FEB-24E UK SUPERCOMPACT
COMBINATION BOILER
USER MANUAL
Morco Products Ltd
Riverview Road, Beverley, East Yorkshire, HU17 0LD
Telephone 01482 325456 Fax 01482 212869
1
2
3
CONTENTS
Section Page
1 USERS INSTRUCTIONS 4
2 GENERAL SPECIFICATIONS 7
3 TECHNICAL DATA
4 GENERAL INSTALLATION REQUIREMENTS 10
5 INSTALLATION INSTRUCTIONS 13
6 COMMISSIONING INSTRUCTIONS 15
7 ROUTINE SERVING INSTRUCTIONS 16
8 TROUBLESHOOTING (SELF DIAGNOSTIC CODES)
9
17/18
4
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1998 (AS AMENDED)
It is the law that all gas appliances are installed by a registered person, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of
safety, to ensure that the law is complied with.
Read these instructions carefully before attempting to operate the appliance. Comply with all applicable warnings. Do not interfere with any sealed components, and use the appliance only in accordance with these
instructions.
INTRODUCTION
The Fagor FEB-24E is a wall hung, room sealed, fan assisted, microprocessor controlled, fully modulating
gas combination boiler for providing both central heating and domestic hot water.
DOMESTIC HOT WATER SER
VICE
Turn the main control switch setting in order to turn the boiler on.
The green light will come on indicating that the boiler is ready to
supply domestic hot water whenever there is a demand for it.
When a hot tap is opened the boiler automatically fires to deliver hot water, and the green light flashes indicating the burner is
on. A water temperature of between 35° and 60° C can be
selected by turning the domestic hot water temperature regulating knob.
HOT W
ATER
AND CENTRAL HEATING SERVICE
With the main control switch on and the green light displayed,
turn the heating selector knob clockwise from the summer setting.. The boiler will fire up automatically when either the time
clock/room stat or boiler stat calls for central heating, or a hot tap
is opened for hot water. If a hot tap is opened the boiler gives priority to hot water delivery with the central heating on standby
until the tap is closed.
The temperature of the radiators can be selected between 60ºC
and 80ºC by turning the knob.
1.- USERS INSTRUCTIONS
FEB-24E
9
6
12
3
1
5
6
1
2
3
4
1.-Pressure gauge
2.-Heating service and heating temperature selector
3.-Main control, reset and D.H.W temperature selector
4.-Clock
5.-Green light power on and flashing burner on
6.-Red light- lock out
5
USING THE PROGRAMMABLE CLOCK
1. Set the correct time by rotating the minute hand until
the arrowhead points at the correct time on the 24 hour dial.
2. Check the position of the manual override switch (just to the
bottom of the clock face). This has three positions:
-Left: is ON overriding the timer mode
-Middle is timer mode, with ON, OFF, times governed by the
time clock.
-Right position is OFF. The heating will not work at all regardless
of the main boiler control switch except if triggered by the built
in frost protection thermostat.
3. To set on/off times, move all the white tappets , in the outer
ring, between the required 'on' and 'off' times.to the outer position. For example, if you want the heating to come on at 6am
and switch off at 10am, move all the tappets outwards between
these two times. Each tappet represents a quarter of an hour.
Set as many on/off times as required within a 24 hour period
RED LIGHT-LOCK OUT
Should the boiler fail to ignite due to lack of gas poor weather
conditions etc. It will “lockout” and the red neon will be displayed. To reset, turn the main control switch to off then turn on
again. If the boiler constantly locks out, call your service engineer.
TURNING THE BOILER OFF
Turn the main control switch to the position.
NOTE: In this position the automatic safety devices such as frost protection and
anti pump seizure are still operative. To shut down completely and isolate the
mains supply the plug must be removed from the wall.
GENERAL GUIDANCE NOTES ON HOT WATER DELIVERY
The temperature of the hot water is governed by both the ambient temperature of the cold water supply and
its flow rate through the boiler. I.E. at a flow rate of 13.6L/min there will be a maximum rise of 25ºC above
ambient. At a flow rate of 6.8L/min there will be a rise of 50ºC above ambient, (the slower the flow rate, the
greater the temperature rise).
The flow rate of the hot water is controlled by the hot outlet tap.
The temperature selector on the boiler is effective only when there is either a low water flow rate or a high
ambient water temperature.
- 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 in use and a kitchen tap is opened virtually all the
hot water will be diverted to the kitchen as it offers the least resistance.
- If an outlet is too restrictive it will slow down the flow rate and increase the temperature. For example the
shower - ensure the head is free from blockages caused by scale.
- Due to the restrictive nature of simple mixer showers it is wise to turn the temperature selector down on
the boiler before using the shower.
- If a tap or shower head is too restrictive due to a fault or blockage, the flow rate will be reduced to below
the rate at which the boiler is able to modulate resulting in a wide swing in temperatures. Either fix the restriction or turn the temperature selector on the boiler down.
- Caution: The boiler can produce water at over 70°C when in central heating mode. If you run a hot
tap when the boiler has been heating the radiators, the initial flow through the hot tap could be very
ON
OFF
ON
OFF
TIMER
6
hot. DO NOT PLACE YOUR HANDS under the tap or use the shower until this initial flow has passed.
- Allow time (30 seconds) for the temperature to stabilise after making an adjustment at the tap before making further adjustments.
APPLIANCE SAFETY
LOCK-OUT
This boiler has a cut-out indicator built in to it. Whenever a malfunction is detected in the boiler, the boiler
switches off automatically and the cut-out indicator lights up (red indicator light) To reset the boiler rotate the
main control knob to the position and go back to the chosen position. Some lockout sequences require the
thermistors to cool to within normal operating temperatures before the boiler will reset. The red indicator light
should go out. IMPORTANT: Whenever the boiler has been left idle for any length of time, or when a new
gas bottle is installed (propane models), the appliance may switch off due to the presence of air in the pipes.
In cases such as these, repeat the ignition operation until all of the air has been purged from the system.
FROST PROTECTION
Providing the boiler power supply and gas supply is connected the boiler will automatically fire on minimum
when near freezing conditions are detected. When the temperature in the system reaches 20°C it will
switch off. For winter storage see notes at the end of this section.
NOTE:It is still necessary to drain the domestic hot and cold water system.
ANTI PUMP SEIZURE DEVICE
When central heating is not being used, but the boiler is in the summer setting (for domestic hot water only)
the pump will automatically run for one minute every 24 hours to prevent it seizing. If the appliance has been
shut down with the electrical supply switched off for a period, this device will not work. The pump may be
found to have jammed when the appliance is switched back on. If so, consult your installer or service engineer.
NOTE: seized pumps are not covered under warranty.
PRESSURE GAUGE
The pressure gauge should indicate approximately between 0,8 and 1,6 bar. If the pressure is seen to
decrease over a period of time there is a water leak. The boiler is fitted with a safety device to prevent it working below a pressure of 0.8 bar.
ROUTINE SERVICING
To ensure continued safe and efficient operation of the appliance it is recommended that it is checked and
serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be regarded as a minimum even if only occasional usage has occurred. It is the law that any service work MUST be carried out by a registered engineer
such as CORGI registered personnel.
SAFETY
It is essential that these instructions are strictly followed for the safe and economical operation of this appliance. The appliance is a fan-assisted room sealed gas boiler and therefore the flue terminal MUST NOT BE
OBSTRUCTED under any circumstances. If it is damaged, turn off the appliance and consult your installer,
or service engineer. If it is known or suspected that a fault exists on the appliance it MUST NOT be used until
the fault has been rectified by a competent person.
PRECAUTIONS AGAINST FREEZING DURING WINTER STORAGE
During cold periods and if the boiler is situated in a place liable to freeze, the D.H.W. circuit must be drained
down as follows:
-Turn off the cold water Supply
-Open all the hot water outlet taps on the installation
-Release the drain plugs fitted at the lowest point of the pipework.
NOTE: There is no drain plug fitted to the DHW side of the boiler.
-When the operation is finished, close the hot water outlet taps and replace the drain plug.
-To put the boiler back into service, open the cold water supply.
NOTE: In a Caravan Holiday Home installation there may be a drain cock on the cold inlet under the
van directly below the boiler which may be used. It is not necessary to drain the heating circuit if it
has been filled with antifreeze.
7
The Fagor FEB-24E is a wall hung, room sealed,
fan assisted, microprocessor controlled fully modulating gas combination boiler for providing both central heating and domestic hot water. It is particularly
suitable for Caravan Holiday Home and Park Home
use. Maximum heat output in either heating or hot
water mode is 23.7.kW (80.840 Btu/h), and priority is
always given to the supply of hot water.
NOTE: The central Heating power is factory set at
70% of its maximum.
The appliance is supplied with a standard concentric
air/flue duct and wall terminal, however additional
extension kits, vertical flue kit are available as
optional extras.
The appliance is intended for use with sealed central
heating systems and is supplied for use with
propane gas.
The appliance includes the following components:
Induced draught fan for the extraction of combustion products and induction of combustion air.
Modulating gas valve with double safety valves
Circulation pump with manual anti-seizure device
Central heating expansion vessel.
Differential air pressure switch. Prevents the boil-
er firing if there is insufficient air supply due to a fault
or blockage.
Water pressure switch. Prevents the boiler firing if
there is less than 0.8 bar in the system.
Thermistors (NTC) There are two thermistors fitted
for automatic control of the domestic hot water and
the central heating flow temperature.
Safety thermostat Shuts down the boiler in the
event of overheating. Resets after a few minutes
cooling
Electronic controls, incorporating the following features:
- Temperature selection for central heating from
between 60 to 85°C.
- Temperature selection for domestic hot water from
between 35 to 60°C.
- Continuous modulation of the gas valve.
- Flame control by ionisation
- Ignition control
- Anti-frost control in the central heating circuit.
- Anti - seizure of the pump.
2.- GENERAL SPECIFICATIONS
Schematic diagram- Hydraulic circuit
1.- Expansion vessel
2.- Pump with Automatic air bleed
3.- Water pressure switch
4.- Central heating thermistor
5.- Three way valve
6.- Overheat thermostat
7.- Air pressure switch
8.- Venturi
9.- Fan
10.- Sealed air box
11.- Copper heat exchanger
12.- Combustion chamber
13.- Ignition electrode
14.- Burner
15.- Flame sensing electrode
16.- Modulating gas valve
17.- Gas inlet
18.- D.H.W Thermistor
19.- Hot Water outlet
20.- Plate heat exchanger
21.- C.H flow
23.- Cold water inlet
24.- C.H return
25.- Pressure relief valve
26.- Automatic By-pass
27.- Expansion vessel valve
28.- Draining valve
1
3
4
7
5
6
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
28
2
A pre-winter check of the amount of antifreeze protection is strongly recommended. The level may
have fallen due to leaks in the system requiring frequent refilling from the filling loop.
8
DIMENSIONS AND CONNECTIONS DETAILS
ELECTRICAL CIRCUIT DIAGRAM
1.- Surge arrestor
2.- Mains connection
3.- Earth
4.- Fan
5.- Pump
6.- Ignition
7.- Burner solenoid valve 1
8.- Burner solenoid valve 2
9.- Front panel control
10.- 3 way valve
11.- Air pressure switch
12.- Room stat (optional)
13.-Room stat connector block
14.- Clock connection
15.- Modulating solenoid valve
16.- Flame sensor
17.- High limit stat
21.- Hot water thermistor
22.- Central heating thermistor
23.- Pressure switch
25.- Burner functioning indicator
26.- Lock out indicator light
30.- Clock
S4 Gas change bridge. Made-
Propane. Break- Nat. Gas
P1 Maximum power adjustment
P2 Minimum Lighting pressure
P3 Output for central heating
adjustment
390
25
60
65
128
85.5
651
72
58
58
65
72
Ø100
65
100
250
705.8
146
GAZ
GAS
195
680
6 5 4 2 1
FEB-24E
9
6
12
3
1
6
5 4
3
1
8
7
2
9
50
1.- 3/4” BSP Central heating return
2.- Mains cable
3.-1/2” BSP Domestic cold water inlet
4.- 3/4” BSP Gas inlet
5.- 1/2” BSP D.H.W. outlet
6.- 3/4” BSP Central heating flow
8.- Pressure Relief Valve
9.- Draining valve for central heating
T.A.:Room thermostat connection
T.A.
17
26
25
S3
P3
P2
P1
FIL
2
3
1
5
6
7
8
101112
13
14
15
16
21
S1
S2
S4
22
MP
2
1
3
4
5
12
3
4
30
J10
J9
J8
J11
J4
J6
J1
J5
J19
J12
J2
4
23
9
9
Model
FEB-24EUK
Category
II2H3P
Type
C12,C32,C42,C52,C82,B22
kW
23.7
Maximum output
Btu/h
80,840
kW
7.6
Central heating and domestic
hot water performances.
Minimum output
Btu/h
26,151
Maximum
kW
28.9
Nominal central heating and
domestic hot input (Gross)
Minimum
kW
9.2
Maximum
kW
26
Nominal central heating and
domestic hot water input (Nett)
Minimum
kW
8.3
Domestic hot water flow rate at 25ºC (l/min)
13.6
Domestic hot water flow rate at 35ºC (l/min)
9.7
Nominal D.H.W. flow rate at 34ºC (l/min)
10
Minimum flow rate for activating D.H.W. (l/min)
2
Maximum
Central heating
2.5
Maximum
D.H.W
10
Operating pressure (bar)
Minimum D.H.W. activation
0.3
Expansion vessel capacity (1)
7
Central heating circu it
60-85
Temperature selection range
(ºC)
D.H.W.circuit
35-60
Natural G-20
20
Gas inlet pressure (mbar)
Propane G -31
37
Natural G-20 (m3/h)
2.75
Gas consumption (Hi)
Propane G -31 (kg/h)
2.04
Electrical supply (V/Hz)
230V~50Hz
Max.power consumption (W)
120
Height
680
Width
390
Dimensions (mm)
Depth
254
Top
200
Bottom
150
Sides
5
Minimum clearance (mm)
Front
5
Gas inlet
18
Domestic cold water inlet
15
D.H.W.outlet
15
Central heating flow
22
Central heating return
29
Net weight (kg)
29
Type of gas
Propane G-31 (FEB-24E UK GLP)
X
92/42/EEC Directive
∗∗∗∗
3.- TECHNICAL DATA
10
4.1 RECOMMENDATIONS
FOR THE USER
This appliance must be installed, adjusted or adapted for use with another type of gas, only by a qualified and competent person.
Its quality and a correct installation will ensure that
your heater works properly.
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1998 (As amended).
It is the law that all gas appliances must be installed
by a registered person, in accordance with the above
regulations.
Failure to install appliances correctly may lead to
prosecution.
It is in your own interest, and that of safety, to ensure
that the law is complied with.
In addition to the above regulations, this appliance
must be installed in accordance with the current IEE
Wiring regulations, Heath and Safety Document No
635 'The Electricity at Work Regulations.
It should also be in accordance with the relevant recommendations in the current editions of all relevant
National Standards. Your particular attention is
drawn to the following standards relevant to an
installation in Leisure Accommodation Vehicles:
BS 5482 part 2 Installations in caravans and non
permanent dwellings.
BS 5482 Part 3 Installations in Boats
BSEN721 Leisure accommodation vehicles ventilation requirements.
BSEN 1949 Installation of LPG System for
Habitational Purposes in Leisure Accommodation
Vehicles.
IMPORTANT: Manufacturers instructions must NOT
be taken in any way as over-riding statutory regula-
tions.
4.2 BOILER LOCATION
In positioning the boiler, the following limitations
MUST be observed:
The position must allow for a suitable flue termination to be made.
The combination boiler must be installed on a flat
vertical wall capable of supporting its weight .
- If the boiler is in a room containing a bath or shower, the boiler controls and power supply must be so
situated that they can not be touched by the person
using the bath or shower. Attention is drawn to the
current IEE Wiring Regulations, and in Scotland the
electrical provisions of the Building Regulations
applicable in Scotland.
- A compartment used to enclose the appliance
MUST be designed and constructed specifically for
the purpose. An existing cupboard, or compartment,
may be used provided it is modified accordingly.
- Ventilation requirements as stated in this manual
must be observed.
- Minimum clearance as stated in the technical data
must be observed.
4.3 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.
- It is ESSENTIAL TO ENSURE, that products of
combustion discharging from the terminal cannot reenter 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 is as
follows:
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 be fitted.
In certain weather conditions the terminal may emit
a plume of steam.
4.4 MINIMUM CLEARANCES
Minimum clearances of 5mm to the front and sides
of the boiler must be observed. However full access
from the front in the form of an opening door, must
be given to allow access to the controls and for servicing.
200mm above the top of the boiler case is required
for the flue assembly.
150mm is required below the boiler to allow easy
access to the gas isolation cock.
4.- GENERAL INSTALLATION REQUIREMENTS
Directly below an opening fixed vent
windows, etc.
Adjacent to an opening fixed vent
windows, etc.
Below gutters.
Below eaves
From a vertical drain pipe or soil pipe
From an internal or external corner
Vertically from a terminal on the same
wall
Horizontally from a terminal on the
same wall
300mm
300mm
75mm
200mm
75mm
300mm
1500mm
300mm
11
4.4 VENTILATION REQUIREMENTS
The following notes are for general guidance:
- The Morco FEB-24E is a room sealed appliance
and needs no purpose provided combustion air ventilation.
- If the boiler is to be built into a small cupboard or
compartment (i.e. at minimum clearances)and overheating can be forseen (i.e. close proximity to a cooking appliance etc) permanent air vents are recommended for cooling purposes in the cupboard or
compartment . The following table gives the minimum
effective areas of the vents.
4.5 ELECTRICITY SUPPLY
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 BE EARTHED
4.6 GAS SUPPLY
- A Propane gas supply at 37m bar is required.
- Ensure the regulator is of sufficient capacity to
carry the maximum boiler input plus the demand for
any other installed appliances.
- Ensure the connection between the supply/bottle
and the caravan holiday home or park home is
designed so that no pressure drop occurs.
- No more than 3 m of 15mm pipe should be used.
Where the supply exceeds 3 m the pipe should be
suitably sized only reducing to 15mm before the boiler
- A full bore isolation cock must be fitted in the supply close to the boiler or use morco part number
FW0391.
- The complete installation must be tested for gas
soundness.
4.7 WATER SYSTEMS - GENERAL
- This appliance is designed for connection to sealed
central heating water systems.
- Prior to filling the central heating system (see section 6.2) It is recommended that where the system is
installed in a caravan holiday home, subject to non continuous use, anti-freeze is used.
4.8 REQUIREMENTS FOR SEALED
WATER SYSTEMS
The heating system design should be based on the
following information:
- The available pump head is given below.
- A minimum flow rate corresponding to a heating differential of 20°C must be obtained at all times.
- A heating by-pass should be fitted to ensure that
the above condition is satisfied. If thermostatic radiator valves are to be installed, at least one radiator
should be without a thermostatic valve (usually the
bathroom radiator).
- 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.
Position of air
vent
Air from room/int
space
Air direct from
outside
HIGH LEVEL
LOW LEVEL
13000 mm
2
13000 mm
2
7500 mm
2
7500 mm
2
0
100
200
300
400
500
0 200 400 600 800 1000
Pressure (mbar)
Flow (l/h)
by-pass open
by-pass closed
AVAILABLE PUMP HEAD
12
- The following paragraphs outline the specifications
of the items fitted to the boiler.
Expansion vessel.
The following table gives the maximum system volume that the integral 7 l expansion vessel can sustain
under different temperature conditions. If the system
volume 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 of both vessels is adequate. If
the pressure gauge indicates 2.2 bar or greater when
the appliance is at maximum temperature with all
radiators in circulation an extra expansion vessel is
required.
Pressure relief valve
A pressure relief valve set 3 bar (43.5psi) is fitted and
a discharge pipe is routed to the 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 be detected. The pipe
should be able to withstand boiling water, be a minimum of 15mm in diameter, and not include any
upward pipe runs or horizontal runs prone to freezing.
4.9 D.H.W
. SYSTEMS
- Check that mains supply pressure is within the prescribed limits (refer to 'technical data' page 7) If necessary, a pressure reducing valve should be fitted to
the mains supply before D.H.W. inlet connection.
- The DHW performance is summarised in the graph:
- The final 1000 mm (40 in) of the mains supply pipe
to the boiler must be copper.
- If the appliance is installed in an area where the
temporary hardness of the water supply is high, say
over 150 ppm, the fitting of an in line scale inhibitor
may be an advantage.
- Devices capable of preventing the flow of expansion water: e.g. non return valves and/or loose jumpered stop cocks should not be fitted unless separate 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.
- For specific information relating to fittings
(exAmPLe:. Shower, washing machines etc.) suitable
for connection in the D.H.W. circuit, consult the Local
Water Undertaking, however the following information is given for guidance.
Domestic hot/cold water supply taps and mixing
taps - All equipment designed for use at mains water
pressure is suitable.
Showers - Any mains pressure shower is suitable,
but if the unit has a loose head which may become
immersed in bath water either an anti-syphonage
device must be fitted, or the length of the flexible
hose must be reduced so that it cannot fall closer
than 13 mm (1/2 in) to the top of the bath.
50 100 150 200 250
1
1,2
1,4
1,6
1,8
2,0
2,2
P
C
85º C
75º C
60º C
P Cold pressure (bar)
C System capacity (litres)
4
35
30
25
20
213
60
55
40
50
45
7651110981412 13
35 °C
10 l/min
60 °C
2.42 l/min
35 °C
5.45 l/min
60 °C
7.55 l/min
49 °C
10 l/min
COLD WATER INLET TEMPERATURE =15ºC
FLOW D.H.W. (l/min)
D H W Performance graph
13
5.1 BOILER PACKAGING
The boilers are supplied in different packagings:
- Boiler
- Flue system (separate packaging)
5.2 FITTING THE BOILER.
- Decide where the boiler is to be fixed on the wall
taking into account the installation requirements
detailed in section 4.2 and the clearances and dimensions described in the the technical data.
The centres for the hanging strap fixing are 85mm
below the top of the boiler casing, see fig below.
The flue pipe centre is 213mm above the hanging
strap centres. NOTE: a fall of about 2º - 3º should be
allowed on the flue pipe to stop water ingress into the
boiler.
A screw fixing should be made on the bottom rail of
the boiler to secure it during transport.
5.3 WIRING INSTRUCTIONS
Warning: observe the usual precautions to ensure
that the electricity supply is isolated before commencing any installation or 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
WARNING: THIS APPLIANCE MUST BE
EARTHED.
ROOM THERMOSTAT:
This appliance may be used in conjunction with an
external room thermostat.
The voltage between the contacts of the room ther-
mostat is 24V (normally closed). Any 24V controls
may be used, but gold contacts are recommended.
DO NOT under any circumstances use a mains supply to the stat as you will blow the P.C.B. in the boiler. Only voltage free switching stats should be used.
Connection of a room thermostat (optional).Proceed
as follows:
Unscrew the screw (A) as it shows figure 1, open
the bottom cover, where the connector of the room
thermostat is placed.
Press out the plastic disc (B) using a screwdriver to
form a hole so you can pass through the wires of the
room stat.
Replace cover.
The room thermostat must be installed on a wall
which is free from any objects and free from direct
contact with either sunlight or draughts.
5.4 WATER AND GAS CONNECTION
Connect the boiler up in such a way as to leave the
connecting pipes self supporting and free from any
stress.
Check that the gas pipe complies with the requirements of section 4.6
In order for the boiler to function correctly and to have
a long working life, the central heating system must
be properly designed, making sure that the temperature difference between the flow and the return will
not be greater then 20°C.
5.- INSTALLATION INSTRUCTIONS
390
128 mm
85.5 mm
213.5 mm
FEB-24E
9
6
12
3
1
MOUNTING BRACKET
HOLE CENTRES
MINIMUM SIDE AND FRONT
CLEARANCE 5mm
14
L
50
927
860
20
Ø60.8
15
25
25°
25
95
Seal
Rubber
sleeve
Clamp
Air
restrictor
ring
Ø 60-100 Coaxial pipe
L= 0.5 m
L= 1 m
HORIZONTAL FLUE Ø 60-100mm COAXIAL
5.5 AIR/FLUE SYSTEM
The standard flue kit supplied with the FEB-24E is a 1m horizontal coaxial air/flue kit as shown below.
There are various other options available, including a vertical flue kit and other variations on the horizontal
kit. Please ask for details. Never use a flue system which is not specifically approved for use with this appliance.
The horizontal pipe may be cut down to the length required. The flue must be fitted with a .2° or 3° downwards incline to prevent any water or condensation from entering in the boiler.
Where a short run of less than 1 m is used, such as in a caravan holiday home, the air restrictor ring
must be inserted into the boiler flue spigot before fitting the elbow.
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Before commissioning the appliance, the whole gas
installation including the meter (if fitted) MUST be
purged and tested for gas soundness.
IMPORTANT: open all doors and windows, extinguish naked lights, and DO NOT SMOKE whilst
purging the gas line.
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
cause the boiler to fail.
6.1 DOMESTIC HOT WATER
Turn on the DHW isolation valve.
Fill and vent the installation by turning on the various
hot water taps in the installation
Make sure that there are no leaks in the installation.
6.2 CENTRAL HEATING CIRCUIT
In order for the boiler to function correctly, the pressure in the central heating circuit must be between
0.8 and 1.6 bar when cold.
Both the boiler and the central heating installation
must be purged of any air in the water pipes which
may cause noise and the incorrect functioning of the
system.
The boiler is fitted with an automatic air vent.
In order to fill the installation correctly the following
sequence must be followed:
- Open one or more radiator bleed vent screws.
- Fill the central heating circuit using the approved
method given in section 4.8
- Turn off each of the air vents as water starts to
appear from them.
- Turn off the filling tap when the pressure gauge
exceeds 1.6 bar.
- Turn the main control switch to the winter setting,
making sure that the pump runs. The pump will not
run if there is insufficient pressure.
- Vent the central heating circuit once more. Then let
the pressure in the circuit settle at 1.6 bar. If necessary open the pressure relief valve to reduce the
pressure in the system.
- Make sure that there are no leaks in the installation.
6.3 GAS CIRCUIT
Purge the gas circuit as described above. Turn on
the gas cock to the installation and check that there
are no leaks using leak detection fluid.
6.4 SETTINGS
Before leaving the factory the boiler is pre-set in
accordance with the information on the data plate,
and therefore needs no further adjustment.
6.5 INITIAL OPERATION
6.5.1 Preliminary warnings
- Make sure that the central heating circuit is
completely full and vented. The pressure gauge
should indicate a pressure of between 0.8 and 1.6
bar.
- Make sure that the air intake and the flue outlet are
not blocked.
6.5.2 Domestic hot water service
To turn on the boiler turn the main control switch on
so the green light shows The boiler is then ready to
supply D.H.W. on demand.
Whenever a hot tap is opened the boiler automatically fires up to deliver hot water. The temperature
selector control should be set at maximum. If the
ambient water temperature is high (as in a hot climate) then the hot water temperature may be
reduced by using this knob.
6.5.3 Hot water and central heating service
Set the tappets on the time clock to an on position
and the main control switch on so the green light is
on. The room stat (if fitted) to max temp. Then turn
the central heating selector clockwise. The boiler will
fire up. By means of the central heating temperature
selector control knob, any water temperature of
between 60 and 85°C may be selected. The boiler
will remain on until the temperature selected on the
room thermostat or on the boiler itself is reached.
Whenever there is a demand for D.H.W. on the central heating setting, the boiler is ready to supply it giving priority to the D.H.W. with the central heating on
standby until the D.H.W. demand ceases.
6.5.4 Turning the boiler off
- Turn the main control switch to the O setting.
- Turn off the gas supply to the boiler.
6.5.5 Appliance safety lock-out
This boiler has a cut-out indicator built in to it.
Whenever a malfunction is detected, the boiler
switches off automatically and the indicator lights up
6.- COMMISSIONING INSTRUCTIONS
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To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a
year should be adequate.
It is the law that any service work must be carried out
by registered personnel (C.O.R.G.I.).
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 detailed below.
MINIMUM CLEARANCE REQUIRED FOR SERVICING AND REPLACEMENT OF PARTS
* Distance at the side
The minimum distance necessary for carrying out
maintenance operations, is 5 mm
* Distance at the top
The minimum distance necessary for carrying out
maintenance operations, is 200mm
* Distance at the bottom
The minimum distance necessary for carrying out
maintenance operations, is 250 mm.
* Distance at the front
The minimum distance necessary for access during
maintenance operations, is 250mm, although this
distance may be reduced to 5 mm, as long as a door
is installed which can be removed when it comes to
carrying out maintenance work.
FRONT COVER REMOVAL
(red pilot light).
To restart the boiler Set the main control on the
position and then turn it back to the chosen position.
The red indicator should go out.
IMPORTANT: Whenever the boiler has been left idle
for any length of time, or when a new gas bottle is
installed (propane models), the appliance may switch
off due to the presence of air in the pipes. In cases
such as these, the main control switch may be turned
to position several times until all the air is
expelled.
6.6 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 time clock and/or room stat (if fitted) are set to the required setting (s).
6.7 USER’S INSTRUCTIONS
Upon completion of testing the system, the installer
should:
- 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 on the efficient use of the system,
including the use and adjustment of all system controls for both D.H.W. and C.H.
- Advise the user of the precautions necessary to
prevent damage to the system, and to the building, in
the event of the system remaining inoperative during
frost conditions.
- Explain the function of the boiler lock-out devices,
and how to reset it. Emphasise that if cut - out persists, the boiler should be turned off and the installer
or service engineer consulted.
- Stress the importance of an annual service by a
CORGI registered heating engineer.
7.- ROUTINE SERVICING INSTRUCTIONS
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The cover is held in place by four spring clips and can
be removed by grasping it at the top and pulling forward sharply to release.
Further access can be gained by removing the control panel. (Four screws), and moving down the electronic box.
BURNER AND HEAT EXCHANGER
INSPECTION AND CLEANING
The front of the sealed air box must first be removed
(8 screws) and care should be taken to avoid damaging the seal. The combustion chamber cover can
then be removed (6 screws) and gas connections
taking care not to damage the delicate insulation
material inside.
Inspect the burner and heat exchanger fins for debris
and soot. Check also for rubbish below the burner.
IGNITION AND DETECTION ELECTRODES
With the combustion chamber cover removed check
the condition of the electrodes for any sign of wear or
damage.
WATER CIRCUIT CHECKS
Inspect the pipe work inside the boiler for leaks.
Check that the pressure in the system is correct (0.8
to 1.6 bar). Check the operation of the relief valve by
turning ¼ turn and check it closes without further
leakage.
Check the correct operation of the gauge. The pressure should increase slightly as the temperature
rises. Finally check the filters which is situated in the
cold water inlet pipe
BURNER PRESSURE
This is factory set, but should you suspect a problem
proceed as follows: There is an easily accessible
burner pressure nipple on the gas feed pipe, between
the burner and the modulating gas valve.
The burner pressure nipple should give a reading of
35 mbar when the boiler is at full power on D.H.W.
mode. Remove the main cable plug to the gas valve
to get a minimum burner pressure reading which
should be 4,4 mbar.N.B. There is a logic program
built into the central heating enabling it to detect
when it is connected to a small system. This may prevent the burner from firing on full (max press) so
ensure burner pressure is only tested in DHW mode.
FINAL CHECKS
Turn all the controls to their max position so that the
appliance begins to function. Check for gas leaks
using a suitable detector.
Check the boiler functions correctly in both central
heating and domestic hot water modes. The green
light will start flashing when the boiler is firing in either
mode.
8.- TROUBLESHOOTING
The FEB-24E has a self diagnostic system built into
its printed circuit board. Should a safety related, or
various other faults occur, then the boiler will failsafe
by locking out, which is indicated by the red neon on
the control panel.
The fault can be identified by the different sequences
in which the red neon flashes and the duration the
neon stays illuminated. The electronic failsafe is also
backed by a mechanical means of protection, should
the electronics fail to detect a fault. These mechanical forms of protection will protect and ensure the
safe shutdown of the boiler.
The software protection built into the P.C.B. will run a
system check on components which are essential to
the safe operation of the boiler. This occurs before
any ignition sequence takes place. If any component
is found to be faulty or out of a predetermined range,
then lockout will be displayed.
FAULT CODES:
Each fault code begins and finishes with the red neon
illuminated for 5 seconds, the relevant fault is then
indicated by the number of 1 second flashes which
occur between the 5 second illuminations. These
range from none to 12 flashes. Please be patient
when counting the sequence as the correct identification of the fault will save time on isolating and rectifying the problem.
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CODE
DESCRIPTION FAULT
0
Repeating 5 second
flashes only with no 1
second flashes
Lack of gas or ignition problems
Flame supervision failure
Burner on but flame indicator off
Minimum burner pressure too low
1
One 1 second flash
Air pressure switch failure / Fan failure
2
Two 1 second flashes
Water Pressure below 0.7 bar
3
Three 1 second flashes
Hi limit thermostat failure
4
Four 1 second flashes
Printed circuit board failure
5
Five 1 second flashes
Flame supervision failure, indicator light on,
burner off
6
Six 1 second flashes
Water overheating
7
Seven 1 second flashes
Control panel failure
9
Nine 1 second flashes
Gas valve control circuit failure
10
Ten 1 second flashes
Domestic hot water thermistor failure
12
Twelve 1 second
flashes
Central heating thermistor failure
EXAMPLES:
Fault 4, P.C.B. failure, would display the following sequence of the red neon:
5 seconds 1 sec
1 sec 1 sec 1 sec 5 seconds
N.B. The sequence repeats itself until either the reset button is depressed or the fault is rectified. Some faults
require the component temperature to return to within operating range before reset. Also some faults may
take up to 3 minutes before lockout is displayed. E.G. Fan failure/ water overheating.
12/7/04
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For more detailed servicing information, workshop manuals, technical advice,
24/06/05 N51J017F7
spare parts, product training, please phone us on 01482 325456 or contact us at the
address below. Our qualified C.O.R.G.I. registered personnel are ready to help and
advise you.
MORCO PRODUCTS LTD, MORCO HOUSE,
RIVERVIEW RD, BEVERLEY HU17 OLD
TEL:01482 325456 FAX:01482 212869 EMAIL: SALES@MORCO
WEBSITE: WWW. MORCOPRODUCTS.CO.UK
PRODUCTS.CO.UK
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