
status
reset
min
min
preheat
max
20 19 18 17
22
21
23
16
2
1
24
14 13 12 11
3
Locate the frozen blockage. It is likely that the pipe is frozen
at the most exposed point external to the building or where
there is some obstruction to flow. This could be at the open
end of the pipe, at a bend or elbow, or where there is a dip in
the pipe in which condensate can collect. The location of the
blockage should be identified as closely as possible before
taking further action.
preheat
15
0
I
1. Follow the routing of the plastic pipe from its exit point on the
appliance, through its route to its termination point.
burner
INDICATED BY “F1” (LOW WATER PRESSURE) - THE BOILER
WILL NOT OPERATE IF THE PRESSURE HAS REDUCED TO
LESS THAN 0.3 BAR UNDER THIS CONDITION.
mode
To unblock a frozen condensate pipe;
10
2. Apply a hot water bottle, microwaveable heat pack or a warm
damp cloth to the frozen blockage area. Several applications
may have to be made before it fully defrosts. Warm water
can also be poured onto the pipe from a watering can or
similar. DO NOT use boiling water.
9
8
7
6
5
4
3. Caution when using warm water as this may freeze and
cause other localised hazards.
4. Once the blockage is removed and the condensate can flow
freely, reset the appliance. (Refer to “To Light the boiler”)
PRESSURE GAUGE
5. If the appliance fails to ignite, call your Gas Safe Registered Engineer,
or in other countries a qualified and competent Gas Installer.
Preventative solutions
Condensate Drain
This appliance is fitted with a siphonic condensate trap system
that reduces the risk of the appliance condensate from freezing.
However should the condensate pipe to this appliance freeze,
please follow these instructions:
a. If you do not feel competent to carry out the defrosting
instructions below please call your local Gas Safe Registered
Engineer, or in other countries a qualified and competent Gas
Installer for assistance.
b. If you do feel competent to carry out the following instructions
please do so with care when handling hot utensils. Do not attempt
to thaw pipework above ground level.
If this appliance develops a blockage in its condensate pipe, its
condensate will build up to a point where it will make a gurgling
noise prior to locking out an “L2” fault code. If the appliance is
reset it will make a gurgling noise prior to it locking out on a failed
ignition “L2” code.
During cold weather, set the boiler stat to maximum, (Must return
to original setting once cold spell is over)
Place the heating on continuous and turn the room stat down to 15ºC
overnight. (Return to normal after cold spell).
Escape of gas
Should a gas leak or fault be suspected contact the Gas Supplier
without Delay. TURN OFF ALL GAS SUPPLIES.
Do NOT search for gas leaks with a naked flame.
Cleaning
For normal cleaning simply dust with a dry cloth.
To remove stubborn marks and stains, wipe with a damp cloth
and finish off with a dry cloth.
DO NOT use abrasive cleaning materials.
Maintenance
The appliance should be serviced at least once a year by a Gas
Safe Registered Engineer, or in other countries a qualified and
competent Gas Installer.
MECHANICAL 24 HOUR TIMER
PROGRAMMING THE TIMER
Permanently OFF
22
23
24
1
2
3
ON segment
8
7
6
5
4
8
20 19 18 1
7
16
9
With the symbol ( ) lining up with the time indicator ( ) the unit will be
permanently OFF.
21
10
With the symbol ( ) lining up with the time indicator ( ) the unit acts as
a timeswitch.
Time & Control
Indicator
OFF segment
Permanent Override
By rotating the central switch so that the symbol (1) lines up with the
time indicator ( ) the unit will be permanently ON.
Permanently ON
1 4 13 1 2 1
1
Note. The segment dial can be turned when the time controller is
operating. In case of power failure, re-adjust the time controller to the
correct time of day, turning the dial in a clockwise direction.
Timer Control
15
1. Decide what times you would like the timeswitch to switch ON and OFF.
2. Push segments towards the programme ring for an OFF period and
push away from ring for an ON period. The minimum switching
interval is 15 minutes and this can be increased in 15 minute steps.
3. Bring the timeswitch into the correct condition by manually turning
the programme ring clockwise through a 24 hour cycle.
4. Turn the programme ring clockwise until the correct time of day on
the ring lines up with the time indicator.
24hr Programme Ring
Timer control segments
1 Segment = 15 mins
Push towards programme ring = OFF
Push away from programme ring = ON
SECTION 1 - USERS INSTRUCTIONS
POINTS FOR THE BOILER USER
Note. In line with our current warranty policy we would ask that you check through the Troubleshooting guide to identify any problems
external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we
reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.
TROUBLESHOOTING
NO HOT WATER
NO CENTRAL HEATING
Check the mains switch (fused
spur) is turned on and ensure
switch mode control knob (A) is
in the summer or winter position
Check the mains switch (fused
spur) is turned on and ensure
switch mode control knob (A) is
in the winter position
Is water coming out of the hot
water tap when turned on?
NO
NO HOT WATER OR
CENTRAL HEATING
Check the fused spur is turned
on and ensure switch mode
control knob (A) is in the winter
position
Check the timer is in an “ON”
position and the room thermostat
is turned up
Does the boiler have a display
showing on the front control
panel?
YES
See boiler “Fault Codes”
section. If ‘0’ is displayed then
contact Morco if your appliance
is under warranty or a Gas
Safe Registered Engineer, or in
other countries a qualified and
competent Gas Installer, if out of
warranty.
Contact a Gas Safe Registered
Engineer, or in other countries
a qualified and competent Gas
Installer.
OPERATION MODES
DISPLAY CODE ON BOILER
Does the boiler operate and
provide central heating?
NO
YES
Check the time settings on the
programmer are as you require
and adjust if necessary
NO
YES
See boiler “Operation Modes”
and “Fault Codes” section
Contact a Gas Safe Registered
Engineer, or in other countries
a qualified and competent Gas
Installer.
See boiler “Operation Modes” and
“Fault Codes” section. If “0” is
displayed then contact a Gas Safe
Registered Engineer, or in other
countries a qualified and competent
Gas Installer.
Note. These letters are permanently displayed while in that mode.
DESCRIPTION
The boiler is in standby mode awaiting either a central heating call or hot water demand.
The boiler has a call for central heating but the appliance has reached the desired
temperature set on the boiler.
The boiler has a call for hot water but the appliance has reached the desired temperature set on
the boiler.
The boiler is operating in central heating mode.
The boiler is operating in hot water mode.
The boiler is operating in pre heat mode.
The water in the cental heating circuit is less than 5ºC. If heating is switched on, this display
code will change to “c”.
9
SECTION 2 - GENERAL SPECIFICATIONS
2.1 GENERAL SPECIFICATIONS
The Morco GB Series II range of boilers are wall mounted, full
sequence, automatic spark ignition low water content, fanned
flue, high efficiency condensing combination boilers.
Note. Due to the high efficiency of the boiler a plume of water
vapour will format the terminal during operation. The boiler is
supplied for use with Propane only at 37mbar (30 mbar for DE)
supply pressure. It is particularly suitable for caravan holiday
home and park home use.
Maximum heat output in either heating or hot water for the GB24
is 24.2kW (82,570 Btu/hr)
Maximum heat output in heating mode for the GB30 is 24.3 kW
(82,570 Btu/hr) with 30.3 kW (103,384 Btu/hr) available for hot
water production.
The boiler can be supplied with a standard concentric flue with
additional extensions, flue deflector and vertical flue kits available
as optional extras. The only flueS that can be fitted are those
detailed in this instruction manual.
The boiler contains the following components:
Cast Aluminium Heat Exchanger
Domestic Hot Water Plate Heat Exchanger
Diverter Valve
Circulating Pump
Pressure Gauge
Safety Valve and Central Heating Expansion Vessel
Automatic Bypass
Daily Pump and Diverter Valve Exercise
Mechanical 24hr Timer
The boiler temperature controls are visible, located in the control
panel. These enable the user to control both CH and DHW
temperatures independently. There is the additional feature of a
DHW preheat facility. Operating and fault codes are displayed on
the status panel.
The boiler is suitable for connection to fully pumped, sealed
heating systems ONLY. Adequate arrangements for completely
draining the system by provision of drain cocks must be provided
in the installation pipework.
Schematic Diagram
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Expansion Vessel
Pump
Auto Air Vent
Water Pressure Switch
Flow Thermistor
Return Thermistor
Divertor Valve
Fan
Venturi
DHW Plate Heat Exchanger
Ignition Electrode
Flame Detection Electrode
Gas Valve
Siphon / Trap
DHW Flow Turbine
System Pressure Gauge
Sump Cover
8
11
1
5
12
9
13
17
3
7
14
10
10
6
2
4
16
15
r
bk
Water
Flow
Turbine
b
bk
p
bk
r
bk
Flow
Return
Water
pressure Thermistor Thermistor
Switch
or
X8
X6
X5
X7
X13
Service
Connector
b
bk
p
bk
y
Fan
b
br
y/g
bk
11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 5 4 3 2 1 3 2 1
KEY
b - blue
bk - black
br - brown
r
- red
p - pink
y - yellow
w - white
y/g - yellow/green
g - grey
or - orange
v - violet
y
p
bk
bk
8
7
6
5
y/g
b
br
4
Spark
Electrode
Flame
Sensor y/g
Electrode
y/g
9
X3
PCB
bk
2
1
b
Spark
Generator
3
5
bk
3
Gas
Valve
y/g
4
X2
2
bk
br
b
Divertor
Valve
v
1
Earth
6
5
X1C
y
y/g
b br
3
p bk
4
X1B
r
Room
Stat
g
1
Pump
bk
2
X1A
r
b
br
Plug
N
L
Main
Supply
y/g
b
b
g
bk
Timer
1 2 3 4
r
Fused
at 4AT
SECTION 2 - GENERAL SPECIFICATIONS
2.2 WIRING DIAGRAM
11
SECTION 3 - TECHNICAL DATA
Table 1 General Data
24
Morco GB Series II
Gas Supply
30
I3p - G31 - 37mbar (30mbar for DE)
Gas Supply Connection
15mm copper compression
Injector Size
(mm)
3.75
3.75
Inlet Connection
Domestic Hot Water
G½
Outlet Connection
Domestic Hot Water
G½
Flow Connection
Central Heating
G¾
Return Connection
Central Heating
G¾
Flue Terminal Diameter
mm (in)
Average Flue Temp-Mass Flow Rate
100 (4)
DHW
Maximum Working Pressure (Sealed Systems)
63ºC - 11g/s
68ºC - 13 g/s
bar (lb/in2)
Maximum Domestic Hot Water Inlet Pressure
bar (lb/in2) (kPa)
Minimum Domestic Hot Water Inlet Pressure*
bar (lb/in2) (kPa)
2.5 (36.3)
10.0 (145) (1000)
0.8 (11.6) (80)
Electrical Supply
1.3 (18.9) (130)
230 V - 50 Hz.
Power Consumption
W
146
Fuse Rating
152
External : 3A
Water Content
Central Heating
litre (gal)
Internal : T4H HRC L250 V
1.2 (0.26)
Domestic Hot Water litre (gal)
0.5 (0.11)
Packaged Weight
Maximum Installation Weight
Boiler Casing Size
Height
kg (lb)
33.8 (74.4)
kg (lb)
31 (68.3)
34.1 (75.2)
31.2 (68.8)
mm (in)
700 (27.5)
Width
mm (in)
395 (15.5)
Depth
mm (in)
285 (11.2)
*Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery
Table 2 - Performance Data - Central Heating
Boiler Input :
Boiler Input ‘Q’
Nett CV
Gross CV
kW
Table 3 - Performance Data - Domestic Hot Water
Max.
Min.
24 30 2430
24.3
24.3
8.0
Maximum DHW Input :
8.0
26.4
26.4
8.7
kW
24.3
30.4
Btu/h 82,912 103,725
Btu/h82,912 82,912 27,296 27,296
kW
Nett CV
2430
8.7
Gross CV
kW
26.4
33
Btu/h 90,077 112,596
Btu/h90,077 90,077 29,684 29,684
Gas Consumption
m3/h1.00 1.25 0.3290.329
m3/h1.00
1.25
ft /h35.33 44.20 11.62 11.62
ft3/h35.33
44.20
kg/hr 1.83
2.26
Maximum kW
24.2
30.3
DHW Output
Btu/h
82,570
103,384
DHW Flow Rate
at 35°C temp. rise.
l/min
gpm
9.9
2.2
12.4
2.8
3
kg/hr 1.83
2.26
0.58
0.58
Boiler Output :
Non Condensing
70oC Mean Water temp.
Condensing
40oC Mean Water temp.
kW
24.2
24.3
8.00
8.00
Btu/h 82,570 82,570 27,296 27,296
kW 25.6
25.6
8.5
8.5
Btu/h 87,347 87,347 29,002 29,002
Seasonal efficiency* SEDBUK 2005
91%
91.1%
Seasonal efficiency* SEDBUK 2009
89%
89%
NOx Classification
Gas Consumption
DHW Specific Rate
l/min
11.5
gpm 2.5
14.5
3.2
CLASS 5
* 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 a notified body.
Note. Gas consumption is calculated using a
calorific value of 95.65 MJ/m3 (2569 Btu/ft3)
gross or 88.0 MJ/m3 (2,360 Btu/ft3) nett
Key to symbols
To obtain the gas consumption at a different
calorific value:
C13 C33 =
A room sealed appliance designed for connection via ducts to a horizontal
or vertical terminal, which admits fresh air to the burner and discharges
the products of combustion to the outside through orifices which, in this
case, are concentric. The fan is up stream of the combustion chamber.
I3P
=
An appliance designed for use on 3rd Family gas, Group P only.
PMS
=
a. For l/s - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m3)
b. For ft3/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
c. For m3/h - multiply l/s by 3.6.
12
Maximum operating pressure of water
SECTION 3 - TECHNICAL DATA
BOILER DIMENSIONS, SERVICES & CLEARANCES
The boiler connections are made on the boiler bulkhead fittings.
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending upon
site conditions.
Side and Rear Flue
a. Provided that the flue hole is cut accurately, e.g. with a core
boring tool or hole cutter the flue can be installed from inside
the dwelling where wall thicknesses do not exceed 600mm
Installation from inside ONLY
b. If a core boring tool or hole cutter is to be used inside the
dwelling the space in which the boiler is to be installed
must be at least wide enough to accommodate the tool.
In either of the above cases safe external access is
required to allow the addition of sealant to seal the flue to
the aluminium flue collar (RSF 060).
17
2.5
from case
395
285
155
Side
flue
dim. A
86.5
WALL
2.5
(24”). Where the space into which the boiler is going to be
installed is less than the length of flue required the flue must
be fitted from the outside.
700
PRV
56.4 37.5
CH RETURN
75
DHW INLET
GAS INLET
28.5 28.5 60.6
DHW OUTLET
65
COND. DRAIN
CH FLOW
43.5
DATA PLATE
Underside View - Dimensions to Wall
103
99
99
99
103
WALL
Front clearance
The minimum front clearance when
built in to a cupboard is 5mm from
the cupboard door but 450mm overall
clearance is still required, with the
cupboard door open, to allow for
servicing.
* Bottom clearance
Bottom clearance after installation
can be reduced to 5mm.
This must be obtained with an
easily removable panel, to enable
the consumer to view the system
pressure gauge, and to provide
the 100mm clearance required for
servicing.
Max 30kW
Max 24kW
2. For flue lengths requiring “D” pack extensions (RSF 341), the flue must incline by 26mm per 1 Metre of flue length.
13
SECTION 4 - GENERAL INSTALLATION REQUIREMENTS
4.1 RECOMMENDATIONS
COMPARTMENT INSTALLATIONS
Current Gas Safety (Installation and Use) Regulation or Rules in
Force.
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
The boiler is suitable only for installation in the specified countries
and should be installed in accordance with the rules in force.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In GB, the installation must be carried out by a Gas Safe
Registered Engineer, or in other countries a qualified and
competent Gas Installer. It must be carried out in accordance with
the relevant requirement of the:
•
Gas Safety (Installation and Use) Regulations
•
Appropriate National Standards
•
The Water Fittings Regulations
•
Current IEE Wiring Regulations
•
Health & Safety Document Nol.635
•
The Electricity at work Regulations 1989.
•
BS5482 Part 1 Code of Practice for Domestic butane and
propane gas burning installation in permanent dwellings,
residential park homes and commercial premises.
•
BSEN1949:2011 Specification for the installation of LPG
Systems for habitation purposes in leisure accommodation
vehicles and other road vehicles.
• The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
IMPORTANT
4.3 FLUE TERMINAL POSITION
Pluming will occur at the terminal so avoid locations where this
will cause a nuisance.
The boiler MUST be installed so that the terminal is exposed to
external air.
It is important that the positions of the terminal allows the free
passage of air accross it at all times.
Minimum acceptable spacing from the terminal to obstructions
and ventilation pump are specified in the table below.
For Caravan Holiday Homes; if the height of the flue terminal
from any ground, decking or steps is under 1.5m then a suitable
terminal guard should be fitted.
The manufacturer’s notes MUST NOT be taken, in any way as
overriding statutory obligations.
For Residential Park Homes, please refer to BS 5440 Part 1.
4.2 BOILER LOCATION
TFC Flue Guard - Model K6 Round Plastic Coated.
The boiler must be installed on a flat and vertical wall, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary unless required
by National Standards.
For Electrical Safety reasons there must be no access available
from the rear of the boiler.
The boiler must not be fitted outside.
BATHROOM INSTALLATIONS
This appliance is rated IP20.
The boiler may be installed in any room or internal space, although
particular attention is drawn to the requirements of the current
IEE (BS.7671) Wiring Regulations and the electrical provisions
of the building regulations applicable in Scotland, with respect to
the installation of the boiler in a room or internal space containing
a bath or shower. For IE reference should be made to the current
ETCI rules for electrical installations and I.S. 813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the appliance
must be installed beyond Zone 2, as detailed in BS.7671.
Ceiling
Terminal Guards are available from boiler suppliers.
www.tfc-group.co.uk
Table 4 - Balanced Flue Terminal Position
Flue Terminal Positions
Min. Spacing*
1. Directly below, above or alongside an opening
window, air vent or other ventilation opening.
300mm (12”)
2. Below guttering, drain pipes or soil pipes.
BS5440-1 2008
25mm ( 1”)*
75mm (3”)
3. Below eaves.
BS5440-1 2008
25mm (1”)*
200mm (8”)
4. Below balconies or a car port roof.
BS5440-1 2008
25mm (1”)*
200mm (8”)
5. From vertical drain pipes or soil pipes.
BS5440-1 2008
25mm (1”)*
150mm (6”)
6. From an internal or external corner or to a boundary along side the terminal. BS5440-1 2008
25mm (1”)*
300mm (12”)
7. Above adjacent ground, roof or balcony level.
300mm (12”)
8. From a surface or a boundary facing the terminal.
600mm (24”)
9. From a terminal facing a terminal. 1,200mm (48”)
10. From an opening in a car port
(e.g. door or window) into dwelling. 1,200mm (48”)
11. Vertically from a terminal on the same wall. 1,500mm (60”)
12. Horizontally from a terminal on the wall.
Recessed
window
Zone 2
2.25m
Zone 1
Vertical Terminals
13. Above the roof pitch with roof slope of all angles.
Above flat roof.
300mm (12”)
300mm (12”)
14. From a single wall face.
From corner walls.
300mm (12”)
300mm (12”)
15. Below velux window 2000mm (79”)
0.6m
16. Above or side of velux window
Zone 0
3G8913a
14
300mm (12”)
600mm (24”)
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2008 dimensions must be followed.
SECTION 4 - GENERAL INSTALLATION REQUIREMENTS
4.4 AIR SUPPLY
It is NOT necessary to have a purpose provided air vent in the
room or internal space in which the boiler is installed. Neither is
it necessary to ventilate a cupboard or compartment in which the
boiler is installed, due to the low surface temperature of the boiler
casing during operation.
4.5 ELECTRICAL SUPPLY
WARNING
This appliance MUST be earthed.
Wiring external to the boiler MUST be in accordance with the
correct IEE Regulations and any local regulations.
The boiler has been pre-fitted with a 3 amp fused approved
moulded 3 pin plug and flying lead, for use with 230V 50Hz.
The plug should be used with an unswitched/shuttered socket
outlet complying with BS1363.
4.6 GAS SUPPLY
4.9 REQUIREMENTS FOR SEALED WATER
SYSTEMS
At maximum CH output 24.2kW at a 20ºC differential and flow rate
17.3 l/min a 3.4m wg head is available for the system
Set all radiators to give around 20ºC temperature differential.
The boiler does not normally need a bypass but at least some
radiators of load at least 10% of the minimum boiler output.
These radiators should be fitted with lockshield valves only.
A sealed system MUST only be filled by a competent person using
an approved filling loop (or other approved method) between the
mains water supply pipe and the central heating return pipe.
Once used, the filling loop should be disconnected and capped off.
4.10 EXPANSION VESSEL
The boiler is fitted with an 8 litre expansion vessel which is
sufficient for a cold fill capacity of up to 143 litres.
For other system volumes refer to table below.
A propane gas supply at 37mbar is required (30 mbar for DE).
Safety valve settingbar
Ensure that regulator is of sufficient capacity to carry the
maximum boiler input plus the full demand for any other installed
appliances.
Vessel charge pressure
System pre-charge pressurebar
Ensure the connection between supply/cylinder to caravan holiday
home or park home is designed so that no pressure drop occurs.
Ensure the pipework is of sufficient size to prevent a pressure
drop greater than 2.5mbar between the final pressure regulator to
the caravan holiday home or park home and all appliances when
the installation is subjected to the anticipated maximum load.
The drain MUST be connected to an approved drainage point.
All pipework and fittings MUST be made of plastic. No other
materials may be used.
For other system volumes
multiply by the factor across
IMPORTANT
The complete installation MUST be tested for gas soundness.
4.7 CONDENSATE DRAIN
A condensate drain is provided on this boiler.
Suitable protection against freezing should be undertaken.
4.8 WATER SYSTEMS - GENERAL
This boiler is designed for connections to fully pumped sealed
system only.
IMPORTANT - A minimum length of 1 metre of copper pipe
MUST be fitted to both central heating and DHW flow and return
connections from the boiler before connection to any plastic piping.
Central Heating System
IMPORTANT - The sealed central heating system must be filled
at all times with an antifreeze / inhibitor and water mix that is
compatible with aluminium heat exchangers. The concentration
levels of the antifreeze / inhibitor should be at least 25% in order
to provide adequate corrosion protection. This level also provides
protection against frost from -7.5ºC to -11ºC (depending on the
product used). The maximum allowable level of antifreeze /
inhibitor is around 40%.
The only products approved are as follows:
-
-
Fernox Alphi 11
Sentinel X500
Failure to use these products may result in damage to the boiler
and / or the radiators in the heating system.
bar
System volume
(litres)
25
50
75
100
125
150
175
190
200
250
300
3.0
0.5 to 0.75
None
1.0
Expansion vessel
volume (litres)
1.61.8
3.13.7
4.75.5
6.37.4
7.89.2
9.411.0
10.912.9
11.914.0
12.514.7
15.618.4
18.822.1
0.0630.074
4.11 PRESSURE RELIEF VALVE
A pressure relief valve set at 3 bar is fitted to the boiler. The
connection is shown in the dimensions and connection details.
The discharge pipework must be suitable for use with 3bar water
at 110ºC without damage to property and persons.
The run and exit point of the pipework should not leave a hazard
or be prone to freezing up.
4.12 DHW SYSTEMS
Check that the mains supply pressure is within the units stated in
the technical data section in this manual
A pressure reducing valve should be fitted if above 10 bar.
In areas of low mains water pressures the domestic hot water
regulator may be removed (by a suitably qualified person). The
boiler will require the flow rate to be set to give a temperature of
35ºC at the tap furthest from the boiler.
In hard water areas where mains water exceeds 200ppm total
hardness, the fitting of a scale reducing device is recommended
(with the requirements of the local water company).
The use of artificially softened water, however, is not permitted.
The boilers are suitable for connection to most types of washing
machine and dishwasher appliances.
15
SECTION 5 - INSTALLATION INSTRUCTIONS
5.1 BOILER PACKAGING
5.4 INTERNAL WIRING
The boilers are supplied in different packagings:
The boiler has been pre-fitted with a 3 amp fused approved
moulded 3 pin and flying lead for use with 230V 50Hz.
•Boiler
•
Flue System (separate)
•
Hardware Pack (separate)
5.2 FITTING/MOUNTING THE BOILER
Decide where the boiler is to be fixed on the wall, taking into
account installation requirements detailed in previous section.
1. Screw the wall mounting plate to the wall choosing one of the
two sets of slots in left and right bank. Ensuring that at least
one of the screws is fitted into a top slot.
Example of fixing
If the supply cord is damaged, it must be replaced by the
manufacturer, its service agent or similarly qualified persons in
order to avoid a hazard.
4
The plug should be used with an
unswitched/shuttered socket outlet
complying with BS1363.
The boiler comes pre-fitted with
a link wire between the room
thermostat/Timer connections on
the terminal strip. This creates a
permanent call for heat and must
be removed when adding a room
thermostat.
Cable
Clamp
ROOM THERMOSTAT - WIRING
2. Lift the boiler onto the wall mounting plate, locating it over the
two tabs.
To fit a room thermostat proceed as follows:
1. Ensure that the electrical supply to the boiler is isolated before
proceeding.
2. Remove the two screws beneath the flap on the front of the
boiler and lower the front panel.
3. Remove the pre-fitted link wire between the Room stat/timer
terminals.
4. Pass the cable through a grommet, secure with the cable
clamp and connect the room stat as shown in the diagram
below.
5. If room stat has a neutral connection, connect this to terminal
N (load) in the fused spur.
6. Carry out all necessary electrical checks.
7. Raise the front panel and relocate the two screws under the
small flap.
8. Check operation of room stat if possible.
Note. If present, remove the bottom end support packaging
and ensure all plastic plugs are removed from CH & DHW
connections.
5.3 WIRING INSTRUCTIONS
WARNING: THIS APPLIANCE MUST BE EARTHED
Connections must be made in such a way that allows complete
isolation of the electrical supply, e.g. double pole switch with
3mm contact separating in both poles.
16
L
N
Room
Stat
N
ROOM
STAT/
TIMER
230VAC Feed
230VAC Return
SECTION 5 - INSTALLATION INSTRUCTIONS
5.5 WATER AND GAS CONNECTIONS
Ensure all boss blanking plugs are removed before making any connections.
Each valve must be fitted to the correct boss as shown in diagram below
Do not subject any of the isolating valves to heat as the seals may be damaged.
Ensure that the green fibre washer is used on the CH flow connection.
IMPORTANT - The gas service cock is sealed with a top hat washer - DO NOT subject to heat.
Pressure Relief Valve (PRV) - Located at the bottom right hand side of the boiler connection via a 15mm diameter stub pipe.
Use a replaceable connection to ease the replacement of the valve if required.
PRV
CH RETURN
DHW INLET
GAS INLET
COND. DRAIN
DHW OUTLET
CH FLOW
Ensure a safe discharge point using temperature and pressure resistant materials.
5.6 AIR / FLUE SYSTEMS
The flue system is part of the appliance and is approved as such. Only use the flue systems supplied by Morco.
The standard flue kit (RSF303) for the Morco GB range is a 600mm as shown below. There is also a 900mm kit available (RSF305).
600
100
60
Turret
60
Part No. RSF303
The minimum cut length is 138mm (includes 30mm into elbow)
The maximum allowable length using extensions (RSF341) is:
GB24 Series II - 8m (minus any flue kit options)
GB30 Series II - 7m (minus any flue kit options)
17
SECTION 5 - INSTALLATION INSTRUCTIONS
5.7 DETERMINING THE FLUE LENGTH
IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions.
STANDARD FLUE KITS
Horizontal Flue Terminal RSF303 (600mm long) - contains: Flue turret, non telescopic single piece flue incorporating a terminal
and inner rubber wall seal.
Extension Kit RSF341 - contains: 1 metre length of flue pipe (Functional length 950mm), 1 support bracket.
When extension kits are used the flue duct must incline 1.5 degrees away from the appliance, to allow the condensate to drain back to
the boiler and out of the condensate drain. It is recommended that a support bracket is fitted on every 1 metre of pipe work used and the
bracket is located as close to the collar as possible. The bracketing must ensure a 1.5 degree fall back to the appliance.
Only use water as a lubricant during assembly.
The horizontal flue kit terminal is classed as part of the maximum flue length.
Once the flue is installed it is IMPORTANT that the white air duct protrudes from the aluminum flue collar (RSF 060) by at
least 17mm. The gap between the aluminium flue collar (RSF 060) and the white air duct MUST be sealed with sealant to
create an adequate seal.
17mm min
WALL
Internal Sealing
Flubber
Fill with
sealant
Fill with
sealant
Aluminium Flue
Collar (RSF 060)
It is IMPORTANT that all attachments are fitted in accordance with the installation instructions provided in this manual.
The TURRET supplied in the Horizontal Flue Kits (RSF303 & RSF305) has an upper combustion sample point with a screw cap seal
and a lower air sample point with an air stopper seal. Ensure all caps & seals are in place.
Additional Termination Kits available for use with these Horizontal Flue Kits (RSF303 & RSF305)
Flue Deflector Kit (RSF300)
The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from
any maximum flue length
Total Maximum Permissible Horizontal Concentric Flue Length combining both Horizontal Flue Kits and Extension Kits
(Measured from centreline of the turret to the outside face of the aluminium flue collar (RSF060))
24 kW appliances
30 kW Appliances
Total Maximum: 8 metres - minus any flue kit options
Total Maximum: 7 metres - minus any flue kit options
Total Maximum Permissible Vertical Flue Length
24 & 30kW Appliances
Total Maximum: 7.5 Metres - minus any 90º bends
Minimum Horizontal Flue Lengths (Centre line of turret to outside face of the aluminium flue collar (RSF060))
Rear Flue - 191mm
Side Flue - 236mm (with minimum 2.5mm clearance)
18
SECTION 5 - INSTALLATION INSTRUCTIONS
5.8 DETERMINING THE FLUE LENGTH
FIGURE 1
REAR FLUE
SIDE FLUE
Cut flue length = distance from edge of turret to outside of
wall dimension A + 47mm.
Cut flue length = distance from edge of turret to outside of
wall dimension B + 47mm.
Note. Minimum dimension A which can be accommodated is
91mm.
Note. Minimum dimension B which can be accommodated is
136mm (with minimum clearance of 2.5mm).
B
A
WALL
WALL
SIDE
Fit
to wall
REAR
Fit
to wall
Minimum clearance 2.5mm
NOTES
Centre of turret to edge of turret = 100mm
Turret has a flue insertion of 30mm
The white outer flue tube must protrude the wall by 17mm.
From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm
Flue length measured from outer terminal lip
to end of outer flue
A or B + 47mm
5.9 CUTTING HORIZONTAL FLUE TERMINAL RSF303 (600MM LONG)
1. Measure from the outer terminal lip to end of outer flue. Mark the
required cut length (A or B + 47mm) around the circumference of the
outer flue and cut following the mark to ensure its cut square.
2. Dress the cut end to make sure all burr’s are removed and the cut
edge is in its original shape.
3. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure its cut square.
10mm
Mark cut length =
A or B + 47mm from terminal lip
4. Remove all burrs and place a light chamfer on the outer edge to aid
assembly.
19
SECTION 5 - INSTALLATION INSTRUCTIONS
5.10 INSTALLING THE FLUE
FITTING FLUE THROUGH THE WALL
1. Ensure the seam and the outlet terminal are
at the top and fitted as shown.
2. Once the flue is installed it is IMPORTANT
that the white air duct protrudes from the
aluminium flue collar (RSF 060) at least
17mm.
Note. If less than 50% of the length of the flue is
internal the flue should be fitted from outside.
3. Fit the internal sealing flubber to the flue
(leave loose) and check protrusion externally
of the white air duct is 17mm.
17mm min
WALL
Internal Sealing
Flubber
Fill with
sealant
4. Fit the turret as below
Fill with
sealant
Aluminium Flue
Collar (RSF 060)
5” hole
FITTING THE TURRET - Ensure the condensate trap / siphon is filled with water
1. Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged.
2. Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged. Make sure the
flue has not rotated or moved forward during fitting and the flue seam is upper most.
3. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold.
4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret flange.
5. Secure clamp to appliance using securing screw.
6. Ensure all sample points are accessible and all sample plugs and caps are fitted.
7. Fully engage the flue into the turret and slide internal flubber to wall.
8. The gap between the aluminium flue collar (RSF 060) and the white air duct MUST be sealed with sealant to create a seal.
Retaining
screw
D
A
B
Flue Outlet
A - Duct Assembly
B - Flue Turret
C - Turret Clamp
D - Seal
20
Flue Outlet
C
Sample points
Clamp Lugs
SECTION 5 - INSTALLATION INSTRUCTIONS
5.11 FLUE EXTENSIONS (RSF341) - OPTIONAL
For side outlet refer to section 1.2 before connecting.
INNER PIPE ASSEMBLY INSTRUCTIONS
1. Make sure that ‘top hat’ on the collar (A) fits over the
rectangular form on the inner plastic pipe (B).
A
3. Slide the pipe and collar assembly back into the outer
housing (E), note that this can only be done at the female
end of the outer housing.
B
Top Hat
E
Rectangular
4. When fitting support brackets (F) make sure they are
positioned on the female side of the neck as shown.
2. Ensure that the flat base of the collar (C) is
positioned on the bottom lip of the pipe (D).
C
D
F
5.12 FLUE DEFLECTOR KIT (RSF300) - OPTIONAL
5.13 90º KIT RSF315 (OPTIONAL)
The flue deflector elbow can be fitted to the flue outlet of the standard
terminal kits RSF303 or RSF305 to deflect the flue products horizontally
to the left or the right only.
This optional kit can be used on both horizontal and
vertical flue kits
1. Refer to the boiler Installation and Servicing Instructions for fitting of
the boiler and its flue system.
Note. The resistance of the deflector is equivalent to 1 metre of flue
length. Ensure this is used when calculating the maximum allowable
flue length.
2. Choose the direction required to deflect the flue products
(horizontally left or right only).
3. Push the deflector elbow onto the angled flue outlet of the terminal
in the desired position and ensure the deflector is pushed up to the
shoulder to fully engage the rubber seal. Drill the terminal through
the hole in the deflector with a 3.2mm (1/8") drill and secure the
deflector with the self tapping screw provided.
1. Use dimensions below for calculating total length
2. When cutting extensions or flue kits always allow
sufficient (+ 30mm air duct + 14mm flue duct) to
allow for correct engagement in the fitting
3. 1 elbow reduces the maximum available length by
1m
Note. Only use water as a lubricant during assembly .
Do not use mineral based oils.
Note. Only use water as a lubricant during assembly. Do not use
mineral based oils.
115
WALL
115
Flue
Deflector
21
SECTION 5 - INSTALLATION INSTRUCTIONS
5.14 FITTING THE OPTIONAL ROOF FLUE KIT (RSF345) (Pitched)
Note.
A 5º or 14º pitched roof plate (not supplied) is required before
proceeding with the installation of this kit.
This kit is suitable for both 5º and 14º pitched roof terminations,
using a concentric flue to run vertically from the top of the boiler and
terminating above roof level.
Connection to the top of the boiler is made using a vertical connector
(supplied in the kit - RSF346).
WEATHER PROOFING
Where the flue passes through the roof line an adequate seal must be
made. This is achieved by using a suitable sealant.
ACCESSORIES
Flue Duct Extension Kits are available for flue lengths extending
beyond 1m. These packs contain 1m extension ducts and may be
cut to the desired length. If 90º elbows are used (RSF315) they will
reduce the overall height by 1m per elbow.
Terminal Position
Minimum Dimension
Directly below an opening,
air brick, windows, etc.
300 mm
Below plastic / painted gutters
300 mm
Painted surface
300 mm
Below eaves or balcony
500 mm
Below velux windows
2000mm
Above or side of velux windows
600mm
5.15 ASSEMBLING THE ROOF FLUE KIT
1. Position the roof plate (supplied separately) over the hole cut in the roof and insert flue
terminal from the roof end.
1
ASSEMBLY A
Flue Terminal
5º & 14º
MAX LENGTH:
7.5m**
MIN LENGTH:
0.950m
**minus any
90º bends
BOILER
5º
RSF050
14º
RSF050
Assembly A
5
2. Ensure that if the length needs to be adjusted to allow an additional 30mm added to
the outer air tube length 14mm added to the inner flue length. This allows correct
engagement into the vertical connector.
Note. Ensure a square cut. remove all burrs and sharp edges.
3. Fit the vertical connector (supplied in the kit) and secure the vertical connector by
applying downward pressure on the connector.
4. Position the clamp on the top face of the flue manifold and push it horizontally
backwards. Locate both clamp lugs into the flue manifold and secure to the flue
manifold clamp with the M5 retaining screw.
5. “Push” assembly A into vertical connector.
Notes. Ensure turret sample points are servicable and all caps and plugs are fitted.
Ensure condensate siphon/trap is filled with water.
6. Finally ensure the roof plate is correctly sealed to the roof.
22
4
Vertical
connector
3
SECTION 5 - INSTALLATION INSTRUCTIONS
5.16 CONDENSATE DRAIN
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.
Condensate
Drain
47
137
156
This appliance is fitted with a siphonic 75mm sealed condensate
trap system that requires filling before operating the appliance for
the 1st time or after maintenance.
All condensate pipework should conform to the following:
a. Where a new or replacement boiler is being installed, access to
an internal ‘gravity discharge’ termination should be one of the
main factors considered in determining boiler location.
b. Plastic with push fit or solvent connections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD)
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipe work should be kept to a minimum
and insulated with Class “O” waterproof pipe insulation.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate
installation diagrams” & BS6798:2009
h. Pipe work must be installed so that it does not allow spillage
into the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
fittings.
NB. Clip runs to prevent pipework disconnecting due to
vibration etc.
In order to minimise the risk of freezing during prolonged very cold
spells, one of the following methods of terminating condensate
drainage pipe should be adopted.
Condensate Pump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
specification recommended by the boiler or pump manufacturer
should be used terminating into a suitable internal foul water
discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (fig 3).
External Drain Connections
The use of an externally run condensate drainage pipe should
only be considered after exhausting all internal termination options
as described previously. An external system must terminate at a
suitable foul water discharge point or purpose designed soak away.
If an external system is chosen then the following measures must
be adopted:
The external pipe run should be kept to a minimum using the most
direct and “most vertical” route possible to the discharge point, with
no horizontal sections in which condensate might collect.
-
-
-
-
For connections to an external soil/vent stack see Fig 4.
Insulation measures as described should be used.
When a rainwater downpipe is used, an air break must be
installed between the condensate drainage pipe and the
downpipe to avoid reverse flow of rainwater into the boiler
should the downpipe become flooded or frozen, see Fig 5.
Where the condensate drain pipe terminates over an open
foul drain or gully, the pipe should terminate below the grating
level, but above water level, to minimise “wind chill” at the open
end. The use of a drain cover (as used to prevent blockage by
leaves) may offer further prevention from wind chill. See Fig 6.
Where the condensate drain pipe terminates in a purpose
designed soak away (see BS 6798) any above ground
condensate drain pipe sections should be run and insulated as
described above. See Fig 7
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas should be
treated as external pipe.
Ensure the customer is aware of the effects created by a frozen
condensate and is shown where this information can be found in
the user manual.
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
Minimum
connection
height up to 3
storeys
Min Ø 19mm
Internal pipe
75
Sink/basin/
bath or
shower
≥ 100
≥ 100
≥ 450
75
Min Ø 19mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Soil & vent stack
Boiler
with 75mm
sealed
condensate
trap
Figure 2 - Connection of a Condensate Drainage Pipe
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil Vent Stack
Internal soil & vent stack
Figure 1 - Connection of Condensate Drainage Pipe to
Internal Soil & Vent Stack
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
continued . . . . .
23
SECTION 5 - INSTALLATION INSTRUCTIONS
CONDENSATE DRAIN - CONT’D.......
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Water/
weather proof
insulation
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
combined foul/
rain water drain
External air
break
Air gap
Terminated
and cut at 45º
43mm 90º male/
female bend
68mm Ø PVCU
Strap on fitting
Figure 7 - Connection of a Condensate Drainage Pipe to an
External Purpose Made Soak Away.
Boiler
with 75mm
sealed
condensate
trap
Water/Weather
proof insulation
Max 3m external
pipework
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
2 rows of three Ø12mm holes
25mm centres, 50mm from
the bottom of the tube, facing
away from the house
24
≥ 300
≥ 25
Min Ø 19mm
Internal pipe
75
Min Ø 30mm
Internal pipe
≥ 500
Limestone
chippings
Minimum
connection
height up to 3
storeys
Figure 6 - Connection of Condensate Drainage Pipe
Upstream of a Sink, Basin, Bath or Shower Waste Trap to
External Drain, Gulley or Ranwater Hopper
Visible air break
at plug hole
Min Ø 19mm
Internal pipe
Sink, basin, bath or
shower with integral
overflow and 75mm trap
75
Figure 5 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater
drain)
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 100
Condensate pump
(Install in accordance with manufacturers instructions)
≥ 450
Min Ø 19mm
Internal pipe
Water/
weather proof
insulation
Minimum 30mm
internal pipe
45º pipe
termination
≥ 25 Below grate
75
Min Ø 19mm
Internal pipe
Water/weather
proof insulation
75
Visible air break
Boiler
with 75mm
sealed
condensate
trap
Figure 4 - Connection of Condensate Drainage Pipe to
External Soil & Vent Stack
Soil & vent stack
Figure 3 - Connection of a Condensate Pump Typical
Method (see manufacturers detailed instructions)
SECTION 6 - COMMISSIONING INSTRUCTIONS
Before commissioning the boiler, the whole gas installation including
the meter (if fitted) MUST be purged and tested for gas soundness.
Purge air from the gas installation by the approved methods only.
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.
Ensure that the flue has been installed correctly and no vents are
blocked. Before commencing commissioning, ensure that the CH
system and DHW and cold water system have been flushed. The
CH system needs to be treated with water treatments that are
approved for use with aluminium alloy heat exchangers.
6.2 CENTRAL HEATING CIRCUIT
Fill the siphon in the condense pipework prior to operating.
In order for the boiler to function correctly, the pressure in the
central heating circuit must be between 1 and 1.5 bar on the
pressure gauge.
Both the boiler and central heating installation must be purged of
any air. The boiler has an auto air vent integral to the pump which
must be loose prior to commissioning.
Add an approved flushing solution to one of the radiators.
Fill the central heating circuit using one of the approved methods
to 1 bar.
GENERAL
Open radiator vent screws and turn off when water appears.
Please Note: The combustion for this appliance has been
checked, adjusted and preset at the factory for operation on
the gas type defined on the appliance data plate. As part of the
commissioning process, the combustion of this appliance must be
checked. A flowchart to assist is provided on page 37.
With the system hot, examine all water connections. The system
pressure should not exceed 2.5 bar.
DO NOT adjust the air/gas ratio valve.
Having checked:
- That the boiler has been installed in accordance with these
instructions.
- The integrity of the flue system and the flue seals, as
described in the Flue Installation section.
Proceed to put the boiler into operation as follows:
Turn off the filling method and disconnect.
Turn off gas, water and electricity when draining down.
Refill and vent the system, add inhibitor and anti-freeze in the
required concentration and check for water leaks.
Check that the condensate operates and the pipework for any
leaks.
6.3 INITIAL OPERATION
Ensure central heating circuit is full and vented, and pressure
gauge is reading 1.0 bar.
CHECK THE OPERATIONAL (WORKING) GAS INLET
PRESSURE
6.4 DOMESTIC HOT WATER MODE
Set up the boiler to operate at maximum
rate by opening hot tap to maximum
flow.
Turn the “mode” control knob to tap/radiator icon
. Ensure all
external controls are calling for heat. Set the integral timer to ON.
With the boiler operating in the
maximum rate condition check that
the operational (working) gas pressure
at the inlet gas pressure test point
complies with the requirements - refer to
“Gas Supply” on page 15.
Gas
Supply
Gas
Pressure
Test
Point
Ensure that this inlet pressure can be
obtained with all other gas appliances in
the property working at maximum.
6.1 DOMESTIC HOT WATER
Turn on the main cold water supply.
Fill and vent the installation by turning on and off the various hot
water taps in the installation.
Check hot water taps in the installation.
when burner is lit.
Display reads “C” then “C”
Ensure all radiators warm up evenly. The CH temperature can be
controlled in between max 80ºC and min 45ºC (flow temp).
Check the DHW functions by turning on a hot water tap.
Close the DHW tap and set the integral timer and external
controls to off.
Display will read “0”.
Legend
D. Boiler Status
E. Burner ‘on’ Indication
F. Pre Heat on/off Indication
A. Mode Control Knob
B. DHW/Preheat Control
C. CH Control
Check for and repair leaks as necessary.
E
off
e
max
reset
min
status
min
preheat
max
preheat
mode
B
C
D
22
20 19 18 1
7
21
23
16
15
0
I
F
3
2
1
24
14 13 12 1
1
10
9
8
7
6
5
4
A
burner
25
SECTION 6 - COMMISSIONING INSTRUCTIONS
THE DISPLAY
The user control has one neon and one display to inform the
user about the status. The display will show the status of the
boiler. The neon will show the status of the flame. If no flame
is detected the neon is off. When the flame is detected the
neon will be lit permanently.
Below is a list with display function in normal operation.
0
Standby, no demand for heat present.
Boiler is active for central heating.
Boiler is active for domestic hot water.
Boiler is heating up the plate heat exchanger.
CH circuit water less than 5ºC.
Below is a list with display in fault condition. If the display is
flashing with “L” or “F” with alternate numbers / letters refer to
page 34.
Boiler is in lockout for a specific error. Display will be
blinking, alternating with a number or letter to show which
error is detected.
Boiler has a fault for a specific error. Display will be
blinking, alternating with a number or letter to show which
error is detected.
Service mode
6.5 FINAL CHECKS
Re-light and test for gas soundness.
Set the CH and DHW temperature knobs to the desired settings.
Ensure that the integral timer and/or room thermostat are set to
the required settings.
6.6 HANDING OVER
After completing the installation and commissioning of the system
the installer should:
•
Hand the Users Instruction to the owner and emphasise their
responsibilities under the relevant national regulations.
•
Explain and demonstrate the lighting and shut down
procedures.
•
Explain the operation of the boiler and the use and
adjustment of the system controls to ensure the greatest
possible fuel economy, consistent with the owners heating
and hot water requirements.
•
Advise the user of the precautions necessary to prevent
damage to the system and to the building in the event of the
system remaining in operation during frosty condition.
•
Explain the function of the boiler fault mode. Emphasise that
if a fault is indicated, refer to Fault Codes in the User Guide.
•
Explain and demonstrate system controls, integral timer
functions and boiler reset procedure.
IMPORTANT - Stress the importance of an annual service by
a competent gas registered engineer.
26
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.1 SERVICING SCHEDULE
For the very latest copy of literature for specification, maintenance practices and parts replacement, visit our website www.morcoproducts.co.uk
where you will be able to download the relevant information.
WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to
the appliance before servicing.
Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.
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. The frequency of servicing will depend upon the installation condition and usage but should be carried out at
least annually.
It is the law that any service work must be carried out by a Gas Safe Registered Engineer, or in other countries a qualified and
competent Gas Installer.
INSPECTION
1. Light the boiler and carry out a pre-service check, noting any
operational faults.
2. Check the flue terminal (and terminal guard if fitted) is
undamaged and clear of any obstruction.
3. Check all water and gas joints for signs of leakage. Remake
any suspect joints ensuring a gas tightness check is carried
out if applicable and the water system is correctly refilled,
vented and re-pressurised.
CLEANING PROCEDURE
Note. In order to carry out either servicing or replacement of
components the boiler upper and lower front panels must
be removed. Refer to Frame 7.2.
1. Clean the main burner. Refer to Frame 7.4.
2. Clean the heat exchanger & condensate trap/siphon. Refer to
Frames 7.5 & 7.6.
3. Check the main injector for blockage or damage. Refer to
Frame 7.3.
4. Check that the flue terminal is unobstructed and that the flue
system is sealed correctly.
The cleaning procedures are covered more fully in Frames 7.3-7.7
and MUST be carried out in sequence.
IMPORTANT.
5. After completing the servicing or exchange of components
always test for gas tightness.
6. When work is complete the front panels MUST be correctly
refitted, ensuring that a good seal is made.
Do NOT OPERATE the boiler if the upper front
panel is not fitted.
7. If, for any reason, the condensate trap/siphon has been
removed ensure the trap is refilled with water before
reassembling.
8. Check the gas consumption if on metered installations.
9. Check combustion by connecting the flue gas analyser to the
flue gas sampling point as shown in the diagram and measure
CO & CO2. (Refer to Section 10, page 37).
If the CO/CO2 ratio is greater than 0.004 AND the integrity of
the complete flue system and combustion circuit seals have
been verified and the inlet gas pressure have been verified,
then contact Morco.
GENERAL
Please Note: During routine servicing, and after any maintenance
or change of part of the combustion circuit, the following must be
checked:
- The integrity of the flue system and the flue seals,
- The integrity of the boiler combustion circuit and the relevant seals
- The operational (working) gas inlet pressure at maximum rate.
Turn on one or more DHW taps.
- The combustion performance.
COMPETENCE TO CARRY OUT THE CHECK OF
COMBUSTION PERFORMANCE
Please Note:
BS 6798:2009 Specification for installation and
maintenance of gas-fired boilers of rated input not exceeding 70kW
net advises that:
- The person carrying out a combustion measurement should have
been assessed as competent in the use of a flue gas analyser and
the interpretation of the results.
- The flue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated in
accordance with the analyser manufacturers requirements, and
- Competence can be demonstrated, for example, by satisfactory
completion of the CPA1 ACS assessment (UK Only), which
covers the use of electronic portable combustion gas analysers in
accordance with BS7967, Parts 1 to 4.
SERVICE MODE
To access the service mode:
Using the central heating potentiometer, starting from the 11 o’clock
position, move the thumb piece to the maximum position, back to the
11 o’clock position and then finally finish at the maximum position.
The letter “S” will now be displayed.
To toggle to maximum DHW output move the thumb piece up to
the 11 o’clock position and then back to maximum. A minimum of 3
seconds will reset the boiler back to normal mode.
Flue Sampling Point
Air Sample
Point
Ensure all caps and seals
are re-fitted after use
27
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.2 BOILER UPPER & LOWER FRONT PANEL REMOVAL / REPLACEMENT
REMOVAL
REPLACEMENT
1. Lift the lower front panel access panel.
4. Hook the upper panel onto the top retaining clips.
2. Unscrew the two fixing screws, close the access panel to
retain the two screws and hinge the lower front panel down
into the service position.
5. Retain the upper panel with the two fixing screws
previously removed ensuring a good seal is made.
3. Remove the two upper front panel fixing screws, lift the
panel and remove.
6. Swing the lower front panel up and retain with the two
screws.
7. Close the lower front panel access panel.
2&6
3&5
1&7
7.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING
1. Disconnect the electrical leads from the fan.
2. Remove the clip from the gas control valve
outlet and ease the pipe upwards rotate and
then ease down to remove.
1
3
3. Remove the extended nut on the fan
mounting bracket.
4. Lift off fan and venturi assembly.
5. Inspect the injector for blockage or damage.
6. Inspect fan outlet sealing gasket and
replace if necessary.
5
Injector
2
28
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.4 BURNER REMOVAL AND CLEANING
1. Ensure the sump is fully drained
3
2. Undo the two screws and remove the sump cover retaining the lower
flue manifold.
2
2
3. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
4. Remove the 2 burner front fixing screws and loosen the 2 rear
extended nuts by at least ten turns.
5. Lift off the burner from the combustion chamber. To facilitate the
removal angle the burner as shown.
IMPORTANT
The burner head is a ceramic plaque construction. Care must be taken
to ensure that the burner is not placed down upon its face as this
may cause damage to the ceramic.
6. Brush off any deposits that may be on the ceramic with a SOFT brush.
7. Inspect the sealing gasket around the burner for any signs of damage.
Replace as necessary.
4
5
4
7.5 CLEANING THE CONDENSATE TRAP/SIPHON
Note: Ensure condensate trap is fully drained before removal.
1. Pull off the rubber pipe at the siphon.
2. Turn the siphon clockwise to disengage and lift to remove.
3. Flush out all deposits with clean water.
4. Reassemble in reverse order
Note. When reassembling ensure the trap is full of water
1
29
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.6 CLEANING THE HEAT EXCHANGER
Note: Ensure the condensate trap/siphon
is fully drained before cleaning. Refer to
Frames 7.5.
1
Ignition Electrode
Flame Detection
1. Remove ignition and flame detection
electrodes. Refer to Frames 7.9 & 7.10.
2. It is advisable to replace the sump cover
prior to the water flush process.
3. Thoroughly flush the heat exchanger
by pouring water into the top of the
combustion chamber ensuring the full top
area is covered.
4. Remove the sump cover and clean loose
deposits from the sump.
Earth Wire
5. Inspect the ignition and detection
electrodes. Ensure that they are clean
and in good condition - replace if
necessary.
3
6. Re-fit the ignition and flame detection
electrodes. Ensure that earth wire is
connected to the electrode
7. Check that the ignition and detection gaps
are correct. Refer to Frames 7.9 & 7.10.
7.7 REASSEMBLY
Reassemble the boiler in the following order:
1. Ensure that the condensate trap/siphon is full of water.
2. Refit the burner ensuring the sealing gasket is correctly
positioned and free from damage (tighten the 4 fixing screws
in the sequence A,B,C,D, shown below).
3. Refit the fan / venturi assembly ensuring the retaining tabs
are correctly positioned and the sealing gasket is correctly
positioned and free from damage.
4. Reconnect the fan electrical leads.
5. Remove the sump cover and refit the lower flue manifold
as shown.
6. Refit the sump cover.
7. Refit the boiler upper and lower front panels.
IMPORTANT. Ensure that the boiler upper front panel
is correctly fitted and that a good seal is made. Replace
seals as necessary.
8. Turn on the gas supply at the gas service cock.
9. Reconnect the electrical supply.
D
B
5
A
30
C
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.8 BURNER REMOVAL
1. Refer to Frame 7.3.
3
2. Undo the two screws and remove the sump cover.
3. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
2
2
4. Remove the 2 front fixing screws and loosen the 2 rear
extended nuts.
4. Lift off the burner from the combustion chamber. To facilitate
the removal angle the burner as shown.
5. Fit the new burner, replacing any damaged or deteriorating
sealing gasket.
4
6. Reassemble in reverse order.
7. Check the operation of the boiler.
5
4
7.9 IGNITION ELECTRODE
1. Remove the burner. Refer to Frame 7.8.
2. Check dimensions are correct as in
diagram below..
Ignition Electrode
3. Reassemble in reverse order.
FOR REMOVAL:
1. Unplug the ignition lead and remove the
earth lead.
2. Remove the 2 retaining screws and
remove the electrode.
3. Reassemble in reverse order replacing the
gasket if necessary.
Spark Gap
3.5mm
e
dg
te
h
aig
Str
m
3m
31
SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7.10 FLAME DETECTION ELECTRODE
1. Remove the burner. Refer to Frame 7.8.
2. Check dimensions are correct as in diagram
below.
3. Reassemble in reverse order.
Flame Detection Electrode
FOR REMOVAL:
1. Unplug the ignition lead and remove the earth
lead.
2. Remove the 2 retaining screws and remove the
electrode.
3. Reassemble in reverse order replacing the
gasket if necessary.
e
dg
te
h
aig
Str
mm
.5
12
7.11 FINAL CHECKS
Turn all controls to “ON” position and check their correct functions in both DHW & CH modes.
Additional replacement of parts information can be found on our website. www.morcoproducts.co.uk
32
SECTION 8 - FACT SHEETS
8 FACT SHEETS
There are a number of detailed fact sheets available for users to download from Morco’s website.
Please visit www.morcoproducts.co.uk
The fact sheets can be located in the troubleshooting section and include:
- Winterisation of Holiday Homes
- Poor Hot Water Delivery - Causes and Solutions
- Low Central Heating Pressure - Fault 1
- Thermostats, Programmers and Thermostatic Radiator Valves
- Combi boiler “cycling”
- Noisy boilers
33
SECTION 9 - FAULT CODES
9 FAULT CODES
DISPLAY CODE ON BOILER
DESCRIPTION
BCC Activation Fault
ACTION
Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
BCC Fault
Low Water Pressure
Check system water pressure is between 1 & 1.5bar on the system pressure gauge (G). To repressurise the system see Section 3. If the boiler still fails to operate then please contact Morco (if
under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.
In all other countries contact a Registered Gas Installer.
Flame Loss
1.Check other gas appliances in the home are working to confirm a supply is present in the property.
2.If other appliances do not work or there are no other appliances, check the gas supply is on at the
meter/Gas Cylinder and/or pre payment meter has credit. If the boiler fails to operate then please
contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the
warranty period. In all other countries contact a Registered Gas Installer.
Return Thermistor
Return temperature greater than flow temperature. Please contact Morco.
Fan Fault
Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
Flow Thermistor
Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
Return Thermistor
Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
Outside Sensor Failure Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
34
Low Mains Voltage
Contact a qualified electrician or your electricity provider.
Unconfigured PCB
Unconfigured PCB. Please contact Morco (if under warranty) or alternatively a Gas Safe
Registered Engineer if outside of the warranty period. In all other countries contact a Registered
Gas Installer.
Flow Temperature
Overheat or No Water
Flow
Check system water pressure is between 1 & 1.5bar on the system pressure gauge (G). To
re-pressurise the system see Section 3. If the boiler fails to operate then please contact Morco
(if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In all other countries contact a Registered Gas Installer.
Ignition Lockout
1. Check other gas appliances in the home are working to confirm a supply is present in the property.
2. If other appliances do not work or there are no other appliances, check the gas supply is on at the
meter/Gas Cylinder and/or pre-payment meter has credit. If the boiler fails to operate then please
contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the
warranty period. In all other countries contact a Registered Gas Installer.
3. Check condensate sump, internal pipe work and siphon, ensuring this is not frozen or blocked through
to external pipe work. If frozen defrost using a non-direct heat method. If the boiler fails to operate then
please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of
the warranty period. In all other countries contact a Registered Gas Installer.
5 Boiler Resets in
15 minutes
1.Turn electrical supply to boiler off and on.
False Flame Lockout
Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty)
or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other
countries contact a Registered Gas Installer.
2.If the boiler fails to operate please contact Morco (if under warranty) or alternatively a Gas
Safe Registered Engineer if outside of the warranty period. In all other countries contact a
Registered Gas Installer.
35
SECTION 10 - COMBUSTION CHECK
FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO
CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks
The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK
The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as
required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN
THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance
has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).
The ECGA should be of the correct type, as specified by BS 7967.
Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer
must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.
KEY:
CO = carbon monoxide
CO2 = carbon dioxide
O2 = oxygen
Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm
ppm = parts per million
GS(I&U)R = Gas Safety (Installation and Use) Regulations
*Setting to Minimum Rate:
1. Turn the CH temperature control knob to the 11 O’clock position.
2. Create a CH demand by ensuring that the system controls are requesting heat and the boiler Mode
Knob is in the Winter Position.
3. Within an overall time of 3 seconds, turn the CH temperature control knob fully clockwise, back to
11 O’clock and then fully clockwise again.
4. “S” will be shown on the display and the boiler output will be reduced to minimum
5. The boiler will remain at minimum rate for 5 minutes before reverting to normal operation
36
SECTION 10 - COMBUSTION CHECK
Start
Set Boiler to Maximum Gas Rate
In accordance with boiler instructions,
(by fully turning on hot tap) set boiler to
operate at maximum rate (full load
condition). Allow sufficient time for
combustion to stabilise.
Note. Do not insert analyser probe during this
period to avoid possible flooding of sensor.
Carry Out Flue Integrity Check Using Analyser
Insert analyser probe into air inlet test point (where available) and allow
readings to stabilise.
Note. Where no air inlet test point is provided then a flue integrity check with
the analyser is not possible. The installer should verify that flue integrity has
been visually checked in accordance with the “Prior to CO level and
combustion ratio check” (see opposite page) before proceeding to the
“check CO level and combustion ratio at maximum rate” stage below.
Verify Flue Integrity
Analyser readings indicate that combustion products and inlet air
must be mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as
per instructions. Check that flue and flue terminal are not obstructed.
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
No
Yes
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
Check CO level and Combustion Ratio
at Maximum Gas Rate
Yes
With boiler still set at maximum gas rate,
insert analyser probe into flue gas
sampling point. Allow readings to stabilise
before recording.
No
Turn off appliance and call Morco Technical Helpline for advice
The appliance must not be commissioned until problems are identified
and resolved. If commissioning cannot be fully completed, the appliance
must be disconnected from the gas supply in accordance with GSIUR.
No
Yes
Check that no seals, e.g. Those on flue extensions, have
been displaced during installation. Rectify if necessary.
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Set Boiler to Minimum Gas Rate
(*see opposite page)
In accordance with boiler instructions, set boiler to
operate at minimum rate (to minimum load condition).
Allow sufficient time for combustion to stabilise.
Yes
Check CO and Combustion Ratio at Minimum Gas Rate
With boiler set at minimum rate, insert analyser probe into flue
gas sampling point. Allow readings to stabilise before recording.
No
Turn off Appliance and Call Morco Technical Helpline
The appliance must not be commissioned until problems
are identified and resolved. If commissioning cannot be
fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. NOTE:
Check and record CO level and combustion ratio at both
maximum AND minimum rate before contacting Ideal.
No
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Yes
Boiler is Operating Satisfactorily
No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all
other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.
37
SECTION 11 - WARRANTY
WARRANTY CONDITIONS
The boiler is guaranteed against manufacturing defects for a period of two years from the
date of first commissioning. However the guarantee is subject to proof of commissioning
in accordance with the Gas Safety (Installation and Use) act 1998.
The guarantee does NOT cover the following issues:
1.Frost damage to any part of the boiler containing water during freezing conditions.
2.The removal of sludge or hard water scale due to lack of antifreeze/inhibitor
3.Damage to electronics caused by a defective electrical supply.
4.Damage or failure caused by insect contamination or blocked water filters.
5.Loss of pressure within the heating system not caused directly by the boiler.
6.Incorrect operation of the boiler caused by defective outlets such as thermostatic
mixers or mono block mixer taps.
7.Damage caused by unauthorised modifications to the boiler from original
specifications.
38
NOTES
39
For more detailed servicing information, workshop manuals, technical advice, spare parts,
product training, please phone us on 01482 325456 or contact us at the address below:
MORCO PRODUCTS LTD
Morco House, Riverview Road, Beverley, East Yorkshire HU17 0LD
TEL: 01482 325456 FAX: 01482 212869 EMAIL: sales@morcoproducts.co.uk
WEBSITE: www.morcoproducts.co.uk
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