GB24 & GB30 Series II
Contents
1. FOR ANY QUERIES PLEASE RING THE MORCO CONSUMER HELPLINE 01482 325456 I NOTE BOILER RESET PROCEDURE reset boiler turn mode control knob to reset position and immediately turn knob back to required setting L me e mm pm mm ee ee ee pm es mm mm Introduction The Morco GB Series is a wall mounted room sealed condensing combination boiler featuring full sequence automatic spark ignition and fan assisted combustion Due to the high efficiency of the boiler condensate is produced from the flue gases and this is drained to a suitable disposal point through a plastic waste pipe at the base of the boiler A condensate plume will also be visible at the flue terminal The Morco GB Series is a combination boiler providing both central heating and instantaneous domestic hot water Safety Current Gas Safety Installation amp 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 qualified and competent Gas Installer In the appro2. 2 5 7 gt 25 case __ 393 285 Side eer 865 5 EE i 1 Flue terminal al l lt 700 100 400 bk z 7 Underside View Dimensions to Wall WA oe n Water Connections and Gas Connection 1 1 ee 1 1 LJ CO 1 1 GER SE i 51 1 43 51 65 1285085 60 6 75 56 4 1375 EE Km ER Al 5 SS T og 9 i 255 8 ee GE EE Front clearance Min Top Clearance Min Top Clearance A 165mm Rear flue type The minimum front clearance when SIDE Flue type 167 193 219 245 271 297 323 349 375 401 built in toa cupboard is 5mm from Distance from Horizontal mm required to achieve 1 5deg fall to Wetter the cupboard door but 450mm overall 26 52 78 104 10 156 182 mm clearance is still required with the i i i 34 cupboard door open to allow for l EA Ehe 1 5 degree servicing A Bottom clearance Bottom clearance after installation can be reduced to 5mm This must be obtained with an easily removable panel to enable 8 0 24kW 6 R ge the consumer to view the system alle pressure gauge and to provide
3. gt Gas Isolation Valve on position shown SECTION 1 USERS INSTRUCTIONS Loss of system water pressure The pressure gauge indicates the central heating system pressure lf 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 the pressure continues to drop a Gas Safe Registered Engineer or in other countries a qualified 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 PRESSURE GAUGE Condensate Drain This appliance is fitted with a siphonic condensate trap system that reduces the risk of the appliance condensate from freezing However should the condensate pipe to this appliance freeze please follow these instructions a If you do not feel competent to carry out the defrosting instructions below please call your local Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer for assistance b If you do feel competent to carry out the following instructions please do so with care when handling hot utensils Do not attempt to thaw pipework above ground level If th
4. gt the 100 ired f Distance in metres from edge of turret to side wall Dimension H mm Clearance required 1 Dimension H must remain inside the Maximum flue length requirement for the designated output of the applaince been installed servicing 2 For flue lengths requiring pack extensions RSF 341 the flue must incline by 26mm per 1 Metre of flue length No flue length greater that the maximum flue length shown above should be exceeded 11 SECTION 4 GENERAL INSTALLATION REQUIREMENTS 4 1 RECOMMENDATIONS Current Gas Safety Installation and Use Regulation or Rules in Force The boiler is suitable only for installation in the specified 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 qualified and competent Gas Installer It must be carried out in accordance with the relevant requirement of the Gas Safety Installation and Use Regulations Appropriate National Standards The Water Fittings Regulations Current IEE Wiring Regulations Health 4 Safety Document 635 The Electricity at work Regulations 1989 55482 1 Code of Practice for Domestic butane and propane gas burning installation in permanent dwellings residential park homes and commercial premises BSEN1949 2011 Specification for the installation of LPG Syst
5. 230VAC Return SECTION 5 INSTALLATION INSTRUCTIONS 5 5 WATER AND GAS CONNECTIONS Ensure all boss blanking plugs are removed before making any connections Each valve must be fitted to the correct boss as shown in diagram below Do not subject any of the isolating valves to heat as the seals may be damaged Ensure that the green fibre washer is used on the CH flow connection IMPORTANT The gas service cock is sealed with a top hat washer DO NOT subject to heat Pressure Relief Valve PRV Located at the bottom right hand side of the boiler connection via a 15mm diameter stub pipe Use a replaceable connection to ease the replacement of the valve if required Ensure a safe discharge point using temperature and pressure resistant materials DHW OUTLET DHW INLET CH RETURN CH FLOW 5 6 AIR FLUE SYSTEMS The flue system is part of the appliance and is approved as such Only use the flue systems supplied by Morco The standard flue kit RSF303 for the Morco GB range is a 600mm as shown below There is also a 900mm kit available RSF305 600 60 Part No RSF303 The minimum cut length is 188mm includes 30mm into elbow The maximum allowable length using extensions RSF341 is GB24 Series minus any flue kit options GB30 Series IJ 7m minus any flue kit options 15 SECTION 5 INSTALLATION INSTRUCTIONS 5 7 DETERMINING THE FLUE LENGTH IMPORTANT
6. Retaining Sample points Clamp Lugs screw Flue Outlet A DuctAssembly B Flue Turret C Turret Clamp Dace Flue Outlet 18 SECTION 5 INSTALLATION INSTRUCTIONS 5 11 FLUE EXTENSIONS RSF341 OPTIONAL For side outlet refer to section 1 2 before connecting INNER PIPE ASSEMBLY INSTRUCTIONS 1 Make sure that top hat on the collar A fits over the 3 Slide the pipe and collar assembly back into the outer rectangular form on the inner plastic pipe B housing E note that this can only be done at the female end of the outer housing Top Hat Rectangular 2 Ensure that the flat base of the collar C is 4 When fitting support brackets F make sure they are positioned on the bottom lip of the pipe D positioned on the female side of the neck as shown 9 5 12 FLUE DEFLECTOR KIT RSF300 OPTIONAL 5 13 90 KIT RSF315 OPTIONAL The flue deflector elbow can be fitted to the flue outlet of the standard This optional kit can be used on both horizontal and terminal kits RSF303 or RSF305 to deflect the flue products horizontally vertical flue kits to the left or the right only 1 SCH 1 Use dimensions below for calculating total length 1 Refer to the boiler Installation and Servicing Instructions for fitting of the boiler and its flue system 2 When cutting extensions or flue kits always allow Note The resistance of the deflector is equivalent to 1 met
7. Where the flue passes through the roof line an adequate seal must be made This is achieved by using a suitable sealant ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired length If 90 elbows are used RSF315 they will Terminal Posion Minimum Dimension reduce the overall height by 1m per elbow Directly below an opening air brick windows etc 300 mm Below plastic painted gutters 5 15 ASSEMBLING THE ROOF FLUE KIT 1 Position the roof plate supplied separately over the hole cut in the roof and insert flue terminal from the roof end Flue Terminal ASSEMBLY A 50 149 RSF050 RSF050 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 flue length This allows correct engagement into the vertical connector Note Ensure a square cut remove all burrs and sharp edges 3 Fit the vertical connector Supplied in the kit and secure the vertical connector by applying downward pressure the connector i connector 4 Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue a manifold clamp with the 5 retaining screw 5 Push assembly A int
8. Complete Benchmark Checklist recording CO and combustion ratio readings as required 35 SECTION 11 WARRANTY WARRANTY CONDITIONS The boiler is guaranteed against manufacturing defects for a period of two years from the date of first commissioning However the guarantee is subject to proof of commissioning in accordance with the Gas Safety Installation and Use act 1998 The guarantee does NOT cover the following issues Frost damage to any part of the boiler containing water during freezing conditions The removal of sludge or hard water scale due to lack of antifreeze inhibitor Damage to electronics caused by a defective electrical supply Damage or failure caused by insect contamination or blocked water filters Loss of pressure within the heating system not caused directly by the boiler A N Incorrect operation of the boiler caused by defective outlets such as thermostatic mixers or mono block mixer taps 7 Damage caused by unauthorised modifications to the boiler from original specifications For more detailed servicing information workshop manuals technical advice spare parts product training please phone us on 01482 325456 or contact us at the address below MORCO PRODUCTS LTD Morco House Riverview Road Beverley East Yorkshire HU17 OLD TEL 01482 325456 FAX 01482 212869 EMAIL sales morcoproducts co uk WEBSITE www morcoproducts co uk 36
9. GENERAL SPECIFICATIONS 2 2 WIRING DIAGRAM B A 1q q T 18 JOPA 10 09UU0 Q See fi i ERE E x x x k ldrkldckldh YOUMS 5 Kab pou UMOJQ Sun MOL O m A 10 6 M d J 19 9 AA 10 SECTION 3 TECHNICAL DATA Table 1 General Data Gas supply I G31 37mbar Flow Connection Central Heating 2 4 Flue Terminal Diameter mm in 100 4 Average Flue Temp Mass Flow Rate DHW 63 C 119 5 Maximum Working Pressure Sealed Systems bar bin 2 5 36 3 Maximum Domestic Hot Water Inlet Pressure bar Ib in kPa 10 0 145 1000 Minimum Domestic Hot Water Inlet Pressure bar Din kPa 0 8 11 6 80 1 3 18 9 130 Domestic Water litre gal 0 5 0 11 34 1 75 2 31 2 68 8 Depth mm in 285 11 2 Required for maximum flow rate Boiler operates down to 2 l min DHW delivery Table 2 Performance Data Central Heating Table 3 Performance Data Domestic Hot Water Boiler Input Maximum DHW Input Nett CV kW 24 3 30 4 Btu h 82 912 103 725 Gross CV Gross CV kW 26 4 33
10. aluminium flue collar RSF 060 at least 17 Le Note If less than 50 of the length of the flue is internal the flue should be fitted from outside Flubber 3 Fit the internal sealing flubber to the flue leave loose and check protrusion externally of the white air duct is 17mm Internal Sealing Fill with 1 UI WI sealant 4 Fit the turret as below Fill with ee d sealant Aluminium Flue Collar RSF 060 5 hole FITTING THE TURRET Ensure the condensate trap siphon is filled with water 1 Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged 2 Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged Make sure the flue has not rotated or moved forward during fitting and the flue seam is upper most 3 Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold 4 Fully engage the clamp location section into the manifold location holes Rotate down on to turret flange 5 Secure clamp to appliance using securing screw 6 Ensure all sample points are accessible and all sample plugs and caps are fitted 7 Fully engage the flue into the turret and slide internal flubber to wall 8 The gap between the aluminium flue collar RSF 060 and the white air duct MUST be sealed with sealant to create a seal
11. amp 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 amp seals are in place Additional Termination Kits available for use with these Horizontal Flue Kits RSF303 amp RSF305 Flue Deflector Kit RSF300 The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length Total Maximum Permissible Horizontal Concentric Flue Length combining both Horizontal Flue Kits and Extension Kits Measured from centreline of the turret to the outside face of the aluminium flue collar RSFO60 24 kW appliances Total Maximum 8 metres minus any flue kit options 30 kW Appliances Total Maximum 7 metres minus any flue kit options Total Maximum Permissible Vertical Flue Length 24 amp 30kW Appliances Total Maximum 7 5 Metres minus any 90 bends Minimum Horizontal Flue Lengths Centre line of turret outside face of the aluminium flue collar RSFO60 Rear Flue 191mm Side Flue 236mm with minimum 2 5mm clearance 16 SECTION 5 INSTALLATION INSTRUCTIONS 5 8 DETERMINING THE FLUE LENGTH FIGURE 1 REAR FLUE Cut flue length distance from edge of turret to outside of wall dimension A 47mm Note Minimum dimension A which can be accommodated is 91mm WALL NOTES Centre of turret to edge of turret 100mm Turret
12. p DHW preheat During normal operation the burner on indicator E will remain illuminated when the burner is lit Note If the boiler fails to light after five attempts the fault code L will be displayed RESET PROCEDURE To reset boiler turn the mode control knob A to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present If the boiler still fails to light consult a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer SECTION 1 USERS INSTRUCTIONS Operation Winter conditions i e CH and DHW required Ensure the mode knob control is set to winter a The boiler will fire 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 4 Set the CH external controls to OFF Note The pump will operate briefly as a self check once every 24 hours regardless of system demand 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 64 C maximum at low draw off rate adjustable via the DHW temperature control B Due to system variation
13. Btu h 90 077 112 596 Gas Consumption Gas Consumption 1 00 1 25 35 33 44 20 kg hr 1 83 2 26 Maximum 30 3 DHW Output 103 384 DHW Flow Rate l min at 35 C temp rise gpm Boiler Input Q Nett CV Boiler Output Non Condensing 242 24 2 8 00 70 C Mean Water temp Btu h 82 570 82 570 27 296 Condensing kW 25 6 25 6 8 5 40 C Mean Water temp Btu h 87 347 87 347 29 002 DHW Specific Rate l min Seasonal efficiency SEDBUK 2005 91 gpm Seasonal efficiency SEDBUK 2009 89 NOx Classification CLASS 5 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a calorific value of 95 65 2569 Btu ft gross or 88 0 MJ m 2 360 Btu ft nett Key to symbols PMS Maximum operating pressure of water To obtain the gas consumption at a different Aroom sealed appliance designed for connection via ducts to a horizontal calorific value or vertical terminal which admits fresh air to the burner and discharges a For l s divide the gross heat input kW by the products of combustion to the outside through orifices which in this the gross C V of the gas case are concentric The fan is up stream of the combustion chamber b divide the
14. an External Purpose Made Soak Away Boiler with 75mm sealed condensate Min 19mm Internal pipe Boilers without 75mm sealed condensate trap must be fitted with 75 trap and visible air break 22 Min 30mm Internal pipe Water Weather proof insulation Max 3m external pipework N N Limestone chippings 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house SECTION 5 INSTALLATION INSTRUCTIONS Figure 4 Connection of Condensate Drainage Pipe to External Soil amp Vent Stack Boiler Water weather with 75mm proof insulation sealed condensate trap Min 30mm Internal pipe Min 19mm Internal Il Soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with 75mm trap and visible air break Minimum connection height up to 3 storeys Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate ER Visible air break trap _ at plug hole Min m 4 Internal pipe g 7 Sink basin bath Minimum 30mm shower with integral internal pipe overflow and 75mm trap Water weather proof insulation E 45 pipe termina
15. and free from damage is correctly fitted and that a good seal is made Replace seals as necessary Reconnect the fan electrical leads 8 on gas supply at the gas service cock 9 Reconnect the electrical supply SS AN SECTION 7 ROUTINE SERVICING INSTRUCTIONS 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 Remove the 2 front fixing screws and loosen the 2 rear extended nuts Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown Fit the new burner replacing any damaged or deteriorating sealing gasket 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 Ignition Electrode FOR REMOVAL Unplug the ignition lead and remove the earth lead Remove the 2 retaining screws and remove the electrode Reassemble in reverse order replacing the gasket if necessary Spark Gap 3 5mm 1 SECTION 7 ROUTINE SERVICING INSTRUCTIONS 7 10 FLAME DETECTION ELECTRODE Remove the burner Refer to Frame 7 8 Check dimensions are correct as in diagram below Reassemble in reverse order FOR REMOVAL Unplug the ignition lead and r
16. filling loop or other approved method between the mains water supply pipe and the central heating return pipe Once used the filling loop should be disconnected and capped off 4 10 EXPANSION VESSEL The boiler is fitted with an 8 litre expansion vessel which is sufficient for a cold fill capacity of up to 143 litres For other system volumes refer to table below 3 0 0 5 to 0 75 None 1 0 Safety valve setting bar Vessel charge pressure bar System pre charge pressure bar System 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 Expansion vessel volume litres 0 063 0 074 4 11 PRESSURE RELIEF VALVE A pressure relief valve set at 3 bar is fitted to the boiler The connection is shown in the dimensions and connection details The discharge pipework must be suitable for use with 3bar water at 110 C without damage to property and persons The run and exit point of the pipework should not leave a hazard or be prone to freezing up 4 12 DHW SYSTEMS Check that the mains supply pressure is within the units stated in the technical data section in this manual A pressure reducing valve should be fitted if above 10 bar In areas of low mains water pressures the domestic hot water regulator may be removed by a suitably qualified pers
17. gross heat input Btu h 1 An appliance designed for use on 3rd Family gas Group only by the gross C V of the gas For m h multiply by 3 6 SECTION 3 TECHNICAL DATA BOILER DIMENSIONS SERVICES amp CLEARANCES The boiler connections are made on the boiler bulkhead fittings The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions Side and Rear Flue a Provided that the flue hole is cut accurately e g with a core boring tool or hole cutter the flue can be installed from inside the dwelling where wall thicknesses do not exceed 600mm CLEARANCES 24 Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY b If a boring tool or hole cutter is to be used inside the dwelling the space in which the boiler is to be installed must be at least wide enough to accommodate the tool In either of the above cases safe external access is required to allow the addition of sealant to seal the flue to the aluminium flue collar RSF 060 BOILER DIMENSIONS
18. is undamaged and clear of any obstruction 3 Check all water and gas joints for signs of leakage Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled vented and re pressurised CLEANING PROCEDURE Note In order to carry out either servicing or replacement of components the boiler upper and lower front panels must be removed Refer to Frame 7 2 1 Clean the main burner Refer to Frame 7 4 2 Clean the heat exchanger amp condensate trap siphon Refer to Frames 7 5 amp 7 6 3 Check the main injector for blockage or damage Refer to Frame 7 3 4 Check that the flue terminal is unobstructed and that the flue system is sealed correctly The cleaning procedures are covered more fully in Frames 7 3 7 7 and MUST be carried out in sequence IMPORTANT 5 After completing the servicing or exchange of components always test for gas tightness 6 When work is complete the front panels MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the upper front panel is not fitted 7 for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before reassembling 8 Check the gas consumption if on metered installations 9 Check combustion by connecting the flue gas analyser to the flue gas sampling point as shown in the diagram and measure CO Refer to Section 1
19. 0 page 35 If the CO CO ratio is greater than 0 004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure have been verified then contact Morco GENERAL Please Note During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue system and the flue seals integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate Turn on one or more DHW taps The combustion performance COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please Note BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements and Competence can be demonstrated for example by satisfactory completion of the CPA1 ACS assessment UK Only which covers the use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 SERVICE MODE To access the service mode Using the centr
20. ENERAL This boiler is designed for connections to fully pumped sealed system only IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both central heating and DHW flow and return connections from the boiler before connection to any plastic piping Central Heating System IMPORTANT The sealed central heating system must be filled at all times with an antifreeze inhibitor and water mix that is compatible with aluminium heat exchangers The concentration levels of the antifreeze inhibitor should be at least 25 in order to provide adequate corrosion protection This level also provides protection against frost from 7 5 C to 11 C depending on the product used The maximum allowable level of antifreeze inhibitor is around 40 The only products approved are as follows Fernox 11 Sentinel X500 Failure to use these products may result in damage to the boiler and the radiators in the heating system 4 9 REQUIREMENTS FOR SEALED WATER SYSTEMS At maximum CH output 24 24kW at a 20 C differential and flow rate 17 3 l min a 3 4m wg head is available for the system Set all radiators to give around 20 C temperature differential The boiler does not normally need a bypass but at least some radiators of load at least 10 of the minimum boiler output These radiators should be fitted with lockshield valves only A sealed system MUST only be filled by a competent person using an approved
21. GB24 6830 Series User amp Installation Instructions rs ne 8 x BOILER OUTPUT To Domestic Hot Water To Central Heating GB24 30 Minimum 8 0 kW 27 296 Btu h GB24 30 Minimum 8 0 kW 27 296 Btu h GB24 Maximum 24 2 kW 82 570 Btu h GB24 30 Maximum 24 2 kW 82 570 Btu h 6830 Maximum 30 3 kW 103 384 Btu h Morco House Riverview Road Beverley East Yorkshire HU17 OLD Morco Products Ltd aveworaewe Tel 01482 325456 Fax 01482 212869 Website www morcoproducts co uk UIN 211292 01 October 2014 GB24 amp GB30 Series I Combination Boiler Destination Country BE Belgium CH Switzerland CZ Czech Republic ES Spain FR France GB UK GR Greece IE Ireland IT Italy NL Netherlands PL Poland PT Portugal 51 Slovenia CONTENTS SECTION PAGE 1 EE ee EE 4 2 ENEE le 8 3 Technical EEN 10 4 General Installation 12 5 Installation INStHUCTIONS TEE 14 6 COMMISSIONINGMMSTRUCTIONS EE 23 7 Routine leie later IN 25 8 IS lee 31 9 ele EE 32 10 EE EE ENEE 34 11 Waranty EE 36 SECTION 1 USERS INSTRUCTIONS Cla
22. Registered Engineer or in other countries a qualified and competent Gas Installer should be called to investigate and rectify the condition causing this and carry out an operational test Only the manufacturers parts are to be used for replacement 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 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 6 6 Set the mode knob control to winter Ml If there is a central heating demand the boiler will commence the ignition sequence Note n normal operation the boiler status display D will show codes Standby no demand for heat CH being supplied DHW being supplied 0 d
23. TURN OFF ALL GAS SUPPLIES Do NOT search for gas leaks with a naked flame Cleaning For normal cleaning simply dust with a dry cloth To remove stubborn marks and stains wipe with a damp cloth and finish off with a dry cloth DO NOT use abrasive cleaning materials Maintenance The appliance should be serviced at least once a year by a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer Permanently ON Time amp Control Indicator X 2 ST WS Tg TUI segment m LC Em O Q 24hr Programme Ring Timer control segments 1 Segment 15 mins Push towards programme ring OFF Push away from programme ring ON SECTION 1 USERS INSTRUCTIONS POINTS FOR THE BOILER USER Note n 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 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 NO HOT WATER NO CENTRAL HEATING Check the mains
24. The boiler must be installed in a vertical position in accordance to the installation instructions STANDARD FLUE KITS Horizontal Flue Terminal RSF303 600mm long contains Flue turret non telescopic single piece flue incorporating a terminal and inner rubber wall seal Extension Kit RSF341 contains 1 metre length of flue pipe Functional length 950mm 1 support bracket When extension kits are used the flue duct must incline 1 5 degrees away from the appliance to allow the condensate to drain back to the boiler and out of the condensate drain It is recommended that a support bracket is fitted on every 1 metre of pipe work used and the bracket is located as close to the collar as possible The bracketing must ensure a 1 5 degree fall back to the appliance Only use water as a lubricant during assembly The horizontal flue kit terminal is classed as part of the maximum flue length Once the flue is installed it is IMPORTANT that the white air duct protrudes from the aluminum flue collar RSF 060 by at least 17mm The gap between the aluminium flue collar RSF 060 and the white air duct MUST be sealed with sealant to create an adequate seal 17mm min Fill with Flubber sealant Fill with d sealant Aluminium Flue Collar RSF 060 It is IMPORTANT that all attachments are fitted in accordance with the installation instructions provided in this manual The TURRET supplied in the Horizontal Flue Kits RSF303
25. XCHANGER Note Ensure the condensate trap siphon is fully drained before cleaning Refer to Ignition Electrode Flame Detection Frames 7 5 Remove ignition and flame detection electrodes Refer to Frames 7 9 amp 7 10 15 advisable to replace the sump cover prior to the water flush process Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered Remove the sump cover and clean loose deposits from the sump Earth Wire Inspect the ignition and detection electrodes Ensure that they are clean and in good condition replace if necessary Re fit the ignition and flame detection electrodes Ensure that earth wire is connected to the electrode Check that the ignition and detection gaps are correct Refer to Frames 7 9 amp 7 10 7 7 REASSEMBLY Reassemble the boiler in the following order Ensure that the condensate trap siphon is full of water Remove the sump cover and refit the lower flue manifold Refit the burner ensuring the sealing gasket is correctly as shown positioned and free from damage tighten the 4 fixing screws Refit the sump cover in the sequence A B C D shown below SE 7 Refit the boiler upper and lower front panels Refit the fan venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly IMPORTANT Ensure that the boiler upper front panel positioned
26. al heating potentiometer starting from the 11 o clock position move the thumb piece to the maximum position back to the 11 o clock position and then finally finish at the maximum position The letter S will now be displayed To toggle to maximum DHW output move the thumb piece up to the 11 o clock position and then back to maximum A minimum of 3 seconds will reset the boiler back to normal mode Ensure all caps and seals are re fitted after use 25 SECTION 7 ROUTINE SERVICING INSTRUCTIONS 7 2 BOILER UPPER amp LOWER FRONT PANEL REMOVAL REPLACEMENT REMOVAL REPLACEMENT 26 Lift the lower front panel access panel 4 Hook the upper panel onto the top retaining clips Unscrew the two fixing screws close the access panel to 5 Retain the upper panel with the two fixing screws retain the two screws and hinge the lower front panel down previously removed ensuring a good seal is made into the service position Swing the lower front panel up and retain with the two Remove the two upper front panel fixing screws lift the screws anel and remove H Close the lower front panel access panel 7 3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Remove the clip from the gas control valve outlet and ease the pipe upwards rotate and then ease down to remove Remove the extended nut on the fan mounting
27. are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GSIUR CO level less an 350ppm AND CO COz ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary 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 ratio less than 0 0040 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 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 amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less 350ppm AND ratio less than 0 0040 Boiler is Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed
28. 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 Ensure the sump is fully drained Undo the two screws and remove the sump cover retaining the lower flue manifold Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns 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 Brush off any deposits that may be on the ceramic with a SOFT brush Inspect the sealing gasket around the burner for any signs of damage Replace as necessary ae mae 7 5 CLEANING THE CONDENSATE TRAP SIPHON Note Ensure condensate trap is fully drained before removal Pull off the rubber pipe at the siphon Turn the siphon clockwise to disengage and lift to remove Flush out all deposits with clean water Reassemble in reverse order Note When reassembling ensure the trap is full of water 27 SECTION 7 ROUTINE SERVICING INSTRUCTIONS 7 6 CLEANING THE HEAT E
29. compartment in which the boiler is installed due to the low surface temperature of the boiler casing during operation 4 5 ELECTRICAL SUPPLY WARNING This appliance MUST be earthed Wiring external to the boiler MUST be in accordance with the correct IEE Regulations and any local regulations The boiler has been pre fitted with a 3 amp fused approved moulded 3 pin plug and flying lead for use with 230V 50 2 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 Ensure that regulator is of sufficient 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 sufficient size to prevent a pressure drop greater than 2 5mbar between the final pressure regulator to the caravan holiday home or park home and all appliances when the installation is subjected to the anticipated maximum load 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 fittings MUST be made of plastic No other materials may be used Suitable protection against freezing should be undertaken 4 8 WATER SYSTEMS G
30. e plastic pipe from its exit point on the appliance through its route to its termination point Locate the frozen blockage It is likely that the pipe is frozen at the most exposed point external to the building or where there is some obstruction to flow This could be at the open end of the pipe at a bend or elbow or where there is a dip in the pipe in which condensate can collect The location of the blockage should be identified as closely as possible before taking further action 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 4 Once the blockage is removed and the condensate can flow freely reset the appliance Refer to To Light the boiler 5 appliance fails to ignite call your Gas Safe Registered Engineer or in other countries a qualified 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 15 C overnight Return to normal after cold spell Escape of gas Should a gas leak or fault be suspected contact the Gas Supplier without Delay
31. eck 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 02 oxygen Combustion Ratio The CO reading measured in ppm divided by the reading first converted to ppm ppm parts per million GS I amp U R Gas Safety Installation and Use Regulations Setting to Minimum Rate Turn the CH temperature control knob to the 11 O clock position Create a CH demand by ensuring that the system controls are requesting heat and the boiler Mode Knob is in the Winter Position 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 S will be shown the display and the boiler output will be reduced to minimum The boiler will remain at minimum rate for 5 minutes before reverting to normal operation SECTION 10 COMBUSTION CHECK Set Boiler to Maximum Gas Rate In accordance with boiler instructions by fully turnin
32. emove the earth lead Remove the 2 retaining screws and remove the electrode Reassemble in reverse order replacing the gasket if necessary 7 11 FINAL CHECKS Turn all controls to ON position and check their correct functions in both DHW amp CH modes Additional replacement of parts information can be found on our website www morcoproducts co uk 30 SECTION 8 FACT SHEETS 8 FACT SHEETS There are a number of detailed fact sheets available for users to download from Morco s website Please visit www morcoproducts co uk The fact sheets can be located in the troubleshooting section and include Winterisation of Holiday Homes Poor Hot Water Delivery Causes and Solutions Low Central Heating Pressure Fault 1 Thermostats Programmers and Thermostatic Radiator Valves Combi boiler cycling Noisy boilers 31 SECTION 9 FAULT CODES 9 FAULT CODES DISPLAY CODE ON BOILER DESCRIPTION ACTION burner burner BCC Activation Fault Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner BCC Fault burner burner Low Water Pressure Check system water pressure is between 1 amp 1 5bar on the system pressure gauge G To re pressurise the system see Section 3 If the boiler still fails to operate
33. ems 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 flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by National Standards For Electrical Safety reasons there must be no access available from the rear of the boiler The boiler must not be fitted outside BATHROOM INSTALLATIONS This appliance is rated IP20 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations 1 5 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers the appliance must be installed beyond Zone 2 as detailed in BS 7671 Ceiling Recessed windo
34. g call or hot water demand burner The boiler has a call for central heating but the appliance has reached the desired temperature set on the boiler burner The boiler has a call for hot water but the appliance has reached the desired temperature set on the boiler burner The boiler is operating in central heating mode The boiler is operating in hot water mode The boiler is operating in pre heat mode burner burner The water in the cental heating circuit is less than 5 C If heating is switched on this display code will change to SECTION 2 GENERAL SPECIFICATIONS 2 1 GENERAL SPECIFICATIONS The Morco GB Series II range of boilers are wall mounted full sequence automatic spark ignition low water content fanned flue high efficiency condensing combination boilers Note Due to the high efficiency of the boiler a plume of water vapour will format the terminal during operation The boiler is supplied for use with Propane only at 37mbar 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 2 kW 82 570 Btu hr with 30 3 kW 103 384 Btu hr available for hot water production The boiler can be supplied with a standard concentric flue with additional extensions flue deflector and vertical flue kits available as optiona
35. g on hot tap set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise Note Do not insert analyser probe during this period to avoid possible flooding of sensor Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air inlet test point where available and allow readings to stabilise Note Where no air inlet test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the Prior to CO level and combustion ratio check see opposite page before proceeding to the check CO level and combustion ratio at maximum rate stage below Verify Flue Integrity Analyser readings indicate that combustion products and inlet air must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed equal to 20 6 OR ess than or equal to Check CO level and Combustion Ratio at Maximum Gas Rate gt With boiler still set at maximum gas rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Yes Turn off appliance and call Morco Technical Helpline for advice The appliance must not be commissioned until problems
36. has a flue insertion of 30mm The white outer flue tube must protrude the wall by 17mm From centreline of turret to wall Rear mount 155mm side including clearance 200mm SIDE FLUE Cut flue 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 to wall Minimum clearance 2 5mm Flue length measured from outer terminal lip to end of outer flue AorB 47mm KO 5 9 CUTTING HORIZONTAL FLUE TERMINAL RSF303 600MM LONG 1 Measure from the outer terminal lip to end of outer flue Mark the required cut length A or B 47mm around the circumference of the outer flue and cut following the mark to ensure its cut square Dress the cut end to make sure all burr s are removed and the cut edge is in its original shape Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square 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 17 SECTION 5 INSTALLATION INSTRUCTIONS 5 10 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 1 Ensure the seam and the outlet terminal are at the top and fitted as shown 2 Once the flue is installed it is IMPORTANT that the white air duct protrudes from the
37. ill 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 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 then when burner is lit Ensure all radiators warm up evenly The CH temperature can be controlled in between max 80 C and min 45 C flow temp Check the DHW functions by turning on a hot water tap Close the DHW tap and set the integral timer and external controls to off Display will read 0 Legend A Mode Control Knob B DHW Preheat Control C CH Control D Boiler Status E Burner on Indication F Pre Heat on off Indication 23 SECTION 6 COMMISSIONING INSTRUCTIONS THE DISPLAY The user control has one neon and one display to inform the user about the status The display will show the status of the boiler The neon will show the status of the flame If no flame is detected the neon is off When the flame is detected the neon will be lit permanently Below is a list with display function in normal operation 0 Standby no demand for heat present Boiler is active for central heating Boiler is active for domes
38. is 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 MECHANICAL 24 HOUR TIMER PROGRAMMING THE TIMER the programme ring clockwise through a 24 hour cycle the ring lines up with the time indicator Note The segment dial can be turned when the time controller is correct time of day turning the dial in a clockwise direction Permanent Override time indicator the unit will be permanently a timeswitch permanently OFF 1 Decide what times you would like the timeswitch to switch ON and OFF 2 Push segments towards the programme ring for an OFF period and push away from ring for an ON period The minimum switching interval is 15 minutes and this can be increased in 15 minute steps 3 Bring the timeswitch into the correct condition by manually turning 4 Turn the programme ring clockwise until the correct time of day on operating In case of power failure re adjust the time controller to the By rotating the central switch so that the symbol 1 lines up with the With the symbol lining up with the time indicator the unit acts as With the symbol 0 lining up with the time indicator the unit will be To unblock a frozen condensate pipe 1 Follow the routing of th
39. l extras The only flueS that can be fitted 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 Schematic Diagram Expansion Vessel Pump Auto Air Vent Water Pressure Switch Flow Thermistor Return Thermistor Divertor Valve Fan 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 Oo ob Venturi DHW Plate Heat Exchanger Ignition Electrode Flame Detection Electrode Gas Valve Siphon Trap DHW Flow Turbine System Pressure Gauge Sump Cover SECTION 2
40. n 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 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm a Internal pipe Internal soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Visible air break Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap Min 19mm Internal pipe 30mm Internal pipe Water weather proof insulation Terminated and cut at 45 Pe 43mm 90 male female bend combined foul water drain External air 1 break Air gap 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to
41. ng in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and any fittings NB Clip runs to prevent pipework disconnecting due to vibration etc In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Soil amp vent stack Minimum connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connec
42. o vertical connector Notes Ensure turret sample points are servicable and all caps and plugs are fitted Ensure condensate is filled with water 6 Finally ensure the roof plate is correctly sealed to the roof 20 SECTION 5 INSTALLATION INSTRUCTIONS 5 16 CONDENSATE DRAIN Condensat Drain This appliance is fitted with a siphonic 75mm sealed condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location Plastic with push fit or solvent connections c Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g Allinstallations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelli
43. on The boiler will require the flow rate to be set to give a temperature of 35 C at the tap furthest from the boiler In hard water areas where mains water exceeds 200ppm total hardness the fitting of a scale reducing device is recommended with the requirements of the local water company The use of artificially softened water however is not permitted The boilers are suitable for connection to most types of washing machine and dishwasher appliances 13 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 fixed on the wall taking into account installation requirements detailed in previous section 1 Screw the wall mounting plate to the wall choosing one of the two sets of slots in left and right bank Ensuring that at least one of the screws is fitted into a top slot Example of fixing A 2 Lift boiler onto the wall mounting plate locating it over the two tabs Note If present remove the bottom end support packaging and ensure all plastic plugs are removed from CH amp 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 se
44. orco 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 burner poner 5 Boiler Resets in 15 minutes 1 Turn electrical supply to boiler off and on 2 If the boiler fails to operate please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner False Flame Lockout Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer 33 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 Ch
45. ow eaves 25mm 1 855440 1 2008 200mm 8 Below balconies or a car port roof BS5440 1 2008 25mm 1 200mm 8 From vertical drain pipes or soil pipes BS5440 1 2008 25mm 1 150mm 6 From an internal or external corner or to a boundary along side the terminal BS5440 1 2008 25mm 1 300mm 12 Above adjacent ground roof or balcony level 300mm 12 From a surface or a boundary facing the terminal 600mm 24 From a terminal facing a terminal 1 200mm 48 From an opening in a car port e g door or window into dwelling 1 200mm 48 Vertically from a terminal on the same wall 1 500mm 60 Horizontally from a terminal on the wall 300mm 12 Vertical Terminals D 300mm 300mm Above the roof pitch with roof slope of all angles Above flat roof D 300mm 300mm From a single wall face 1 1 1 From corner walls 1 2 2 2 2 Below velux window 2000mm 79 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 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
46. parating in both poles 14 5 4 INTERNAL WIRING The boiler has been pre fitted with a 3 amp fused approved moulded 3 pin and flying lead for use with 230V 50Hz If the supply cord is damaged it must be replaced by the manufacturer its service agent or similarly qualified persons in order to avoid a hazard The plug should be used with an unswitched shuttered socket outlet complying with BS1363 The boiler comes pre fitted with a link wire between the room thermostat Timer connections on the terminal strip This creates a permanent call for heat and must be removed when adding a room thermostat ROOM THERMOSTAT WIRING To fit a room thermostat proceed as follows 1 Ensure that the electrical supply to the boiler is isolated before proceeding 2 Remove the two screws beneath the flap on the front of the boiler and lower the front panel 3 Remove the pre fitted link wire between the Room stat timer terminals 4 Pass the cable through a grommet secure with the cable clamp and connect the room stat as shown in the diagram below 5 If room stat has a neutral connection connect this to terminal N load in the fused spur 6 Carry out all necessary electrical checks 7 Raise the front panel and relocate the two screws under the small flap 8 Check operation of room stat if possible OO Oy LV OF OI KC 230VAC Feed
47. re of flue sufficient 30mm air duct 14mm flue duct to length Ensure this is used when calculating the maximum allowable allow for correct engagement in the fitting flue length 3 1 elbow reduces the maximum available length by 2 Choose the direction required to deflect the flue products 1m horizontally left or right only Note Only use water as a lubricant during assembly 3 Push the deflector elbow onto the angled flue outlet of the terminal Do not use mineral based oils in the desired position and ensure the deflector is pushed up to the shoulder to fully engage the rubber seal Drill the terminal through the hole in the deflector with a 3 2mm 1 8 drill and secure the deflector with the self tapping screw provided Note Only use water as a lubricant during assembly Do not use mineral based oils M Deflector 19 SECTION 5 INSTALLATION INSTRUCTIONS 5 14 FITTING THE OPTIONAL ROOF FLUE KIT RSF345 Pitched Note A 5 or 14 pitched roof plate not supplied is required before proceeding with the installation of this kit This kit is suitable for both 5 and 14 pitched roof terminations using a concentric flue to run vertically from the top of the boiler and terminating above roof level Connection to the top of the boiler is made using a vertical connector supplied in the kit RSF346 WEATHER PROOFING
48. s and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap the lower the rate the higher the temperature and vice versa Approx flow temperatures for the boiler thermostat settings are Knob Setting Minimum Flow Temperature 40 C 104 F 64 C 147 F Maximum Central Heating The boiler controls the central heating radiator temperature to a maximum of 80 C and a minimum of 45 adjustable the CH temperature control C The boiler is a high efficiency combination boiler which is most efficient 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 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 filled with antifreeze if installed in a caravan holiday home or park home Refer to
49. 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 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 Does the boiler operate and Ssa 018 Cortas provide central heating section If 0 is displayed then contact Morco if your appliance is under warranty or a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer if out of warranty See boiler Operation Modes and Fault Codes section Check the time settings on the programmer are as you require and adjust if necessary Contact a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer See boiler Operation Modes and Fault Codes section If 0 is displayed then contact a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer Contact a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer OPERATION MODES DISPLAY CODE ON BOILER Note These letters are permanently displayed while in that mode DESCRIPTION burner The boiler is in standby mode awaiting either a central heatin
50. te by opening hot tap to maximum flow Gas Supply With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point complies with the requirements refer to Gas Supply on page 13 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 2 CENTRAL HEATING CIRCUIT Fill the siphon in the condense pipework prior to operating In order for the boiler to function correctly the pressure in the central heating circuit must be between 1 and 1 5 bar on the pressure gauge Both the boiler and central heating installation must be purged of any air The boiler has an auto air vent integral to the pump which must be loose prior to commissioning Add an approved flushing solution to one of the radiators Fill the central heating circuit using one of the approved methods to 1 bar Open radiator vent screws and turn off when water appears Turn off the filling 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 Ref
51. 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 a Caravan Holiday Home or Park Home the heating circuit and radiators should be filled with an approved antifreeze see section 4 8 The level of antifreeze should be checked annually by a competent person If the home is occupied during very cold and freezing weather the central heating should be run continuously and the room stat or thermostatic radiator valves set at a minimum of 15 C 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 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 L will be displayed Refer to fault chart Flame Failure Should this occur a fault code F will be displayed Refer to fault chart continued Legend Mode Control Knob DHW Preheat Control Knob CH Control Knob Boiler Status Burner on Indication Pre Heat on off Indication Mechanical Timer Pressure Gauge Condensate Drain
52. 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 burner burner Flame Loss 1 Check other gas appliances in the house are working to confirm a supply is present in the property 2 If other appliances do not work or there are no other appliances check the gas supply is on at the meter 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 burner burner Return Thermistor Return temperature greater than flow temperature Please contact Morco burner burner Fan Fault Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner Flow Thermistor Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner Return Thermistor Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternati
53. tic hot water Boiler is heating up the plate heat exchanger A CH circuit water less than 5 C Below is a list with display in fault condition If the display is flashing with L or F with alternate numbers letters refer to page 32 L Boiler is in lockout a specific error Display will be blinking alternating with a number or letter to show which error is detected F Boiler has a fault for a specific error Display will be blinking alternating with a number or letter to show which error is detected 5 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 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 E
54. tion gt 25 Below grate SECTION 6 COMMISSIONING INSTRUCTIONS Before commissioning the boiler the whole gas installation including the meter if fitted MUST be purged and tested for gas soundness Purge air from the gas installation by the approved methods only WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT smoke Ensure that the flue has been installed correctly and no vents are blocked Before commencing commissioning ensure that the CH system and DHW and cold water system have been flushed The CH system needs to be treated with water treatments that are approved for use with aluminium alloy heat exchangers GENERAL Please Note The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate As part of the commissioning process the combustion of this appliance must be checked A flowchart to assist is provided on page 35 DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE Set up the boiler to operate at maximum ra
55. tions 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 rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates 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 ru
56. ved 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 Important Notes This appliance must not be operated without the casing correctly fitted and forming an adequate seal Ifthe boiler is installed in compartment then the compartment MUST NOT be used for storage purposes f itis known or suspected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer 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
57. vely a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner Outside Sensor Failure Restart the appliance if the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer Berner Low Mains Contact a qualified electrician or your electricity provider burner burner Unconfigured PCB Unconfigured PCB Please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer Flow Temperature Overheat Check system water pressure is between 1 amp 1 5bar on the system pressure gauge G or No Water Flow To re pressurise the system see Section 3 If the boiler fails to operate then please contact Morco if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer burner burner Flame Loss 1 Check other gas appliances in the house are working to confirm a supply is present in the property 2 If other appliances do not work or there are no other appliances check the gas supply is on at the meter and or pre payment meter has credit If the boiler fails to operate then please contact M
58. w Zone 2 3G8913a COMPARTMENT INSTALLATIONS Acompartment 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 modified for the purpose 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 specified in the table below For Caravan Holiday Homes if the height of the flue terminal from any ground decking or steps is under 1 5m then a suitable terminal guard should be fitted 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 Min Spacing Directly below above or alongside an opening window air vent or other ventilation opening 300mm 12 Below guttering drain pipes or soil pipes BS5440 1 2008 25mm 1 75mm 3 Bel
59. xplain 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 Siress the importance of an annual service by a competent gas registered engineer 24 SECTION 7 ROUTINE SERVICING INSTRUCTIONS 7 1 SERVICING SCHEDULE For the very latest copy of literature for specification maintenance practices and parts replacement visit our website www morcoproducts co uk where you will be able to download the relevant information WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity supply to the appliance before servicing Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a Gas Safe Registered Engineer or in other countries a qualified and competent Gas Installer INSPECTION 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the flue terminal and terminal guard if fitted
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