morco GB 24 ErP Series II User guide

Download

GB24 ErP & GB30 ErP

Series II

User & Installation Instructions

BOILER OUTPUT

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)

off

reset

mode

max

min

preheat

min

statusburner

max

preheat

Series IIGB24

To Central Heating:

GB24/30 Minimum 8.0 kW (27,296 Btu/h) GB24/30 Maximum 24.2 kW (82,570 Btu/h)

UIN 212134 A05 April 2017

Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD

Morco Products Ltd

Tel: 01482 325456 Fax: 01482 212869 Website: www.morcoproducts.co.uk

ERP DATA

MODEL

SYMBOL UNITS 24 30

Condensing Boiler n/a n/a yes yes

Low Temperature Boiler n/a n/a no no

B1 Boiler n/a n/a no no

Cogeneration Space Heater n/a n/a no no

Equipped with a Supplementary Heater n/a n/a no no

Combination Heater n/a n/a yes yes

Nominal Heat Output for Space Heating

Full Load P

Part Load P

Auxiliary Electricity Consumption

Full Load el

Part Load el

Standby P

Seasonal Space Heating Energy Efciency

Full Load

Part Load

Standby Loss P

Ignition P

4 kW 24.3 24.3

1 kW 8.0 8.0

max kW 0.042 0.031

min kW 0.012 0.013

SB kW 0.005 0.005

stby kW 0.050 0.050

ign kW 0 0

% 90.0 90.0

% 98.7 98.7

Emissions NO

Annual Energy Consumption Q

Sound Power Level, Indoors L

Domestic Hot Water

AEC kWh 16 16

AFC GJ 6 6

x mg/kWh 26 26

HE GJ 75 75

WA dB 45 46

PRODUCT FICHE

MORCO COMBINATION BOILER

Morco Products Ltd

ERP DATA

SYMBOL UNITS MODEL

24 30

Condensing boiler Yes Seasonal Space heating efciency class A Rated heat output kW 24

Seasonal space heating energy efciency

Annual energy consumption Q Sound power level, indoors L Water heating energy efciency class A

Seasonal Space Heating Energy Efciency of the Boiler *%

Temperature control (from che of temperature control) %

Class I Class II Class III Class IV Class V Class VI Class VII Class VIII

1% 2% 1.5% 2% 3% 4% 3.5% 5%

ƞs

HE GJ 76

WA dB 45 46

% 94*

Solar Contribution (from che of solar device)

Collector Size

(in m2)

= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x =

Seasonal Space Heating Energy Efciency of Package

Seasonal Space Heating Energy Efciency Class of Package

Tank Volume

(in m3)

Collector

Efciency

(in %)

Tank rating

A* = 0.95

A = 0.91 B = 0.86 C = 0.83

D-G = 0.81

TOTAL: A+B+C=

GG F E D C B A A+ A++

< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%

The energy efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a building, as the efciency is inuenced by further factors such as heat loss in the products in relation to the building size and its characteristics

 

A+++

Morco GB24 & GB30 Series II

Combination Boiler

Destination Country:

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

CONTENTS

SECTION PAGE

1 Users Instructions ..........................................................................................................................................6

2 General Specications ...................................................................................................................................10

3 Technical Data ...............................................................................................................................................12

4 General Installation Requirements.................................................................................................................14

5 Installation Instructions ..................................................................................................................................16

6 Commissioning Instructions ...........................................................................................................................25

7 Routine Servicing Instructions .......................................................................................................................27

8 Fact Sheets ....................................................................................................................................................33

9 Fault Codes....................................................................................................................................................34

10 Combustion Ratio Check ...............................................................................................................................36

11 Warranty ........................................................................................................................................................38

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

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

Due to the high efciency of the boiler, condensate is produced from the ue 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 ue terminal.

The Morco GB Series II is a combination boiler providing both central heating and instantaneous domestic hot water.

Safety

Current Gas Safety (Installation & Use) Regulations or rules in force.

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.

In other countries the installation must be carried out by a qualied

and competent Gas Installer. In the approved country the boiler is installed, this must be in accordance with their current rules in force.

It is essential that the instructions in this booklet are strictly followed,

for safe and economical operation of the boiler.

Electricity Supply

This appliance must be earthed.

Supply: 230 V ~ 50 Hz. The fusing should be 3A.

Minimum Clearances

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.

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.

To light the boiler. Refer to Boiler Controls

1. CHECK THAT THE ELECTRICITY SUPPLY TO BOILER IS OFF.

2. Set the mode knob control (A) to ‘Off’.

3. Set the Domestic Hot Water temperature control (B) and

Central Heating temperature control (C) to ‘max’.

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

5. Switch ON electricity to the boiler and check that all

controls, e.g. timer and room thermostat, are ON (refer to mechanical timer instructions - Page 8).

6. Set the mode knob control to winter (

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

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

Important Notes

 This appliance must not be operated without the casing correctly

tted 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 qualied and

competent Gas Installer.

 Under NO circumstances should any of the sealed components on

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 qualied 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.

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 ve attempts the fault

code

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 qualied and competent Gas

Installer.

will be displayed.

SECTION 1 - USERS INSTRUCTIONS

Operation

Winter conditions - i.e. CH and DHW required.

Ensure the mode knob control (A) is set to winter ( )

The boiler will re and supply heat to the radiators but will give

priority to DHW on demand.

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 briey as a self-check once every 24

hours, regardless of system demand.

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.

Control of water temperature

Domestic Hot Water

The DHW temperature is limited by the boiler controls to 64oC maximum at low draw-off rate, adjustable via the DHW temperature control (B).

Due to system variations and seasonal temperature uctuations DHW ow rates/temperature rise will vary, requiring adjustment

at the draw off tap : the lower the rate the higher the temperature, and vice versa.

Approx. ow temperatures for the boiler thermostat settings are:

Knob Setting Flow Temperature

Minimum 40oC (104oF)

Maximum 64

C (147oF)

To shut down the boiler

Set the mode knob control to OFF

To relight the boiler

Repeat the procedure detailed in ‘To light the boiler’.

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:

- Turn off the cold water supply

- Open all hot and cold water taps

- Open all drain plugs in the hot and cold water system (do not

drain the central heating circuit, which should have been lled with antifreeze if installed in a caravan holiday home or park

home).

Refer to the Holiday Home or Park Home owner’s handbook for the drain plug positions and further instructions on draining down.

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.

When installed in a Caravan Holiday Home or Park Home the

heating circuit and radiators should be lled 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.

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

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).

The boiler is a high efciency combination boiler which is most efcient when operating in condensing mode.

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

BOILER CONTROLS

Legend

A. Mode Control Knob B. DHW/Preheat Control Knob C. CH Control Knob D. Boiler Status E. Burner ‘on’ Indication F. Pre Heat on/off Indication G. Mechanical Timer H. Pressure Gauge J.K.Condensate Drain

Gas Isolation Valve (on position shown)

off

A B C D

ALL FROST DAMAGE IS OUTSIDE OF THE WARRANTY.

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.

Refer to fault chart.

Flame Failure

Should this occur a fault code will be displayed. Refer to fault chart.

continued . . . . . .

status burner

max

min

reset

mode

preheat

min

max

1 3

1 2

1 1

preheat

Series IIGB24

SECTION 1 - USERS INSTRUCTIONS

PRESSURE GAUGE

1 1

1 2

1 3

1 6

preheat

min

max

mode

reset

off

status burner

max

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 qualied and

competent Gas Installer should be consulted.

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.

Condensate Drain

This appliance is tted 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 qualied and competent Gas

Installer for assistance.

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.

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 ow. 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 identied as closely as possible before

taking further action.

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.

3. Caution when using warm water as this may freeze and cause other localised hazards.

Once the blockage is removed and the condensate can ow

4. freely, reset the appliance. (Refer to “To Light the boiler”)

If the appliance fails to ignite, call your Gas Safe Registered Engineer,

or in other countries a qualied and competent Gas Installer.

Preventative solutions

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 ame.

Cleaning

For normal cleaning simply dust with a dry cloth.

To remove stubborn marks and stains, wipe with a damp cloth

and nish 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 qualied and

competent Gas Installer.

MECHANICAL 24 HOUR TIMER

PROGRAMMING THE TIMER

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.

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.

Permanent Override

By rotating the central switch so that the symbol ( time indicator ( ) the unit will be permanently ON.

With the symbol (

) lining up with the time indicator ( ) the unit acts as

a timeswitch.

With the symbol (

) lining up with the time indicator ( ) the unit will be

permanently OFF.

1) lines up with the

Permanently OFF

OFF segment

ON segment

24hr Programme Ring

Timer Control

Permanently ON

Time & Control Indicator

1 3

Timer control segments 1 Segment = 15 mins Push towards programme ring = OFF Push away from programme ring = ON

SECTION 1 - USERS INSTRUCTIONS

POINTS FOR THE BOILER USER

Note. In line with our current warranty policy we would ask that you check through the Troubleshooting guide to identify any problems

external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.

TROUBLESHOOTING

NO HOT WATER

Check the mains switch (fused

spur) is turned on and ensure

switch mode control knob (A) is

in the summer or winter position

Is water coming out of the hot

water tap when turned on?

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 qualied and

competent Gas Installer, if out of

warranty.

Contact a Gas Safe Registered

Engineer, or in other countries

a qualied and competent Gas

Installer.

NO CENTRAL HEATING

Check the mains switch (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 operate and

provide central heating?

YES

Check the time settings on the

programmer are as you require

and adjust if necessary

See boiler “Operation Modes” and

“Fault Codes” section. If “0” is

displayed then contact a Gas Safe

Registered Engineer, or in other

countries a qualied and competent

Gas Installer.

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

Does the boiler have a display

showing on the front control

panel?

YES

See boiler “Operation Modes”

and “Fault Codes” section

Contact a Gas Safe Registered

Engineer, or in other countries

a qualied and competent Gas

Installer.

OPERATION MODES

DISPLAY CODE ON BOILER

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”.

SECTION 2 - GENERAL SPECIFICATIONS

1 Expansion Vessel 2 Pump 3 Auto Air Vent 4 Water Pressure Switch 5 Flow Thermistor 6 Return Thermistor 7 Divertor Valve 8 Fan 9 Venturi 10 DHW Plate Heat Exchanger 11 Ignition Electrode 12 Flame Detection Electrode 13 Gas Valve 14 Siphon / Trap 15 DHW Flow Turbine 16 System Pressure Gauge 17 Sump Cover

Schematic Diagram

2.1 GENERAL SPECIFICATIONS

The Morco GB Series II range of boilers are wall mounted, full sequence, automatic spark ignition low water content, fanned

ue, high efciency condensing combination boilers.

Note. Due to the high efciency of the boiler a plume of water

vapour will format the terminal during operation. The boiler is supplied for use with Propane only at 37mbar (30 mbar for DE) supply pressure. It is particularly suitable for caravan holiday home and park home use.

Maximum heat output in either heating or hot water for the GB24 is 24.2kW (82,570 Btu/hr)

Maximum heat output in heating mode for the GB30 is 24.3 kW (82,570 Btu/hr) with 30.3 kW (103,384 Btu/hr) available for hot water production.

The boiler can be supplied with a standard concentric ue with additional extensions, ue deector and vertical ue kits available as optional extras. The only ueS that can be tted are those

detailed in this instruction manual.

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.

The boiler contains the following components:

Cast Aluminium Heat Exchanger Domestic Hot Water Plate Heat Exchanger Diverter Valve Circulating Pump Pressure Gauge Safety Valve and Central Heating Expansion Vessel Automatic Bypass Daily Pump and Diverter Valve Exercise Mechanical 24hr Timer

The boiler temperature controls are visible, located in the control panel. These enable the user to control both CH and DHW temperatures independently. There is the additional feature of a DHW preheat facility. Operating and fault codes are displayed on the status panel.

SECTION 2 - GENERAL SPECIFICATIONS

Turbine

2.2 WIRING DIAGRAM

Fused

at 4AT

1 2 3 4

Timer

X1A

X1BX1CX2X3

brb

y/g

23456123451234568 79

Main

Supply

Stat

Room

Plug

Pump

y/g

Earth

Divertor

Gas

Spark

Electrode

Valve

y/g

bk b

v br

y/g

Spark

Generator

y/g

PCB

- blue

- black

- brown

- red

bbkbrrpyw

KEY

- pink

- yellow

- white

- yellow/green

- grey

- orange

- violet

y/ggor

X13

X5X6X8

y/g

123

12345123456789

y/g

Flame

Sensor

Electrode

b br

Fan

1234123456

1011

p y

Return

Thermistor

Service

Connector

Flow

Thermistor

Water

pressure

Flow

Water

Switch

SECTION 3 - TECHNICAL DATA

Table 1 General Data

Morco GB Series II

Gas Supply I

Gas Supply Connection 15mm copper compression

Injector Size (mm) 3.75 3.75

Inlet Connection Domestic Hot Water G ½

Outlet Connection Domestic Hot Water G ½

Flow Connection Central Heating G ¾

Return Connection Central Heating G ¾

Flue Terminal Diameter mm (in) 100 (4)

Average Flue Temp-Mass Flow Rate DHW 63ºC - 11g/s 68ºC - 13 g/s

Maximum Working Pressure (Sealed Systems) bar (lb/in

Maximum Domestic Hot Water Inlet Pressure bar (lb/in

Minimum Domestic Hot Water Inlet Pressure* bar (lb/in

) 2.5 (36.3)

) (kPa) 10.0 (145) (1000)

) (kPa) 0.8 (11.6) (80) 1.3 (18.9) (130)

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 ow rate. Boiler operates down to 2 l/min DHW delivery

24 30

- G31 - 37mbar (30mbar for DE)

Table 2 - Performance Data - Central Heating

Boiler Input : Max. Min. 24 30 24 30

Boiler Input ‘Q’ Nett CV kW 24.3 24.3 8.0 8.0

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

Gross CV kW 26.4 26.4 8.7 8.7

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

Gas Consumption m

kg/hr 1.83 2.26 0.58 0.58

Boiler Output :

Non Condensing kW 24.2 24.3 8.00 8.00

C Mean Water temp. Btu/h 82,570 82,570 27,296 27,296

Condensing kW 25.6 25.6 8.5 8.5

C Mean Water temp. Btu/h 87,347 87,347 29,002 29,002

Seasonal efciency* SEDBUK 2005 91% 91.1%

/h 1.00 1.25 0.329 0.329

/h 35.33 44.20 11.62 11.62

Table 3 - Performance Data - Domestic Hot Water

Maximum DHW Input : 24 30

Nett CV kW 24.3 30.4

Btu/h 82,912 103,725

Gross CV kW 26.4 33

Btu/h 90,077 112,596

Gas Consumption m

kg/hr 1.83 2.26

Maximum kW 24.2 30.3

DHW Output Btu/h 82,570 103,384

DHW Flow Rate l/min 9.9 12.4 at 35°C temp. rise. gpm 2.2 2.8

DHW Specic Rate l/min 11.5 14.5

gpm 2.5 3.2

/h 1.00 1.25

/h 35.33 44.20

Seasonal efciency* SEDBUK 2009 89% 89%

NOx Classication CLASS 5

* The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from

which it has been calculated have been certied by a notied body.

Note. Gas consumption is calculated using a

caloric value of 95.65 MJ/m3 (2569 Btu/ft3) gross or 88.0 MJ/m3 (2,360 Btu/ft3) nett

To obtain the gas consumption at a different

caloric value:

a. For l/s - divide the gross heat input (kW) by

the gross C.V. of the gas (MJ/m

b. For ft

/h - divide the gross heat input (Btu/h)

)

by the gross C.V. of the gas (Btu/ft3)

c. For m

/h - multiply l/s by 3.6.

Key to symbols

PMS = Maximum operating pressure of water

= A room sealed appliance designed for connection via ducts to a horizontal

13 C33

or vertical terminal, which admits fresh air to the burner and discharges

the products of combustion to the outside through orices which, in this

case, are concentric. The fan is up stream of the combustion chamber.

= An appliance designed for use on 3rd Family gas, Group P only.

SECTION 3 - TECHNICAL DATA

DATA PLATE

3952.5

2.5

from case

700

Side

flue

dim. A

285

86.5

155

CH FLOW

DHW OUTLET

COND. DRAIN

GAS INLET

DHW INLET

CH RETURN

PRV

43.5 65

28.5 28.5

60.6 75 37.556.4

Underside View - Dimensions to Wall

W A L L

103 99

99 103

BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler bulkhead ttings.

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 ue hole is cut accurately, e.g. with a core

boring tool or hole cutter the ue can be installed from inside

the dwelling where wall thicknesses do not exceed 600mm

(24”). Where the space into which the boiler is going to be

installed is less than the length of ue required the ue must be tted from the outside.

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 ue to the aluminium ue collar (RSF 060).

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 ue lengths requiring “D” pack extensions (RSF 341), the ue must incline by 26mm per 1 Metre of ue length.

SECTION 4 - GENERAL INSTALLATION REQUIREMENTS

0.6m

Zone 0

Recessed window Zone 2

Ceiling

3G8913a

2.25m

Zone 1

4.1 RECOMMENDATIONS

Current Gas Safety (Installation and Use) Regulation or Rules in Force.

The boiler is suitable only for installation in the specied countries

and should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a Gas Safe

Registered Engineer, or in other countries a qualied 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 Specication for the installation of LPG

Systems for habitation purposes in leisure accommodation vehicles and other road vehicles.

IMPORTANT

The manufacturer’s notes MUST NOT be taken, in any way as overriding statutory obligations.

4.2 BOILER LOCATION

The boiler must be installed on a at and vertical wall, capable of

adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be tted 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 tted 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.

COMPARTMENT INSTALLATIONS

A compartment used to enclose the boiler should be designed and constructed specially for this purpose.

An existing cupboard or compartment may be used, provided

that it is modied for the purpose.

• The position selected for installation MUST allow adequate space for servicing in front of the boiler.

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 specied in the table below.

For Caravan Holiday Homes; if the height of the ue terminal

from any ground, decking or steps is under 1.5m then a suitable

terminal guard should be tted.

For Residential Park Homes, please refer to BS 5440 Part 1.

Terminal Guards are available from boiler suppliers.

TFC Flue Guard - Model K6 Round Plastic Coated.

www.tfc-group.co.uk

Table 4 - Balanced Flue Terminal Position

Flue Terminal Positions

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. 25mm ( 1”)* BS5440-1 2008 75mm (3”)

3. Below eaves. 25mm (1”)* BS5440-1 2008 200mm (8”)

4. Below balconies or a car port roof. 25mm (1”)* BS5440-1 2008 200mm (8”)

5. From vertical drain pipes or soil pipes. 25mm (1”)* BS5440-1 2008 150mm (6”)

6. From an internal or external corner or to a 25mm (1”)* boundary along side the terminal. BS5440-1 2008 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. 300mm (12”)

Vertical Terminals

13. Above the roof pitch with roof slope of all angles. 300mm (12”)

Above at roof. 300mm (12”)

14. From a single wall face. 300mm (12”) From corner walls. 300mm (12”)

15. Below velux window 2000mm (79”)

16. Above or side of velux window 600mm (24”)

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

Min. Spacing*

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-tted with a 3 amp fused approved moulded 3 pin plug and ying lead, for use with 230V 50Hz.

The plug should be used with an unswitched/shuttered socket outlet complying with BS1363.

4.6 GAS SUPPLY

A propane gas supply at 37mbar is required (30 mbar for DE).

Ensure that regulator is of sufcient capacity to carry the

maximum boiler input plus the full demand for any other installed appliances.

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 sufcient size to prevent a pressure drop greater than 2.5mbar between the nal pressure regulator to

the caravan holiday home or park home and all appliances when the installation is subjected to the anticipated maximum load.

IMPORTANT

The complete installation MUST be tested for gas soundness.

4.7 CONDENSATE DRAIN

A condensate drain is provided on this boiler.

The drain MUST be connected to an approved drainage point.

All pipework and ttings MUST be made of plastic. No other

materials may be used.

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 tted to both central heating and DHW ow and return

connections from the boiler before connection to any plastic piping.

Central Heating System

IMPORTANT - The sealed central heating system must be lled

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.

4.9 REQUIREMENTS FOR SEALED WATER

SYSTEMS

At maximum CH output 24.2kW at a 20ºC differential and ow 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 tted with lockshield valves only.

A sealed system MUST only be lled by a competent person using an approved lling loop (or other approved method) between the

mains water supply pipe and the central heating return pipe.

Once used, the lling loop should be disconnected and capped off.

4.10 EXPANSION VESSEL

The boiler is tted with an 8 litre expansion vessel which is sufcient for a cold ll capacity of up to 143 litres.

For other system volumes refer to table below.

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume Expansion vessel (litres) volume (litres)

25 1.6 1.8 50 3.1 3.7 75 4.7 5.5 100 6.3 7.4 125 7.8 9.2 150 9.4 11.0 175 10.9 12.9 190 11.9 14.0 200 12.5 14.7 250 15.6 18.4 300 18.8 22.1

For other system volumes multiply by the factor across 0.063 0.074

4.11 PRESSURE RELIEF VALVE

A pressure relief valve set at 3 bar is tted 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 tted if above 10 bar.

In areas of low mains water pressures the domestic hot water

regulator may be removed (by a suitably qualied person). The boiler will require the ow 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 tting of a scale reducing device is recommended

(with the requirements of the local water company).

The use of articially softened water, however, is not permitted.

The boilers are suitable for connection to most types of washing machine and dishwasher appliances.

SECTION 5 - INSTALLATION INSTRUCTIONS

5.1 BOILER PACKAGING

The boilers are supplied in different packagings:

• Boiler

• Flue System (separate)

• Hardware Pack (separate)

5.2 FITTING/MOUNTING THE BOILER

Decide where the boiler is to be xed 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 tted into a top slot.

Example of fixing

2. Lift the boiler onto the wall mounting plate, locating it over the two tabs.

5.4 INTERNAL WIRING

The boiler has been pre-tted with a 3 amp fused approved moulded 3 pin and ying lead for use with 230V 50Hz.

If the supply cord is damaged, it must be replaced by the

manufacturer, its service agent or similarly qualied persons in order to avoid a hazard.

The plug should be used with an unswitched/shuttered socket outlet complying with BS1363.

The boiler comes pre-tted 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.

ROOM THERMOSTAT - WIRING

To t a room thermostat proceed as follows:

1. Ensure that the electrical supply to the boiler is isolated before proceeding.

Cable Clamp

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.

2. Remove the two screws beneath the ap on the front of the

boiler and lower the front panel.

3. Remove the pre-tted 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 ap.

8. Check operation of room stat if possible.

ROOM STAT/ TIMER

230VAC Feed

230VAC Return

Room Stat

SECTION 5 - INSTALLATION INSTRUCTIONS

CH FLOW

DHW OUTLET

COND. DRAIN

GAS INLET

5.5 WATER AND GAS CONNECTIONS

Ensure all boss blanking plugs are removed before making any connections.

Each valve must be tted 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 bre washer is used on the CH ow 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.

Ensure a safe discharge point using temperature and pressure resistant materials.

DHW INLET

CH RETURN

PRV

5.6 AIR / FLUE SYSTEMS

The ue system is part of the appliance and is approved as such. Only use the ue systems supplied by Morco.

The standard ue kit (RSF303) for the Morco GB range is a 600mm as shown below. There is also a 900mm kit available (RSF305).

Turret

100

600

The minimum cut length is 138mm (includes 30mm into elbow)

The maximum allowable length using extensions (RSF341) is:

GB24 Series II - 8m (minus any ue kit options)

GB30 Series II - 7m (minus any ue kit options)

Part No. RSF303

SECTION 5 - INSTALLATION INSTRUCTIONS

WALL

Aluminium Flue Collar (RSF 060)

Fill with sealant

17mm min

Internal Sealing

Flubber

Fill with sealant

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 ue incorporating a terminal

and inner rubber wall seal.

Extension Kit RSF341 - contains: 1 metre length of ue pipe (Functional length 950mm), 1 support bracket.

When extension kits are used the ue 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 tted 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 ue kit terminal is classed as part of the maximum ue length.

Once the ue is installed it is IMPORTANT that the white air duct protrudes from the aluminum ue collar (RSF 060) by at least 17mm. The gap between the aluminium ue collar (RSF 060) and the white air duct MUST be sealed with sealant to create an adequate seal.

It is IMPORTANT that all attachments are tted 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 Deector Kit (RSF300) The resistance is the equivalent of 1 metre of ue pipe and therefore must be deducted from

any maximum ue 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 ue collar (RSF060))

24 kW appliances Total Maximum: 8 metres - minus any ue kit options 30 kW Appliances Total Maximum: 7 metres - minus any ue 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 ue collar (RSF060))

Rear Flue - 191mm

Side Flue - 236mm (with minimum 2.5mm clearance)

SECTION 5 - INSTALLATION INSTRUCTIONS

5.8

DETERMINING THE FLUE LENGTH

FIGURE 1

REAR FLUE

Cut ue length = distance from edge of turret to outside of

wall dimension A + 47mm.

Note. Minimum dimension A which can be accommodated is 91mm.

REAR

Fit

to wall

WALL

SIDE FLUE

Cut ue length = distance from edge of turret to outside of

wall dimension B + 47mm.

Note. Minimum dimension B which can be accommodated is 136mm (with minimum clearance of 2.5mm).

SIDE

Fit

to wall

WALL

Minimum clearance 2.5mm

Flue length measured from outer terminal lip

NOTES

Centre of turret to edge of turret = 100mm Turret has a ue insertion of 30mm The white outer ue tube must protrude the wall by 17mm. From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm

to end of outer ue

5.9 CUTTING HORIZONTAL FLUE TERMINAL RSF303 (600MM LONG)

1. Measure from the outer terminal lip to end of outer ue. Mark the

required cut length (A or B + 47mm) around the circumference of the

outer ue 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.

4. Remove all burrs and place a light chamfer on the outer edge to aid assembly.

10mm

Mark cut length =

A or B + 47mm from terminal lip

A or B + 47mm

SECTION 5 - INSTALLATION INSTRUCTIONS

Flue Outlet

A - Duct Assembly B - Flue Turret C - Turret Clamp D - Seal

Flue Outlet

Retaining screw

Clamp Lugs

Sample points

WALL

Aluminium Flue Collar (RSF 060)

Fill with sealant

17mm min

Internal Sealing

Flubber

Fill with sealant

5” hole

5.10 INSTALLING THE FLUE

FITTING FLUE THROUGH THE WALL

1. Ensure the seam and the outlet terminal are

at the top and tted as shown.

2. Once the ue is installed it is IMPORTANT

that the white air duct protrudes from the

aluminium ue collar (RSF 060) at least

17mm.

Note. If less than 50% of the length of the ue is

internal the ue should be tted from outside.

3. Fit the internal sealing ubber to the ue

(leave loose) and check protrusion externally of the white air duct is 17mm.

4. Fit the turret as below

FITTING THE TURRET - Ensure the condensate trap / siphon is lled with water

1. Ensure the rubber seal is tted correctly on the appliance manifold and that all ue seals are undamaged.

2. Hold the ue rmly and push the turret on until it has travelled 30mm on to the ue pipe and is fully engaged. Make sure the

ue has not rotated or moved forward during tting and the ue seam is upper most.

3. Push the turret into the manifold ensuring the upper plastic lip is ush with the top of the manifold.

4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret ange.

5. Secure clamp to appliance using securing screw.

6. Ensure all sample points are accessible and all sample plugs and caps are tted.

7. Fully engage the ue into the turret and slide internal ubber to wall.

8. The gap between the aluminium ue collar (RSF 060) and the white air duct MUST be sealed with sealant to create a seal.

SECTION 5 - INSTALLATION INSTRUCTIONS

Flue Deector

WALL

115

5.11 FLUE EXTENSIONS (RSF341) - OPTIONAL

INNER PIPE ASSEMBLY INSTRUCTIONS

1. Make sure that ‘top hat’ on the collar (A) ts over the

rectangular form on the inner plastic pipe (B).

A B

Top Hat

Rectangular

2. Ensure that the at base of the collar (C) is

positioned on the bottom lip of the pipe (D).

For side outlet refer to section 1.2 before connecting.

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.

4. When tting support brackets (F) make sure they are

positioned on the female side of the neck as shown.

5.12 FLUE DEFLECTOR KIT (RSF300) - OPTIONAL

The ue deector elbow can be tted to the ue outlet of the standard terminal kits RSF303 or RSF305 to deect the ue products horizontally

to the left or the right only.

1. Refer to the boiler Installation and Servicing Instructions for tting of the boiler and its ue system.

Note. The resistance of the deector is equivalent to 1 metre of ue

length. Ensure this is used when calculating the maximum allowable

ue length.

2. Choose the direction required to deect the ue products (horizontally left or right only).

3. Push the deector elbow onto the angled ue outlet of the terminal in the desired position and ensure the deector is pushed up to the

shoulder to fully engage the rubber seal. Drill the terminal through

the hole in the deector with a 3.2mm (1/8") drill and secure the deector with the self tapping screw provided.

Note. Only use water as a lubricant during assembly. Do not use mineral based oils.

5.13 90º KIT RSF315 (OPTIONAL)

This optional kit can be used on both horizontal and vertical ue kits

1. Use dimensions below for calculating total length

2. When cutting extensions or ue kits always allow

sufcient (+ 30mm air duct + 14mm ue duct) to allow for correct engagement in the tting

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.

SECTION 5 - INSTALLATION INSTRUCTIONS

5º & 14º

MAX LENGTH:

7.5m**

MIN LENGTH:

0.950m

Flue Terminal

RSF050

14º

RSF050

5º

Assembly A

Vertical connector

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 ue to run vertically from the top of the boiler and

terminating above roof level.

Connection to the top of the boiler is made using a vertical connector (supplied in the kit - RSF346).

WEATHER PROOFING

Where the ue 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 ue 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.

5.15

ASSEMBLING THE ROOF FLUE KIT

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

1. Position the roof plate (supplied separately) over the hole cut in the roof and insert ue

terminal from the roof end.

ASSEMBLY A

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 ue length. This allows correct

engagement into the vertical connector.

Note. Ensure a square cut. remove all burrs and sharp edges.

3. Fit the vertical connector (supplied in the kit) and secure the vertical connector by applying downward pressure on the connector.

4. Position the clamp on the top face of the ue manifold and push it horizontally backwards. Locate both clamp lugs into the ue manifold and secure to the ue

manifold clamp with the M5 retaining screw.

5. “Push” assembly A into vertical connector.

Notes. Ensure turret sample points are servicable and all caps and plugs are tted.

Ensure condensate siphon/trap is lled with water.

6. Finally ensure the roof plate is correctly sealed to the roof.

SECTION 5 - INSTALLATION INSTRUCTIONS

Sink/basin/

bath or

shower

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Internal soil & vent stack

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break

≥ 100

5.16

CONDENSATE DRAIN

137

Condensate

Drain

156

This appliance is tted with a siphonic 75mm sealed condensate

trap system that requires lling 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 t 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

ttings.

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

specication 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. (g 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 ow of rainwater into the boiler should the downpipe become ooded 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.

Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack

Boiler

with 75mm

sealed

condensate

trap

Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break

Min Ø 19mm Internal pipe

Soil & vent stack

Minimum connection height up to 3

≥ 450

storeys

Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack

continued . . . . .

SECTION 5 - INSTALLATION INSTRUCTIONS

≥ 25 Below grate

ONDENSATE DRAIN - CONT’D.......

Figure 3 - Connection of a Condensate Pump Typical Method (see manufacturers detailed instructions)

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Condensate pump (Install in accordance with manufacturers instructions)

Visible air break

Figure 5 - Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe (only combined foul/rainwater drain)

Figure 4 - Connection of Condensate Drainage Pipe to External Soil & Vent Stack

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Boilers without 75mm sealed

condensate trap must be fitted with

a 75mm trap and visible air break

Min Ø 30mm

Internal pipe

Water/weather proof insulation

Soil & vent stack

Minimum connection

≥ 450

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

Boiler

with 75mm

sealed

condensate

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

trap

Terminated and cut at 45º

43mm 90º male/ female bend

Water/ weather proof insulation

combined foul/ rain water drain

External air break

Air gap

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

Min Ø 19mm Internal pipe

Min Ø 30mm Internal pipe

Water/Weather proof insulation

Max 3m external pipework

Boiler

with 75mm

sealed

condensate

trap

Min Ø 19mm Internal pipe

Sink, basin, bath or

shower with integral

overflow and 75mm trap

Visible air break

≥ 100

at plug hole

Minimum 30mm

internal pipe

Water/ weather proof insulation

45º pipe

termination

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

≥ 300

≥ 500

≥ 25

Limestone chippings

SECTION 6 - COMMISSIONING INSTRUCTIONS

Gas

Supply

Gas Pressure Test Point

Before commissioning the boiler, the whole gas installation including

the meter (if tted) 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 ue 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 ushed. The

CH system needs to be treated with water treatments that are approved for use with aluminium alloy heat exchangers.

GENERAL

Please Note: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on

the gas type dened on the appliance data plate. As part of the

commissioning process, the combustion of this appliance must be

checked. A owchart to assist is provided on page 37.

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 ue system and the ue seals, as

described in the Flue Installation section.

Proceed to put the boiler into operation as follows:

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 ushing solution to one of the radiators.

Fill the central heating circuit using one of the approved methods to 1 bar.

Open radiator vent screws and turn off when water appears.

Turn off the lling method and disconnect.

With the system hot, examine all water connections. The system pressure should not exceed 2.5 bar.

Turn off gas, water and electricity when draining down.

Rell 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

Set up the boiler to operate at maximum rate by opening hot tap to maximum

ow.

With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point complies with the requirements - refer to “Gas Supply” on page 15.

Ensure that this inlet pressure can be obtained with all other gas appliances in the property working at maximum.

6.1 DOMESTIC HOT WATER

Turn on the main cold water supply.

Fill and vent the installation by turning on and off the various hot water taps in the installation.

Check hot water taps in the installation.

Check for and repair leaks as necessary.

6.4 DOMESTIC HOT WATER MODE

Turn the “mode” control knob to tap/radiator icon . Ensure all external controls are calling for heat. Set the integral timer to ON.

Display reads “C” then “C”

Ensure all radiators warm up evenly. The CH temperature can be

controlled in between max 80ºC and min 45ºC (ow temp).

Check the DHW functions by turning on a hot water tap.

Close the DHW tap and set the integral timer and external controls to off.

Display will read “0”.

Legend

A. Mode Control Knob B. DHW/Preheat Control C. CH Control

off

when burner is lit.

D. Boiler Status E. Burner ‘on’ Indication F. Pre Heat on/off Indication

max

status burner

reset

mode

min

preheat

min

max

B C D

preheat

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 ame. If no ame is detected the neon is off. When the ame 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

ashing with “L” or “F” with alternate numbers / letters refer to

page 34.

Boiler is in lockout for a specic error. Display will be

blinking, alternating with a number or letter to show which error is detected.

Boiler has a fault for a specic 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.

SECTION 7 - ROUTINE SERVICING INSTRUCTIONS

Flue Sampling Point

Air Sample Point

Ensure all caps and seals

are re-fitted after use

7.1

SERVICING SCHEDULE

For the very latest copy of literature for specication, 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 efcient 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 qualied and

competent Gas Installer.

INSPECTION

1. Light the boiler and carry out a pre-service check, noting any

operational faults.

2. Check the ue terminal (and terminal guard if tted) 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 relled,

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.

Check the main injector for blockage or damage. Refer to

3. Frame 7.3.

4. Check that the ue terminal is unobstructed and that the ue

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

retted, ensuring that a good seal is made.

Do NOT OPERATE the boiler if the upper front

panel is not tted.

7. If, for any reason, the condensate trap/siphon has been

removed ensure the trap is relled with water before reassembling.

8. Check the gas consumption if on metered installations.

Check combustion by connecting the ue gas analyser to the

ue gas sampling point as shown in the diagram and measure

CO & CO2. (Refer to Section 10, page 37).

If the CO/CO2 ratio is greater than 0.004 AND the integrity of

the complete ue system and combustion circuit seals have been veried and the inlet gas pressure have been veried,

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 ue system and the ue 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 Specication for installation and maintenance of gas-red 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 ue gas analyser and

the interpretation of the results.

- The ue 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 nally nish 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.

SECTION 7 - ROUTINE SERVICING INSTRUCTIONS

7.2

BOILER UPPER & LOWER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL

1. Lift the lower front panel access panel.

2. Unscrew the two xing screws, close the access panel to

retain the two screws and hinge the lower front panel down into the service position.

3. Remove the two upper front panel xing screws, lift the

panel and remove.

2&6

1&7

REPLACEMENT

4. Hook the upper panel onto the top retaining clips.

5. Retain the upper panel with the two xing screws

previously removed ensuring a good seal is made.

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

7. Close the lower front panel access panel.

3&5

7.3

FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from the fan.

2. Remove the clip from the gas control valve

outlet and ease the pipe upwards rotate and then ease down to remove.

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.

Injector

SECTION 7 - ROUTINE SERVICING INSTRUCTIONS

7.4

BURNER REMOVAL AND CLEANING

1. Ensure the sump is fully drained

2. Undo the two screws and remove the sump cover retaining the lower

ue manifold.

3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

4. Remove the 2 burner front xing 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.

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

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. Remove ignition and ame detection

electrodes. Refer to Frames 7.9 & 7.10.

2. It is advisable to replace the sump cover

prior to the water ush process.

3. Thoroughly ush 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.

5. Inspect the ignition and detection electrodes. Ensure that they are clean and in good condition - replace if necessary.

6. Re-t the ignition and ame 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.

Ignition Electrode

Earth Wire

Flame Detection

7.7

REASSEMBLY

Reassemble the boiler in the following order:

1. Ensure that the condensate trap/siphon is full of water.

2. Ret the burner ensuring the sealing gasket is correctly

positioned and free from damage (tighten the 4 xing screws

in the sequence A,B,C,D, shown below).

3. Ret 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 ret the lower ue manifold

as shown.

6. Ret the sump cover.

7. Ret the boiler upper and lower front panels.

IMPORTANT. Ensure that the boiler upper front panel

is correctly tted 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.

SECTION 7 - ROUTINE SERVICING INSTRUCTIONS

3mm

Straight edge

Spark Gap

3.5mm

7.8

BURNER REMOVAL

1. Refer to Frame 7.3.

2. Undo the two screws and remove the sump cover.

3. Lift the manifold to clear the bottom sealing gasket and remove

manifold.

4. Remove the 2 front xing 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.

6. Reassemble in reverse order.

Check the operation of the boiler.

7.9

IGNITION ELECTRODE

1. Remove the burner. Refer to Frame 7.8.

2. Check dimensions are correct as in

diagram below..

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.

Ignition Electrode

SECTION 7 - ROUTINE SERVICING INSTRUCTIONS

12.5mm

Straight edge

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.

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.

Flame Detection Electrode

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

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

9 FAULT CODES

SECTION 9 - FAULT CODES

DISPLAY CODE ON BOILER

DESCRIPTION

BCC Activation Fault

BCC Fault

Low Water Pressure

Flame Loss

Return Thermistor

Fan Fault

ACTION

Restart the appliance - if the boiler fails to operate then please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

Check system water pressure is between 1 & 1.5bar on the system pressure pressurise the system see Section 3. If the boiler still fails to operate then please contact Morco (if under

warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.

In all other countries contact a Registered Gas Installer.

1. Check other gas appliances in the home are working to conrm a supply is present in the property.

2. If other appliances do not work or there are no other appliances, check the gas supply is on at the meter/Gas Cylinder and/or pre payment meter has credit. If the boiler fails to operate then please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

Return temperature greater than ow temperature. Please contact Morco.

Restart the appliance - if the boiler fails to operate then please contact or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

gauge (G). To re-

Morco

(if under warranty)

Flow Thermistor

Return Thermistor

Outside Sensor Failure

Low Mains Voltage

Uncongured PCB

Flow Temperature Overheat or No Water Flow

Ignition Lockout

Contact a qualied electrician or your electricity provider.

Uncongured PCB. Please contact

Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

Check system water pressure is between 1 & 1.5bar on the system pressure re-pressurise the system see Section 3. If the boiler fails to operate then please contact (if under

warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty

period. In all other countries contact a Registered Gas Installer.

1. Check other gas appliances in the home are working to conrm a supply is present in the property.

2. If other appliances do not work or there are no other appliances, check the gas supply is on at the meter/Gas Cylinder and/or pre-payment meter has credit. If the boiler fails to operate then please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

3. Check condensate sump, internal pipe work and siphon, ensuring this is not frozen or blocked through to external pipe work. If frozen defrost using a non-direct heat method. If the boiler fails to operate then

please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

Morco

(if under warranty) or alternatively a Gas Safe

Morco

(if under warranty)

Morco

(if under warranty)

Morco

(if under warranty)

gauge (G). To

Morco

5 Boiler Resets in 15 minutes

False Flame Lockout

1. Turn electrical supply to boiler off and on.

2. If the boiler fails to operate please contact Safe Registered Engineer if outside of the warranty period. In all other countries contact a Registered Gas Installer.

Morco

(if under warranty) or alternatively a Gas

Morco

(if under warranty)

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

= carbon dioxide

O2 = oxygen

Combustion Ratio = The CO reading measured in ppm divided by the CO

ppm = parts per million

GS(I&U)R = Gas Safety (Installation and Use) Regulations

reading first converted to ppm

*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

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.

Insert analyser probe into air inlet test point (where available) and allow

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.

Carry Out Flue Integrity Check Using Analyser

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.

2 more than or

equal to 20.6% OR CO

Yes

less than or equal to

0.2%?

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.

readings to stabilise.

O2 more than or

equal to 20.6% OR CO

less than or equal to

0.2%?

Yes

Check CO level and Combustion Ratio

at Maximum Gas Rate

With boiler still set at maximum gas rate,

insert analyser probe into flue gas

sampling point. Allow readings to stabilise

before recording.

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Check that no seals, e.g. Those on flue extensions, have

been displaced during installation. Rectify if necessary.

CO level less

than 350ppm AND CO/CO

Yes

ratio less than

0.0040?

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.

Ensure test points are capped, boiler case is correctly replaced and all

other commissioning procedures are completed. Complete Benchmark

Yes

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.

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.

CO level less

than 350ppm AND CO/CO

ratio less than

0.0040?

Yes

Boiler is Operating Satisfactorily

No further actions required.

Checklist, recording CO and combustion ratio readings as required.

SECTION 11 - WARRANTY

WARRANTY CONDITIONS

The boiler is guaranteed against manufacturing defects for a period of two years from the

date of rst 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 lters.

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 modications to the boiler from original specications.

NOTES

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

morco GB 24 ErP Series II User guide

Specifications and Main Features

Frequently Asked Questions

User Manual