Morco 24CPM, 30CPM User Instructions And Installation Manual

Morco 24CPM and 30CPM
User Instructions and Installation Manual
For Caravan Holiday Homes and Park Homes
Model Morco Morco Morco Morco
Gas 24CPM 30CPM 24CPM Nat 30CPM Nat
LPG
LPG
Type
Gas Gas
Domestic Hot
26kW 24kW 31kW 26kW 24kW 31kW 30kW
water
Central Heating
30kW
EC-TYPE EXAMINATION CERTIFICATE 177208
Morco
House,
Riverview
Tel: 01482 325456
MORCO
www.morcoproducts.co.uk
PRODUCTS
Road,
Beverley,
Fax:
01482 212869
LTD
East
Yorkshire,
HU17
OLD
~
...
~.....-....~......-......-....
.-..-.
--~-
.....
HEATING
..__
~~--
--
&
HOT
-
....
-
--
....
~
WATER
.._
.
~
'-..____/
1. USER INSTRUCTIONS GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1998 (AS AMENDED)
It
is
the law that all gas appliances are installed by a registered person,
accordance with the above regulations. Failure to install appliances correctly could
is
in
lead to prosecution. It
is
law Read these instructions carefully before attempting to operate the appliance.
Comply with all applicable warnings. and use the appliance only
This manual should
1.1
The Marco 24CPM and 30CPM condensing combination boilers are wall hung, room sealed, fan assisted, microprocessor controlled, fully modulating boilers capable of supplying both central heating (CH) and instantaneous hot water (DHW).
The boiler can
complied with.
be
Introduction
be
set to work
• DHW supply only
your own interest, and that
Do
not interfere with any sealed components,
in
accordance with these instructions.
left with the owner of the boiler.
in
a number of ways:
of
safety, to ensure that the
in
CH
supply only
• Both
The temperature of the control panel.
CH
and DHW supply
CH
and DHW supply can
be
set by using the knobs
on
the
DHW Comfort Mode
The boiler has a "Comfort Mode" for hot water delivery only, that can the front panel. heats" water prior to use to ensure faster delivery. With this mode switched boiler will fire periodically even when With this mode switched off the boiler will only fire for hot water delivery when a tap opened. This
In
this mode the boiler "learns" your hot water requirements and "pre-
no
is
called "economy mode"
hot tap
is
opened-
this
is
be
selected
on
the
normal operation.
LCD Display
Depending control panel the following can
• Temperatures of water
on
the boiler status and user interaction with buttons and dials
be
in
the
displayed
CH
circuit-
on
the LCD panel:
both actual and target
on
the
on
is
• Temperature
• Fault
• Pressure
Codes-
in
the
of
DHW-
in
the event of a problem
CH
target only
circuit
3
1.2
CONTROL
PANEL
1 . On/off switch
2.
LCD display panel and yellow status LEOs
3.
Central heating temperature control knob
4.
Domestic hot water temperature control knob
5.
Central heating pressure test button
6.
Reset push button/burner LED
4
1.
On/off switch
This knob is used to turn the boiler
boiler after a fault code has been displayed
2.
LCD
The table below shows the various combinations
LED lights that give the boiler status at that point
Stand-by Mode: When there is no heat demand for
central heating
LCD
(default).
CH
temperature and status
DHW
LED
Setpoint mode:
CRJDHW temperature when adjusting control knobs. Left dot is flashing. After I 0 seconds, display shows actual CH Temperature.
display and yellow status
(CH) or domestic hot water (DHW).
display shows actual
mode: LCD display shows actual
mode: While DHW mode is active, status
DHW
is
ON.
LCD
CH
flow temperature
CH
LED CH is
display shows target
ON.
CHIDHW
LEOs
flow
on
and
off-
llr
&=i
fit
IU
[IJf
ffi
it will NOT reset the
of
displays and
in
time
8
m
~
~
m
a
11
..
E
e
fJ
C04iiFOFU
~
COiiiFcmf
~
COMfORT
~
COMFORT
~
Pressure mode:
on the LCD display button.
Comfort LED Comfort is ON.
Error
on
Burner LED turns D.
Service mode:
Service is ON.
It
remains active for I 0 seconds.
mode:
mode: A fault code appears automatically
the LCD display. The fault code is flashed and
CH
water pressure (bar) can be seen by
pressing the pressure
If
comfort mode is active, status
If
service mode
is
active, status LED
test-
gr)
tFa
or
~
at
~
lit
tfM
I •
8
m
G
Bl
~~r:~
e m!l_ e
0
e
·
0
CmlFORT
~
COJd1F0.'1T
~
COMFORT
~
roMFORT
~
5
3.
CH
temperature
This has 3 functions:
1.
Set the CH target temperature between 30 deg C and 80 deg C
2.
Select heating mode ON
3.
The service mode is set by turning the knob fully is only for use
control
by
engineers
knob
or
OFF
clockwise-
this
Service Mode
4.
DHW
This has 3 functions:
Temperature
1.
Set the DHW target temperature between 35 deg C and 60 deg C
2. Select comfort/economy mode - change between these modes by turning the knob fully clockwise and then back within 3 seconds.
3. The DHW supply can be switched off by turning the knob fully anti-clockwise.
MAX.
control
--...-..-.~...-..
=--===:;;=-·==-
···~--
knob
.----Heating
,--------+---Heating
..
~
OFF
ON
MIN
Comfort/ECO Mode
Selection
----t--Hot
'------------.--
COMFORT
Water OFF
Hot Water ON
MIN
'
5.
CH
Pressure
This is used to see what pressure is held read between1.0 -1.4 bar. In order to see the pressure on the LCD display, push the button. The value will be displayed for approximately 10 seconds.
6.
Reset push button/ burner LED
This is used to reset the boiler after
In addition the colour
• Red LED - the boiler is in fault mode and a code should be visible on the LCD panel
• Blue
LED-
the boiler is operating normally and the burner is ignited
test
button
in
the CH circuit - it should
any
fault codes are displayed on the LCD panel.
of
the LED indicates the following:
6
1.3
GENERAL
GUIDANCE
ON
HOT
WATER
DELIVERY
The temperature
of
the cold water supply and its flow rate through the boiler.
24CPM model at a flow rate
above ambient.
ambient, (the slower the flow rate, the greater the temperature rise).
The flow rate allowed by the boiler is achieved.
The temperature selector knob on the boiler is effective only when there is either a low water flow rate
- The boiler can theoretically supply more than one outlet simultaneously However in practice the tap which is nearest will receive the most hot water. If
the shower is
diverted to the kitchen as it offers the least resistance.
- If
an
outlet temperature. For example, ensure the shower head caused
If
a tap or shower head is too restrictive due to a fault
­will be reduced to below the rate
in a wide swing selector on the boiler down.
by
scale.
of
the hot water is governed by both the ambient temperature
In
the case
of
1 0.6L/min there will be a maximum rise
At
a flow rate
of
the hot water
or
a high ambient water temperature.
in
use and a kitchen tap
is
too restrictive it will slow down the flow rate and increase the
in
temperatures. Either fix the restriction or turn the temperature
of
6.8L/min there will be a rise
is
controlled
at
of
by
the hot outlet tap, until the max flow
is
opened virtually all the hot water will be
is
free from blockages
or
blockage, the flow rate
which the boiler
is
able to operate, resulting
of
sooc
of
the
35°C
above
A eaution:The boiler can
heating radiators,
PLACE has passed.
-Allow
adjustment
mode.
the
YOUR
time
(30
at
If
you
initial
HANDS
the
flow
seconds)
tap
run a
through
under
before
produce
hot
tap
the
tap
for
the
making
water at
when
the
or
temperature
further
hot
use
the
tap
the
adjustments.
over
boiler
could
shower
to
stabilise
1o·c when in central
has been be
very
until
after
heating
hot.
this
DO NOT
initial
making
flow
the
an
7
1.4
GENERAL
ANTI PUMP SEIZURE DEVICE
ADVICE
When central heating domestic hot water only) the pump will automatically run for 30 seconds every 23 hours to prevent it supply switched off for a period, this device will not work. The pump may have Gas Safe Registered
NOTE: Seized pumps are not covered under warranty. ROUTINE SERVICING
To ensure continued safe and efficient operation that it servicing will depend upon the particular installation conditions and usage but general once a year should nas occurred.
It
Registered Engineer.
SAFETY It
operation of this appliance. The appliance therefore the flue terminal MUST NOT it is the fault has been rectified by a competent Gas Safe Registered Engineer.
jammed
is
checked and serviced as necessary at
is
the law that any service work MUST
is
essential that these instructions are strictly followed for the safe and economical
is
damaged, turn off the appliance and consult your installer, or service engineer. If it
known or suspected that a fault exists
when the appliance
is
not being used, but the boiler
seiz1ng.
Eng1neer.
is
in
the summer setting (for
If the appliance has been shut down with the electrical
be
found to
is
switched back on. If so, consult your installer or
of
the appliance it
re_gular
be
regarded as a minimum even if only occasional usage
be
carried out by a competent Gas Safe
is
a fan-assisted room sealed gas boiler and
BE
OBSTRUCTED under any circumstances. If
on
the appliance it MUST NOT
intervals. The frequency
is
recommended
be
used until
of
in
THERMOSTATS/TIMERS/PROGRAMMERS
be
This appliance may
in
function example: the boiler will not fire temperature has been reached or a time clock CH
to operate.
If
the boiler is installed in a Caravan Holiday Home, refer
home, Note: There
-Leave any residual water
NOTES ON FROST PROTECTION The heating circuit and radiators should contain the correct level
prevent damage during freezing conditions and should not Opening the hot and cold water drain cocks should be sufficient
water from the boiler.
However in some installations air
to
ensure the water has drained. The filling loop valve below the boiler may also
be
used as an extra drain point.
the home. These devices may override the controls of the boiler. For
for
the positions
are
no
all
taps
and
fitted with one of the above devices to control the central heating
in
CH
mode when a
of
all drain plugs.
drain plugs fitted
plugs open until the boiler
to
continue
to
to
drain.
it
rna}!
the
be
actual
necessary
room
is
outside of the time zone selected for
boiler.
is
next needed for service. This will allow
thermostat senses its set point
to
the user manual
be
drained down.
to
to
blow through the system
for
of
antifreeze
drain all the
the
to
with
ALL
8
FROST DAMAGE IS OUTSIDE OF THE
WARRANTY
2. GENERAL SPECIFICATION
The Marco 24-CPM and 30-CPM are a range
boilers that use premix technology and achieve a grade A rating
of
high efficiency condensing combination
in
SAP 2009. They are
designed to provide both Domestic Hot Water (DHW) and Central Heating (CH), although
the CH does not operate while the DHW is being used. The boilers are designed to be
wall hung and are room sealed, that is they obtain the air for combustion from outside
of
the dwelling and a fan returns the products
in
particularly suited to use
be supplied ready to run on either LPG
Caravan Holiday Homes and Park Homes. The boilers can
or
combustion to the outside. The range is
Natural Gas.
Both horizontal and vertical flues can be used and various elbows can be used to
of
accommodate a more complex route between the boiler and the outside
the dwelling.
The main printed circuit board provides all the functionality and safety features for
the boiler. The board operates the gas valve, fan, pump,3-way valve and flame supervision. The safety systems built into your appliance provide entire safety for you and your
appliance. The safety systems are:
> Flue Gas Over-heat Safety System (105 °C) > Flame Failure Supervision > Boiler Over-heat Safety thermostat 2 levels: 95 °C and 105 °C) > DHW (Domestic Hot Water) Over-heat thermostat > CH Over Pressure Protection (3 bar) > CH Low Water Pressure Protection (0,8 bar) > High Voltage Protection System (260 VAC) > Low Voltage Protection System (160 VAC) > EMC (Electromagnetic Compatibility) Filter > Thermal Accumulation Protection (with by-pass circuit and "pump over-run") > Water Flow Supervision > Pump Run Protection (0,4 bar) > Pump Anti-sticking Function > 3
Way
> Automatic Air Vent > Expansion Vessel (7 litres)
Valve Anti-sticking Function
9
1-
Stainless steel heat exchanger
2-
Air I gas manifold
3-
Fan
12-
Igniter
13-
Ignition electrodes
14-
Ionization electrode
4-
Pump
5- Hydraulic
6- Gas
7-
8-
9-
10-
11-
10
valve
Water
CH
tlo\v
CH
return
DHW tlow turbine
Air I gas mixer box
circuit-
pressure
NTC
NTC
flow manifold
transducer
sensor-
immersion
sensor - surface type
type
15- Flue gas 16-
Hydraulic
1 7- Automatic air 18-
Air
inlet
1 9-
Expansion
20- Siphon(Condensate Trap)
NTC
pipe
sensor
circuit-
vent
vessel ( 7 litres)
return manifold
21- Plate heat exchanger
22- Thermal
cut-off
160
°C
3-TECHNICAL
Gas
Category*
Boiler
Type
Performances
CH
CH
CH
CH Max.
CH CH
DHW
DHW Max. Heat Output DHW DHW
Gas Natural Gas (Max. Load) Natural Gas (Min. Load) Propane (Max. Load) Propane (Min. Load)
Type
of
gas
Min. Heat Output (80160 Max. Heat Output (80160 °C) Min. Heat Output (50/30 °C)
Heat Min. Heat Input Max. Heat Input
Min. Heat Output
Min. Heat lnput Max. Heat Input
Consumption**
DATA
Output (50130 °C)
°C)
24CPM
I I
2H3i>
CrJ<~J·
Ci*l•
C4:3<¥lt
C.s:JW,
C,)(:(,)t
Cal(xJ
G 20 G
6,6
22.2 7,3
24
6,8
22,8
6,7
26
6,8
27
22,2
2,38 2,92 0,71
1,77 2,17
0,64
31
7,9
8,8
24
8,2
22,8
8
26
8,2
27
c
IJCxh
Cnt«>t
G20
8, I
27,3
9
30
8,4
28
8,2
31
8,4
32
JOCPM
II
21m
C:Jl!.liol•
c4l(X)•
C'i<xl>
0,88
0,77
Ct~(~
031
9,6
27,3
10,8
30
10
28
9,7
31
10
32
Unit
kW kW kW kW kW kW
kW kW kW kW
m
m3/h
kglh kglh
3
I
lh
Gas
Supply Natural Gas (G 20) Propane (G 31)
Domestic Min. Flow
Flow
Max. Flow rate at 35 Min. Operating Pressure Max. Operating Pressure Set Temperature Range
Central Min. Operating Pressure Max. Operating Pressure Set
Temperature Range
General Electrical Supply Fuse Rating Electrical Power Consumption Expansion Vessel Dimensions (HxWxL) Weight (Net) Seasonal Efficiency (SEDBUK) IP rating
Pressure
Hot
Water
Rate
For Activating
Rate
°C
Heating
temp. rise
20 20 37
37
3 3
14
12
(~t=JI
•c)
10,6 12,7
0,2 0,2
7
35-60 35-60
0,8 0,8
(~t=32
7
3 3
30-80 30-80
230V AC- 50Hz 230V AC- 50Hz
4A
115
4A
115
7 7
775x454x3 70 775x454x3 70
40 40,5
90,0-NG
I 91,3-LPG 90,1-NG I 91,6-LPG
IPX40
IPX40
.,C)
mbar mbar
Jtr/min
I trim in ltr/min
bar bar
oc
bar bar
oc
VAC/Hz
A
watt
ltr
mm
kg
%
**For gas
}>
c type boilers
combustion is provided from outside via air gas
ducts.
consumption-
(Crl(XJ,
Only MOR
CO
Calorific Value (Net) Natural gas: 34.52 MJim3 Propane: 78.5 MJim
c33(s),
c43{xh
CsJ(x),
supplied
flue options
c63(x),
C8J(x))
supp!yducts
may
3
are air independent gas appliances. Air required for
with products
be
used.
of
combustion, discharged by flue
11
MAIN BOARD PCB
Main
(24 kW,
installing
board
30
an
has
different
parameters
such
kW, Natural gas, Propane,). A
appropriate
(Boiler Control Card) to
as
main
fan
speeds
board
the
main
can
be
board.
Main Board - Technical and Functional Specifications
General
Power supply range (standard):
!Power supply frequency:
Working temperature range: Fusing: 4A
Inputs
Water pressure switch: 0,5 - 2,5 V DHW flow turbine
195-253 50Hz
0
oc-
60
Max.
14
1/min
according
converted to another type
VAC
to
the
boiler
oc
de
(0,0 - 4,0 bar)
types
by
10
CH flow NTC sensor: CH return NTC sensor: Flue gas NTC sensor: Thermal cut-off: Room thermostat: Ionization current: min.
Outputs
Gas valve: 230 VAC Igniter: Pump: 230 VAC Fan: 3 way electrical valve 230 VAC
k0hm@25
10
k0hm@25
10
k0hm@25
oc
160
24VDC
11-lA
230 VAC
230 VAC
°C °C
oc
12
30 sec 3 MIN
13
24CPM
30CPM
Wiring
I
In
-
Black
-Blue
-Brown
-Grey
-Orange
-Pink
- Purple
-Red
-Yellow
-
YellowGreen
-White
Diagrams
rn1
'A
clgD
30
I I
031
I
32
D D
33
23
@)
18
~~~====:::::::::=.~
X10
liiiil
27
22
@)
X2B
I
II
X2A
I
I I I
24
[Q]
B 2s
26
21
~
I XlC I XlB I XlA
PENLPENL
4
INFORMATION
1
230
VAC
2
230
3
230
4
230
5
230
6 Ignition electrodes
7 Ionization electrode 8 230VAC Fan
9 230
1 0
20
~
12
13
14
15
16 PWM Fan control
17 Water pressure sensor 1 8 DHW Flow turbine 19 Boiler
20 Fuse4A 21 22
23 DHW potentlonmeter
24 Reset button 25 Flame LED (blue)
26 Error
27 Connector
28 Pressure button 29 Status
30
31
32 Status LED Service
33 LCD2x7
34
35
36 Outside temp. sensor (Optional)
Room
VAC
Power supply
VAC Pump VAC
Gas valve
VAC Igniter
VAC
3
way
PC
communication/ e-Bus port
CH
ratum
NTC
CH
flow
NTC
CUI-off
160"C
Flue
gas
NTC
chip
card
Power
switch
CH
potentiometer
LED
(red)
MICS20
LED Status Status
Terminal 24VDC
CH
LED
DHW
LED
Comfort
RT
/Opentherm
thermostat
divertar valve
sensor
sensor
sensor
(BCC)
port
(Optional)
RT(Optlonal)
.q-
.-
4. GENERAL INSTALLATION
FOR
This appliance must be installed, adjusted of
A correct installation will ensure that your boiler works properly.
GAS SAFETY (INSTALLATION amended).
It
accordance with the above regulations.
Failure to install appliances correctly may lead to prosecution. It is
with.
In
with the current:
lEE Wiring regulations,
Heath and Safety Document No 635 'The Electricity at Work Regulations. It should also be
editions following standards relevant to an installation
BS 5482 part 2 Installations
BSEN721 Leisure accommodation vehicles ventilation requirements.
BSEN 1949 Installation
THE
gas, only by a qualified and competent person.
is
the law that all gas appliances must be installed by a registered person,
in
addition to the above regulations, this appliance must be installed
Accommodation Vehicles.
USER
or
adapted for use with another type
AND
your own interest, and that
in
accordance with the relevant recommendations
of
all relevant National Standards. Your particular attention is drawn to the
in
caravans and non permanent dwellings.
of
LPG System for Habitational Purposes in Leisure
USE) REGULATIONS 1998 (As
of
safety, to ensure that the law is complied
in
accordance
in
the current
in
Caravan Holiday Homes:
in
For Park Home installation refer to:
BS3632 Specifications for Residential Park Homes
BS5440 Flueing and Ventilation
any
IMPORTANT: Manufactures instructions must NOT be taken in
over-riding statutory regulations.
4.1
BOILER LOCATION
In
positioning the boiler, the following limitations MUST be observed:
for
The position must allow
The combination boiler must be installed on a flat vertical wall capable
supporting its weight.
If the boiler is
power supply must be so situated that they can not be touched by the person using the bath Regulations, and Regulations applicable
A compartment used to enclose the appliance MUST be designed and
constructed specifically for the purpose. An existing cupboard, may be used provided it is modified accordingly.
Minimum clearance as stated
4.3)
in
a room containing a bath or shower, the boiler controls and
or
shower. Attention is drawn to the current lEE Wiring
in
Scotland the electrical provisions
in
a suitable flue termination to be made.
of
the Building
Scotland. (See 4.8).
in
the technical data must be observed (see
way
or
compartment,
as
of
15
4.2 FLUE TERMINAL POSITION
The boiler MUST
be
installed so that the terminal
is
exposed to the external
air.
It
is
important that the position
of
the terminal allows free passage
of
air
across it at all times.
Where the terminal
is
fitted
in
a position to which children, the elderly, or disabled people have access (less than 1.5m above steps, decking or ground), a suitable terminal guard should
In
certain weather conditions the terminal may emit a plume
It
is
ESSENTIAL TO ENSURE, that products of combustion discharging from
be
fitted.
of
steam.
the terminal cannot re-enter the building, or vehicle, through ventilators,
windows, or other sources of natural air infiltration, such
as
other flues etc, with
the exception of doors, but not the opening windows thereof.
The minimum acceptable dimensions from the terminal to obstructions and ventilation openings
Directly below Adjacent to
an
an
opening fixed vent, windows, etc. 300mm
opening fixed vent, windows, etc.
is
as follows:
300mm
Below gutters 75mm Below eaves
200mm
From a vertical drain pipe or soil pipe 75mm
an
From Vertically from a terminal Horizontally from a terminal
internal or external corner 300mm
on
the same wall
on
the same wall 300mm
1500mm
For domestic and Park Home applications please refer to BS5440.
4.3 MINIMUM CLEARANCES
Minimum clearances of 25mm observed. However full access from the front must
200mm above the top
300mm
be
given to allow access to the controls
of
the boiler case
is
required below the boiler to allow easy access to the gas isolation
on
each side and the front of the boiler must
in
the form of
and
for servicing.
is
required for the flue assembly.
an
cock and filling loop.
If the boiler minimum clearances) and overheating can to another heat source such as a cooker or fire) it
ventilation
the minimum effective areas
is
to
be
installed
be
installed into a small cupboard or compartment (i.e. at the
be
foreseen (i.e. close proximity
is
recommended that
in
the cupboard for cooling. The following table gives
of
the vents:
be
opening door,
16
Position vents source source
of
air Air from an internal Air from an external
High Level Low level
4.4
ELECTRICITY
A 3 amp fused three pin plug for use with 230V-50Hz is supplied fitted to the appliance.
It should be used with a shuttered socket outlet complying with BS 1363
THIS APPLIANCE MUST
4.5
GAS
A Propane gas supply at 37mbar is required or a 20mbar for natural gas
Ensure the regulator is input plus the demand for any other installed appliances.
Ensure the connection between the supply/bottle and the caravan holiday home or park home
SUPPLY
13000 sq.
1300 sq.
SUPPLY
BE
is
designed so that no pressure drop occurs.
Mm
Mm
EARTHED
of
sufficient capacity to carry the maximum boiler
7500 sq.mm 7500 sq.mm
of
No more that 3 m 3 m the pipe should be suitably sized only reducing to 15mm before the boil­er
A full bore isolation cock must be fitted use Marco part number FW0391.
If using bottled propane the bottle size must be taken account of.
The complete installation must be tested for gas soundness.
4.6
CENTRAL
This appliance systems only.
Requirements
The heating system design should be based A heating by-pass should
installed, at least one radiator should be fitted with lock shield valves (usually the bathroom radiator or towel rail).
HEATING
is
designed for connection to sealed central heating water
for
Sealed
15mm pipe should be used. Where the supply exceeds
in
the supply close to the boiler or
SYSTEM
Water
be
Systems
on
the following information:
fitted. If thermostatic radiator valves are to
be
17
A sealed system must only be filled by a competent person using an approved filling loop connected between the mains water supply pipe and the central heating return pipe. Once filled the loop should be disconnected and left adjacent to the boiler.
Antifreeze/Inhibitor
The sealed CH circuit should, at all times be filled with the correct concentration of a suitable antifreeze/inhibitor. Marco recommend Fernox Alphi
of
at least 25%. This will provide protection
on
the CH CIRCUIT ONLY down to
11
at a concentration
-11
deg Celsius and sufficient protection from corrosion.
Expansion Vessel
The following table gives the maximum system volume that the integral 7 litre expansion vessel can sustain.
Vessel charge/initial Total
water
content
system
of
CH
pressure
system
(bar)
(litres)
0.5 1 1.5
83
64
44
If the total water content exceeds that shown, an additional expansion vessel must be fitted and connected to the heating system primary return pipe as close as possible to the appliance. If an extra vessel is required, ensure that the total capacity panel indicates 2.2 bar with all radiators
of
both vessels is adequate. If the pressure display on the boiler control
or
greater when the appliance is at maximum temperature
in
circulation an extra expansion vessel is required.
Pressure Relief Valve
A pressure relief valve set 3 bar (43.5psi) outside
of
the appliance. This discharge pipe should be extended to terminate safely away from the appliance to a point where a discharge would not cause damage to persons or property but would boiling water, be a minimum
of
15mm
be
detected. The pipe should
runs or horizontal runs prone to freezing.
is
fitted and a discharge pipe
be
in
diameter, and not include any upward pipe
is
routed to the
able to withstand
4.7
DOMESTIC
Check that mains supply pressure is within the prescribed range
WATER
SYSTEM
of
0.2 - 1
Obar. exceeds this limit, a pressure reducing valve should be fitted to the mains supply before the inlet connection.
of
The final 1 000 mm
in
must be
18
15mm copper.
the mains supply pipe to the boiler and the hot water outlet
If it
If the appliance is installed where the temporary hardness of the water is high, say over 150 ppm (as defined by BS 7593 1993 Table 2), the fitting of an in line scale inhibitor is required. This must be comply with the requirements of the local water company.
Devices capable of preventing the flow of expansion water: e.g. non return valves and/or loose - jumpered stop cocks should not be fitted u arrangements are made for expansion water.
If a non-return valve is fitted in the incoming water supply - e.g. in line with scale inhibitor then a D.H.W. expansion vessel MUST be obtained and fitted.
nless separate
4.8 INSTALLATION IN A BATHROOM
The appliance is rated IPX4D
The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of t Regulations and, in Scotland, 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. 8 13:2002 If the appliance is to be installed in a room cont appliance can be installed in Zones 1 & 2, as detailed in BS. 7671. Although consideration must also be given when fitting boilers within bathrooms to adhere to the current gas safety regulations.
he current IEE (BS.7671) Wiring
aining a bath or shower then the
19
20
5.2 GAS AND WATER CONNECTIONS
Connect the boiler up in such a way as to leave the connecting pipes self supporting
be
and free from any stress. The Gas pipe must Check the gas pipe complies with the requirements in section 4.5.
supported by a clip to the bulkhead.
Gas and water connections are made to the boiler as
1.
CH
Flow-%"
2.
DHW
3.
Gas
4.
DHW Inlet
5.
CH
Return -
6.
Condensate Drain
7.
Pressure Relief- 15mm copper stub pipe
I
CD
'
®
'
in
the diagram below:
BSP
Outlet-
Inlet-%"
%"
BSP
BSP
(mains)-%"
%"
BSP
BSP
®
0
2
171
~
3
0
4
0 7
0
5
21
5.3
WIRING
INSTRUCTIONS
Warning: observe the usual precautions to ensure that the electricity supply is
or
isolated before commencing any installation
service work.
The appliance is fitted with a 3 amp. fused 3 pin plug for use with 230
V-50Hz.
It
should be fitted to a shuttered socket outlet complying with BS 1363. If the
in
appliance needs to be wired to a fused spur (for example 3 pin plug should be removed and fitted to a double pole type
a bathroom) then the
3A
fused spur.
WARNING: THIS APPLIANCE MUST BE EARTHED.
Room ThermostatfTime Clock/Programmer
This appliance may be used This device MUST HAVE a volt free contact used to switch the boiler
mains voltage enters the boiler via the control device terminals then BOILER DAMAGE WILL OCCUR. If
For the connection
1.
Remove front casing
of
a control device proceed as follows:
2. Lower control box by removing the 2 side screws
3. Undo the 2 screws securing the connection cover panel.
4. Remove the link wire (coloured blue as below)
5. Connect volt free heating control switch wire
in
conjunction with an external control device.
in
doubt contact a qualified electrician.
on
and off. If
If fitting a room thermostat. it must be installed on a wall which is free from any
or
objects and free from sunlight
X7A
I erminal
N L
Block--
Room
stat
draughts.
It is possible to fit a 230VAC Thermostat!Time Clock/Programmer - Please
contact Marco for advice on
22
how
to install.
5.4 AIR/FLUE SYSTEM
The flue system
is
a
p~rt
of
the appliance and
is
approved as such. Use only flue
systems supplied by Marco that are approved for use with this boiler.
be
Both horizontal and vertical flues can maximum flue lengths apply. These are based horizontal flue and
Flue Type Horizontal 24CPM 7m
Horizontal Vertical 24CPM Vertical 30CPM
Model
30CPM 4m
no
elbows for the vertical flue.
Maximum Flue Length
8m Sm
used with these boilers. The following
on
the use
of
one elbow for the
Each 90 degree elbow added to the flue decreases the maximum length available
by 1m. Eacfl 45 degree elbow added to the flue decreases the
max1mum
len_gth ayailable by 0.5m. Please contact Marco for more details when designing true kitS.
The horizontal flue pipe may
be
The flue must
fitted with a
be
cut down to the length required.
or
downwards incline towards the boiler to
ensure condense flows back into the boiler.
In
cold or humid weather, water vapour
leaving the flue terminal. Care must
be
in
the flue gas may condense when
taken when locating the boiler to avoid
pluming causing nuisance to the occupier of the adjacent property.
is
The installer must ensure that an adequate seal
outer pipe and the corresponding part
be
can
eased by the use of silicon based lubricant. Normal grease/oil or sealant
in
any elbow or connector. The connection
formed between the inner and
are not allowed.
The black glastic terminal must
positioned with the rain shield to the top
on
the
be
horizontal flue system.
be
The air/flue terminal must
exposed to the external air and allow free passage
of air across it at all times.
The minimum acceptable dimension between the terminal and
in
obstructions/oQenings are outlined
chapter 4.2. For domestic and Park homes
refer to BS5440.
23
5.5
CONDENSATE
TRAP
All condensing boilers generate condensate discharge. The amount condensate water depends on the working conditions
1.
can be up to
A plastic discharge pipe should be fitted to the outlet pipe trap using the black rubber connector provided and the pipe should run into the drain point. Only plastic materials are suitable.
If the pipe work
Home any external pipes must be insulated against freezing and increased to a 32mm diameter. Pipe work runs should be kept to the minimum possible. All horizontal pipes must be connected at a slight 2 or 3 degree downwards incline to ensure a good flow.
Before connecting the flue the condensate trap must be filled with water. This
is achieved by tipping 1 litre
the boiler as below. This prevents the risk
escaping into the dwelling. Take care when filling the condensate trap if the
drain pipe is not already connected.
7 litres per hour.
is
not terminated within the Caravan Holiday Home
of
water into the INNER flue terminal on top
of
of
your appliance. This
of
products
the condensate
or
of
combustion
of
Park
of
5.6
24
CONDENSATE
National and local requirements drains should be taken account of. There are the condensate waste pipe under the home as below and the other is to drain into a soak away, details
for
of
which are on the following page.
DRAIN
a Caravan Holiday
TERMINALS
for
the connection
of
the condensate trap to
2 suggested ways
or
Park Home. One is to drain into the
of
draining
---··-.··~''"-=
1
5
y
4
-
~f/J22
~500
----1"'
·
.---
--..::..
---
0
0
~
'
AI
~
...;
7
Soak
1.
2.
3.
4.
5.
6.
Away
Key
Condensate pipe Section
of
pipe above or below ground
100mm diameter pipe Bottom sealed Limestone chippings Two rows
of
12mm holes at 25mm centres
7. Minimum hole size 400mm deep x 300mm wide
25
6.
COMMISSIONING
During commissioning the appliance, the following should be checked:
1.
2.
Gas
Water
Supply
Supply
3. CH Circuit
4.
Condensate
Trap
5. Flue Connections
6. Electrical Circuit
7. Flue
IMPORTANT: Open all
DO
gas
Analysis
NOT SMOKE
whilst
doors
and
purging
windows,
the
gas
line.
extinguish
naked lights, and
Before commencing the commissioning procedure, ensure that the central heating system and the domestic hot and cold water system have been flushed. This will remove contamination which could block the filters fitted to the cold inlet and C.H. return connections resulting
6.1
GAS
The tested for
the type
SUPPLY
whole
for
gas
gas
installation including the
soundness.
of
gas
used.
in
incorrect functioning
meter
Check
the
supply
of
the boiler.
(if fitted)
MUST
be purged and
inlet pressure to the boiler is correct
DOMESTIC
6.2
Turn on the mains cold
Fill and
vent
Make sure that there are no leaks
HOT
WATER
water
the installation
isolation valve.
by
turning on hot and cold
in
the installation.
water
taps.
GAS PRESSURE TEST
6.3 CENTRAL HEATING CIRCUIT
In
order
circuit
pressing the button on the control panel and reading the value on the LCD display.
4.6.
The 25% antifreeze/inhibitor. In environments Celsius this percentage should be higher, with a maximum concentration 40%.
meter.
26
for
the boiler to function correctly, the pressure in the central heating
must
The
be between 1.0 and 1.4
bar
when cold. This can be seen by
pressure can be increased by the use
central heating circuit should be filled with a
were
The
concentration d anti freeze I inhibitor should be checked using a refracto-
of
the filling loop - refer to
mix
of
water
temperatures drop
and at least
below
-11 deg of
PO
INT
Both the boiler and the central heating installation should have been purged of any air the boiler. The boiler
1.
One
in
is
located
the
CH
circuit which may cause noise/malfunctions/damage to
is
fitted with two automatic air vents:
on
the pump
2.
The other
AUTOMATIC
is
located externally on top
AUTOMATIC
......
AIR
AIR
VENT
......
VENT
of
the boiler
Always ensure that both the caps on the automatic air vents are
loose prior
to
commissioning.
6.4 CONDENSATE TRAP
Ensure the trap
Ensure all connections are water tight and that the condensate discharge pipe
is correctly installed (see 5.6.).
is
full with 1 litre of water. (See 5.5.)
6.5 FLUE CONNECTIONS
Ensure that the flue has a fall
boiler.
Make sure that the air intake and the flue outlet are not blocked.
of
2-3 degrees back towards the
27
6.6 ELECTRICAL CONNECTIONS
Gas Consumption
24CPM
30CPM
Unit
Natural Gas (max load)
2.38
2.92
m³/hour
Natural Gas (min load)
0.71
0.88
m³/hour
Propane (max load)
1.77
2.17
kg/hour
Propane (min load)
0.64
0.77
kg/hour
The timer switches the boiler off.
Checks to ensure electrical safety should be carried out by a qualified person
ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit using a suitable test meter.
6.7 FLUE GAS ANALYSIS
If the boiler is on a metered gas supply carry out a gas rate test at the gas meter. The boiler needs to be in s front panel fully clockwise and the service LED will now be on. Turn the knob counter clockwise and then fully clockwise again and the service LED will flash. The boiler is now set in “high-rate” service mode. Turn on the hot water tap and carry out a gas rate test at the gas meter. The gas consumption should be as below within a toleranc 5%. If the reading is outside of this range then, with the use of a flue gas analyser, refer to gas valve adjustment in chapter 7.
ervice mode which is achieved by turning the CH knob on the
e of
If no meter is available or the boiler is on bottled gas then, with the use of a flue gas analyser, refer to gas valve adjustment in the chapter 7.
6.8 INITIAL OPERATION Domestic hot water
To turn on the boiler follow the user instructions at the front of this manual. Whenever a hot tap is opened the boiler automatically fires up to deliver hot water. The
temperature selector control should be se temperature is high (as in a hot climate) then the hot water temperature may be reduced by using this knob.
t at maximum. If the ambient water
Central heating
Set the timer/thermostat/programmer so that the boiler will fire in CH mode. Refer to chapter 1 User Instructions to operate the CH circuit.
The central heating temperature control knob allows water temperature of between 30 and 80°C to be
The temperature selected on the thermostat/programmer is reached
The temperature selected on the boiler CH control knob is reached
selected. The boiler will remain on until:
28
6.9 FAULT CODE/LOCK OUT
If the boiler develops a fault the reset button will show red and a fault code will show
on
the LCD panel. See Fault codes
To reset the boiler after a fault, press the reset button and it should change from red
to either:
• Clear if the boiler is unlit or
• Blue if the boiler is lit.
in
chapter 9 for further details.
6.10 FINAL CHECKS
• Re-light and test for gas soundness
• Set the C.H. and D.H.W. temperature selectors to the required settings.
• Ensure that the timer/thermostat/programmer are set to the required settings.
6.11 USER INSTRUCTIONS
Upon Commissioning
• Give the 'users Instructions' to the owner and emphasise their responsibilities under the "Gas Safety (Installation and Use) Regulations 1998"
• Explain and demonstrate the lighting and shut down procedures.
• Advise the owner adjustment of all system controls for both D.H.W. ana
• Advise the user
tq
and cond1t1ons.
• Explain the function
them. Emphasise that if fault codes and lock outs persist, the boiler should be turned off and a Gas Safe Engineer consulted.
• Stress the importance Engineer.
the home,
of
the boiler the engineer should:
on
the efficient use
of
the precautions necessary to prevent damage to the system,
in
the event of
the boiler safety devices, fault codes and how to reset
of
an
of
the system remaining inoperative during frost
annual service by a competent Gas Safe Registered
of
the system, including the use and
C.
H.
29
7.
ROUTINE SERVICING
To ensure continued efficient operation
is
that it cy
of
but
i~
It reg1stered engmeer.
7.1
Remove 2 screws at the bottom Pull forward at the bottom to disengage catches then lift the cover pins at the top
checked and serviced as necessary- at regular intervals. The frequen-
servicing will depend upon the particular installation conditions and usage
in
generar once a year should be adequate.
the law that any service work must be carried out by a gas safe
Front Cover Removal
of
the front panel
of
the boiler .
of
the appliance, it
is
recommended
off
the
.....
...
..
...
..
......
7.2
Servicing Schedule
Before commencing any service operation, ISOLATE the mains electric supply, and TURN OFF the gas supply at the main service cock. Service the appliance by following the full procedure aetailed below.
1.
30
Run the boiler
check, noting any operational faults.
2.
Check the combustion performance whilst running maximum output, if suitable equipment for flue gas analysis (Note: the flue sampling point can
For correct boiler operation
greater than
adjustment
in
DHW mode and
0.004).
in
section 7.3
CH
mode and carry out a pre service
in
DHW mode at
is
available.
be
found on the flue turret elbow.
the CO/C02 ratio
If
this is not the case then refer to gas valve
should
not
be
3.
Check that the DHW filter is not blocked.
4.
Check that the flue terminal is unobstructed and that the flue system is sealed correctly.
5.
Remove the fan and burner assembly. Inspect, and if necessary, clean the
or
main burner using a soft brush any abrasive materials.
6.
Remove ignition and ionization electrodes. Inspect and clean as necessary using a soft brush. If either replace the electrode and its gasket. Measure electrode separation as below:
of
vacuum cleaner. Do not use a wire brush or
the electrodes show signs
of
damage or wear,
7.
Remove the fan and burner assembly. Inspect the inside
chamber and if necessary clean the inside
not brush the insulation at the rear, check the combustion chamber insulation panels for damage and replace
a.
Remove the burner injector/gas restrictor.lnspect the injector for blockage damage and clean/replace as necessary.
9. Remove the condensate trap bottom cleaning nut. Drain/clean as necessary
Important
In
order to carry out servicing or replacement
sealing panel must be removed, care must be taken to refit and seal correctly. After completing the servicing
soundness detection fluid as appropriate.
Notes:
or
exchange
of
any disturbed joints or test points by means
if
necessary
of
of
the tubes with a soft brush. Do
of
parts the boiler front panel and
gas components, always test for gas
of
of
the combustion
a tightness test
or
or
leak
When work is complete the boiler front panel ensuring a good seal is made.
& sealing panel must be replaced,
31
7.3
Gas
Valve
Adjustment
Connect the flue gas analyser to the sampling point which is located of
the air/flue system
on
the turret
Operate the boiler at maximum load (see section 7.4 Service Mode).
(---+
Be sure that boiler is running at maximum load
Wait approximately 4 minutes for the stabilisation
Check the
If the
C02
C02 value is not
value against the Setting Values Table below
in
the range (±0.2), gas valve adjustment
maximum fan speed).
of
the values.
is
necessary.
Turn the flow adjustment screw (see figure below) with 2.5 mm allen key counter-
clockwise (in direction +ve) to increase or clockwise (in direction -ve) to decrease gas flow
Adjust the required
Wait for the stabilization
(C02
value) to the burner.
C02
value (±0.1) according to the setting values table.
of
the values
Operate the boiler at minimum load (see section 7.4, Service Mode).
Be sure that boiler is running at minimum load (---+minimum fan speed).
Wait approximately 4 minutes for the stabilization
Check the
If the
C02
C02
value against the Setting Values Table below
value is not
in
the range (±0.2) gas valve adjustment is necessary.
of
the values.
Turn the offset adjustment screw with 2.5 mm allen key clockwise (in direction +ve) to increase or counter-clockwise (in direction -ve) to decrease minimum
C02
value.
of
Wait for the stabilization
the values.
Recheck the values at maximum load and minimum load because each
adjustment changes the previous setting value (See the flow adjustment and offset adjustment graphs below.
Setting Values
Boiler Model
Fan Speed (rpm)
1620 8,7 (±0,1) 5,6 (±0,2) 1860
Morco24CPM
4680
1620 8,5 (±0,1)
Morco 30CPM
4800
Natural Gas Propane
C02
(%)
9,3 (±0,1) 4,5 (±0,2)
9,0 (±0,1)
02(%)
6,1
(±0,2) 1860
5,1
(±0,2)
Fan Speed (rpm)
4440
4440
C02
10,0 10,8
9,7
10,8
(±0,1) (±0,1)
(±0,1) (±0,1)
(%)
02(%) 5,7 (±0,2) 4,4 (±0,2) 6,2 (±0,2) 4,4 (±0,2)
32
1
---
Boiler Load {Fan Speed)
a) Flow Adjustment
SEALING
LABEL\--
OFFSET ADJUSTMENT
,'
_/
:
- l
- - ,
FEEDBACK
---
Boller Load
{Fan Speed)
b) Offset Adjustment
CONNECTION
FlOW(CO) ADJUSTMENT
SEALING
lAB
EL
7.4
Service
Turn the
After the soft start time ends, the boiler will run
To operate the boiler
Mode
CH
knob fully clockwise. Status LED Service will be
at
the minimum load.
at
the maxmum load, turn the
CH
ON
knob to the off position and back again to the service mode position within 3 seconds. (If the stays
status LED Service will blink
in
off position, the main board will cancel the service mode). The
to
indicate the maximum load.
Service mode will be inactive after 10 minutes.
It is possible cancel the soft start function by turning the
CH
knob to the
off position and back again to the service mode position within 3 seconds.
CH knob
33
8.
COMMON PROBLEMS AND FAULT CODES
8.1
Common
Hot water temperature at the taps is reduced. This may be because the temperature of
the mains cold water supply is colder during the winter period.
problems
The gas supply to the boiler has run out,
gas bottles will supply enough gas to run low power appliances such as cookers and gas fires, but will fail to supply high powered appliances such as the combination
boiler.
During busy periods, the mains cold water supply to the boiler may be subjected to
variations the hot water outlet.
If the mains power supply to the boiler has been interrupted
time clock/programmer (if fitted) must be reset to the correct time, if the boiler is to
be operated
8.2 Fault
The Marco 24 CPM and 30 CPM Boilers have a self diagnostic system built into their printed circuit board. Should a fault for safety related boiler will failsafe by locking out, which The fault can be identified by the code backed by a mechanical means
in
pressure, this will result
in
the timed sequence
Codes
in
of
protection, should the electronics fail to detect a fault.
or
is
about to run out. Near empty propane
in
fluctuations
central heating mode.
is
indicated by the
in
the LCD display. The electronic failsafe
in
the hot water temperature at
or
turned off, then the
or
other reasons occur, then the
red
LED
on
the control panel.
is
also
of
These mechanical forms boiler. The software protection built into the P.C.B. will
which are essential to the safe operation of the boiler. This occurs before any ignition
sequence takes place, if any component range, the boiler will lockout with the fault code displayed
will comprise a number.
is pressed.
Fault conditions can be divided
1. Lockout Conditions
Lockout flue gas over heat
Lockout boiler over heat
No flame signal
Flame loss
Flame simulation
Failure flow-return supervision
Failure gas valve circuit
protection will protect and ensure the safe shut down of the
run
a system check
is
found to
NOTE: The red LED stays on constantly until the reset button
in
2 groups:
be
faulty or out of a predetermined
on
the LCD screen. Each Fault
on
components
V1N2
34
Failure fan speed
These fault codes can only be cleared by pressing the reset push-button, then display
panel will be
2.
Blocking Conditions
in
stand-by mode. While
in
lockout conditions, Burner LED will turn RED.
Boiler over heat CH
Failure
flow sensor (NTC)
Failure flue gas sensor (NTC) CH
Failure
return sensor (NTC)
Failure power supply
Failure water pressure of
These fault codes will reset as soon as the cause example, when
CH
water pressure is out
of
operating range, blocking condition will be
generated and keep the system off until the pressure
8.3
Lockout
Error
code
NO
lCD
display
Conditions
Lack
of
electricity.
and
Cause
Solutions
-
Power
;....
On I off
)-
3
amp
the problem disappears. For
is
within operating range again.
Solution - Check list
supply connections. Check
switch is
fuse in fuse spur
ON
or
4amp
fuse PCB
of
Lack
°C
;;;.
~
.,.
,.,
,
.,
- Lack
j;.
~
~
,.
:..
,..
);.
Lockout flue gas
01
I
01
06
12
The
flue gas sensor sensed
(over
Lockout
105
°C.)
boiler overheat
.
CH
flow temp. has exceeded t 05 °C
or
CH
return temp. exceeds
Boiler overheat CH flow temp has exceeded 95 or
return temp. exceeds 90°C,
Heat exchanger
Thermal operated.
cut-off
overheat
overheat
160
°C
90
°C
stat
may have continuity.
circulation, Check
Flow & Return isolation valves are open.
Ful1
TRV
system have a by-pass By-pass settings Pump Faulty Flue-gas
Flow & Return isolation valves are open.
Full
By-pass settings
Pump tai lure Faulty Flow I return NTC
Boiler will remain
flow temperature drops into operating range.
Check
failure
of
circulation, Check
TRV
Thermal
or
set to maximum 3 setting
NTC
systems have a by-pass
or
set
cut
or
wire detached
to maximum3 setting
or
wire
detached
in
this error mode until
out in heat exchanger for
13
Flue gas NTC Open circuit
If
boiJer is cold -
;...
Check Sensor has been damaged.
~
Replace NTC
wiring has not become disconnected
or
35
36
9 . WARRANTY CONDITIONS
The boiler date in
of
accordance with the gas safety (Installation and Use) act. 1998.
is
guaranteed against manufacturing defects for a period of one year from the
first commissioning. However the guarantee is subject to proof
of
commissioning
The guarantee does NOT cover the following issues:
of
Frost damage to any part of
The removal
sludge or hard water scale due to lack
the boiler containing water during freezing conditions.
of
antifreeze/inhibitor or water
quality.
Damage to electronics caused by a defective electrical supply.
Damage or failure caused by insect contamination or blocked water filters.
Loss off pressure within the heating system not caused directly by the boiler.
Incorrect operation of the boiler caused by defective outlets such as thermostatic
mixers or mono block mixer taps.
Damage caused by unauthaurised modifications to the boiler from original spec-
ifications.
For more detailed servicing information, workshop manuals, technical advice, spare parts, product training, please contact us at the address below.
MORCO PRODUCTS LTD
Marco House, Riverview Road, Beverley, East Yorkshire HU17
TEL: 01482 325456
FAX: 01482 212869
EMAIL: sales@morcoproducts.co.uk
www.
morcoproducts.co.uk
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