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User & Installation Instructions
GB24 & GB30
preheat
preheat
min
min
max
mode
reset
off
statusburner
max
e
GB24
Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD
Morco Products Ltd
Tel: 01482 325456 Fax: 01482 212869
Website: www.morcoproducts.co.uk
To Domestic Hot Water:
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)
To Central Heating:
GB24/30 Minimum 8.0 kW (27,296 Btu/h)
GB24/30 Maximum 24.2 kW (82,570 Btu/h)
BOILER OUTPUT
UIN 209783 A03
April 2014
1

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  • Page 1

    GB24 & GB30
    User & Installation Instructions

    off

    e

    max

    reset
    mode

    min

    preheat

    min

    max

    status

    burner

    preheat

    GB24

    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 209783 A03
    April 2014



  • Page 2

    2

    Morco GB24 & GB30

    Destination Country:

    Combination Boiler

    BE = Belgium
    CH = Switzerland
    CZ = Czech Republic
    ES = Spain
    FR = France
    GB = UK
    GR = Greece
    IE = Ireland
    IT = Italy
    NL = Netherlands
    PL = Poland
    PT = Portugal
    SI = Slovenia



  • Page 3

    Contents
    SECTION PAGE
    1

    Users Instructions...........................................................................................................................................4

    2

    General Specifications....................................................................................................................................8

    3

    Technical Data................................................................................................................................................10

    4

    General Installation Requirements.................................................................................................................12

    5

    Installation Instructions...................................................................................................................................14

    6

    Commissioning Instructions............................................................................................................................23

    7

    Routine Servicing Instructions........................................................................................................................25

    8

    Fact Sheets.....................................................................................................................................................31

    9

    Fault Codes....................................................................................................................................................32

    10

    Combustion Ratio Check................................................................................................................................34

    11 Warranty.........................................................................................................................................................36

    3



  • Page 4

    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 is a wall mounted, room sealed, condensing
    combination boiler, featuring full sequence automatic spark ignition
    and fan assisted combustion.

    The Morco GB 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 and installed in accordance with the
    current edition of I.S. 813 “Domestic Gas Installations”. The current
    Building Regulations and reference should be made to the current
    ETCI rules for electrical installation.

    4. Ensure that all hot water taps are turned off.

    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 6).

    It is essential that the instructions in this booklet are strictly followed,
    for safe and economical operation of the boiler.

    6. Set the mode knob control to winter (

    Electricity Supply

    Note. In normal operation the boiler status display (D) will
    show codes:

    This appliance must be earthed.
    Supply: 230 V ~ 50 Hz. The fusing should be 3A.

    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.

    ).

    If there is a central heating demand the boiler will commence
    the ignition sequence.



    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.

    Note : If the boiler fails to light after five attempts the fault
     Under NO circumstances should any of the sealed components on
    code
    will be displayed.
    this appliance be used incorrectly or tampered with.
     This appliance can be used by children from 8 years and above
    and persons with reduced physical, sensory or mental capabilities
    or lack of experience and knowledge if they have been given
    supervision or instruction concerning use of the appliance in a safe
    way and understand the hazards involved. Children shall not play
    with the appliance. Cleaning and user maintenance shall not be
    made by children without supervision.
     Children should be supervised to ensure that they do not play with
    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.

    4

    RESET PROCEDURE
    To reset boiler, turn the mode control knob (A) to reset position
    and immediately turn knob back to required setting. The boiler
    will repeat the ignition sequence if a heat demand is present.
    If the boiler still fails to light consult a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas
    Installer.



  • Page 5

    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



    Minimum 40o C (104oF)



    Maximum 64o 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

    F

    E

    3

    2

    1

    24

    14 13 12 11

    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

    5



  • Page 6

    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

    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.
    reset

    min

    min

    preheat

    max

    mode

    20 19 18 17

    22

    21

    23

    16

    15

    0

    I

    preheat

    2

    1

    24

    14 13 12 11

    3

    To unblock a frozen condensate pipe;
    1. Follow the routing of the plastic pipe from its exit point on the
    appliance, through its route to its termination point.
    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.

    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

    6

    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



  • Page 7

    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”.

    7



  • Page 8

    SECTION 2 - gENERAL SPECIFICATIONS
    2.1 General Specifications
    The boiler contains the following components:

    The Morco GB range of boilers are wall mounted, full sequence,
    automatic spark ignition low water content, fanned flue, high
    efficiency condensing combination boilers.

    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

    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 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)

    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.

    Maximum heat output in heating mode for the GB30 is 24.2 kW
    (82,570 Btu/hr) with 30.3 kW (103,384 Btu/hr) available for hot
    water production.
    The boiler is supplied with a standard concentric flue with
    additional extensions, flue deflector and vertical flue kits available
    as optional extras.
    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.

    8

    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

    11
    5
    1
    12
    9
    13

    17

    7

    14

    8

    3

    6
    2

    4

    16

    15

    10



  • Page 9

    r

    bk

    Water
    Flow
    Turbine

    b

    bk

    p

    bk

    r

    bk

    Flow
    Return
    Water
    pressure Thermistor Thermistor
    Switch

    or

    X8

    X6

    X5

    X7

    Service
    Connector

    b

    bk
    p

    bk
    y

    Fan

    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

    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

    b

    br

    y/g

    bk

    bk

    8

    7

    Flame
    Sensor
    Electrode

    y/g

    9

    5

    br

    4

    Spark
    Electrode

    b

    X3

    y/g

    y/g

    6

    PCB

    bk

    2

    1

    b

    Spark
    Generator

    3

    5

    bk

    3

    X2

    Gas
    Valve

    y/g

    4

    2

    bk
    br

    b

    Divertor
    Valve

    b

    1

    Earth

    5

    X1C
    6

    bk

    r

    Room
    Stat

    bk

    1

    X1A
    2

    Pump

    br y/g

    b

    3

    X1B
    4

    r

    br

    Plug

    N

    L

    Main
    Supply

    y/g

    b

    b

    b

    bk

    bk

    Timer

    1 2 3 4

    r

    Fused
    at 4AT

    SECTION 2 - gENERAL SPECIFICATIONS

    2.2 wiring diagram

    9



  • Page 10

    section 3 - TECHNICAL DATA
    Table 1 - General Data
    Morco GB
    24 30
    Gas supply I3p - G31 - 37mbar
    Gas Supply Connection 15mm copper compression
    Injector Size
    (mm) 3.75 3.75
    Inlet Connection
    Domestic Hot Water
    G 1/2
    Outlet Connection
    Domestic Hot Water
    G 1/2
    Flow Connection
    Central Heating
    G 3/4
    Return Connection
    Central Heating
    G 3/4
    Flue Terminal Diameter
    mm (in)
    100 (4)
    Average Flue Temp-Mass Flow Rate
    (DHW)
    63oC - 11g/s
    68oC - 13g/s
    2
    Maximum Working Pressure (Sealed Systems)
    bar (lb/in )
    2.5 (36.3)
    Maximum Domestic Hot Water Inlet Pressure
    bar (lb/in2)
    10.0 (145)
    Minimum Domestic Hot Water Inlet Pressure*
    bar (lb/in2)
    0.8 (11.6)
    1.3 (18.9)
    Electrical Supply 230 V ~ 50 Hz.
    Power Consumption
    W 146 152
    Fuse Rating External : 3A Internal : T4H HRC L250 V
    Water content
    Central Heating
    litre (gal)
    1.2
    (0.26)
    Domestic Hot Water
    litre (gal)
    0.5
    (0.11)
    Packaged Weight
    kg (lb)
    33.8 (74.4)
    34.1 (75.2)
    Maximum Installation Weight
    kg (lb)
    31 (68.3)
    31.2 (68.8)
    Boiler Casing Size Height
    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 24 30
    24.3

    24.3

    8.0

    Maximum DHW Input :

    8.0

    Btu/h 82,912 82,912 27,296 27,296
    kW

    26.4

    26.4

    8.7

    8.7



    Nett CV

    kW

    24 30
    24.3

    30.4

    Btu/h 82,912 103,725


    Gross CV

    kW

    26.4

    33

    Btu/h 90,077 112,596



    Btu/h 90,077 90,077 29,684 29,684

    Gas Consumption

    m3/h 1.00 1.25 0.329 0.329



    m3/h 1.00

    1.25



    ft3/h 35.33 44.20 11.62 11.62

    ft /h 35.33

    44.20

    kg/hr 1.83

    2.26



    kg/hr 1.83

    2.26

    0.58

    0.58

    24.2

    8.00

    8.00

    Boiler Output :
    Non Condensing
    70oC Mean Water temp.
    Condensing
    40oC Mean Water temp.

    kW

    24.2

    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%

    89%

    89%

    Seasonal efficiency* SEDBUK 2009





    NOx Classification



    CLASS 5





    Gas Consumption

    3

    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

    DHW Specific Rate

    l/min
    11.5
    gpm 2.5

    14.5
    3.2

    * 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.

    10

    Maximum operating pressure of water



  • Page 11

    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 spinning.
    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

    Underside View - Dimensions to Wall

    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

    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.

    11



  • Page 12

    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

    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

    12

    300mm (12”)

    Vertical Terminals

    600mm (24”)

    * Only one reduction down to 25mm is allowable per installation
    otherwise BS5440-1 2008 dimensions must be followed.



  • Page 13

    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 24.24kW 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.

    Safety valve setting bar

    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 pressure bar

    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)
    1.6 1.8
    3.1 3.7
    4.7 5.5
    6.3 7.4
    7.8 9.2
    9.4 11.0
    10.9 12.9
    11.9 14.0
    12.5 14.7
    15.6 18.4
    18.8 22.1
    0.063 0.074

    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.

    13



  • Page 14

    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.

    14

    L
    N
    ROOM
    STAT/
    TIMER

    N
    Room
    Stat



  • Page 15

    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 - 8m (minus any flue kit options)
    GB30 - 7m (minus any flue kit options)

    15



  • Page 16

    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 spinning by at least 17mm.
    The gap between the spinning 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
    Spinning

    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)

    16



  • Page 17

    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.

    17



  • Page 18

    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 spinning 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
    Spinning
    5” hole

    Fitting the Turret
    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 spinning 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

    18

    Flue Outlet

    C

    Sample points

    Clamp Lugs



  • Page 19

    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

    19



  • Page 20

    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 separately
    supplied vertical connector (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


    RSF050

    Assembly A

    14º
    RSF050

    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 separately) 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.
    Note. Ensure turret sample points are servicable and all caps and plugs are fitted.
    6. Finally ensure the roof plate is correctly sealed to the roof.

    20

    4

    Vertical
    connector
    3



  • Page 21

    section 5 - installation Instructions
    5.16 Condensate Drain
    Condensate
    Drain

    Condensate
    Drain

    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.

    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 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 . . . . .

    21



  • Page 22

    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

    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

    22

    ≥ 300

    ≥ 25

    Min Ø 19mm
    Internal pipe

    Water/Weather
    proof insulation

    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)



  • Page 23

    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 35.

    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 13.

    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.

    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”.

    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.

    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

    reset

    min

    status

    e

    max

    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

    23



  • Page 24

    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 32.
    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.

    24



  • Page 25

    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.


    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

    25



  • Page 26

    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.
    6. Swing the lower front panel up and retain with the two
    screws.

    3. Remove the two upper front panel fixing screws, lift the
    panel and remove.

    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. Undo the gas pipe union connection to the
    injector housing.

    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

    26



  • Page 27

    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

    27



  • Page 28

    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

    28

    C



  • Page 29

    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

    29



  • Page 30

    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

    30



  • Page 31

    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

    31



  • Page 32

    SECTION 9 - fault codes

    9 fault codes
    DISPLAY CODE ON BOILER

    DESCRIPTION

    ACTION

    Outside Sensor Failure

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    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, or in other countries a
    qualified and competent Gas Installer if outside of the warranty period.

    5 Boiler Resets in 15 minutes

    1. Turn power off and on at the fused spur.
    2. If the boiler fails to operate please contact Morco (if under warranty) or
    alternatively a Gas Safe Registered Engineer, or in other countries a
    qualified and competent Gas Installer if outside of the warranty period.

    False Flame Lockout

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    BCC Activation Fault

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    BCC Fault

    Low Water Pressure

    Flow Temperature Overheat

    Flame Loss

    Ignition Lockout

    32

    Check system pressure is between 1 & 1.5bar on the pressure gauge.
    If the boiler fails to operate then please contact Morco (if under
    warranty) or alternatively a Gas Safe Registered Engineer, or in other
    countries a qualified and competent Gas Installer if outside of the
    warranty period.

    1. Check other gas appliances in the dwelling 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. If the boiler fails to operate then please
    contact Morco (if under warranty) or alternatively a Gas Safe
    Registered Engineer, or in other countries a qualified and competent
    Gas Installer if outside of the warranty period.

    Fan Fault

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    Flow Thermistor

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    Return Thermistor

    Reset the appliance - if the boiler fails to operate then please contact
    Morco (if under warranty) or alternatively a Gas Safe Registered
    Engineer, or in other countries a qualified and competent Gas Installer
    if outside of the warranty period.

    Return Thermistor

    Return temperature greater than flow temperature. Please contact
    Morco.



  • Page 33

    33



  • Page 34

    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

    34



  • Page 35

    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.

    35



  • Page 36

    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.

    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

    36






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