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Morco FEB-24ED Technical Documentation Manual
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Morco FEB-24ED Technical Documentation Manual

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FEB-24ED TECHNICAL DOCUMENTATION
01-12-08 version 1.0

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Summary of Contents for Morco FEB-24ED

  • Page 1 FEB-24ED TECHNICAL DOCUMENTATION 01-12-08 version 1.0...

  • Page 2: Table Of Contents

    1- WARNINGS AND PRECAUTIONS ..........1 2 - FEATURES ......................2 3 - DESCRIPTION OF FUNCTIONING...............5 3.1.1 General description .......................5 3.1.2 Hydraulic Circuit ......................4 3.1.2 PCB (Photograph)......................9 3.1.3 Gas Circuit ........................14 3.1.4 Air circuit........................18 3.2 - External auto test functions...................19 3.3- On board auto test functions and boiler configuration set up........26 3.4 -Trouble shooting + lock out codes........

  • Page 3: 1- Warnings And Precautions

    t e c h n i c a l Warnings and precautions 1.- Warnings and precautions In order for the boiler to function correctly, it is vitally important for the appliance to be correctly adjusted on installation in accordance with gas installation regulations. Boiler installation must comply with the conditions described by in the user and installation manual provided with the appliance Important:...

  • Page 4: Features

    Features 2.- Features is a The boiler FEB-24ED wall hung, room sealed, fan assisted, microprocessor controlled fully modulating gas combination boiler for providing both central heating and domestic hot water. The boiler has a continuous electronic modulation fi eld. The 24kW boiler has an output power of between 7.6 kW and 23.7 kW (6,536 and 20,382 Kcal/h).
  • Page 5 Features Technical data: Models FEB-24ED Category 2H3P Type Central heating performances Maximum 23,7 output kcal/h 20.382 Minimum output kcal/h 6.536 Domestic hot water performances Maximum 23,7 output. kcal/h 20.382 Minimum output kcal/h 6.536...

  • Page 6: Description Of Functioning

    Description of functioning 3.- Description of functioning 3.1.- General description 3.1.1.- Hydraulic Circuit Hydraulic Circuit FEB-24ED 1. Expansion vessel 2. Pump 3. Low pressure switch 4. Central heating thermistor 5. Three way valve 6.
  • Page 7 t e c h n i c a l Description of functioning Filling the heating circuit: In order for the boiler to function correctly, the heating circuit pressure must be at around 1.6 b when it is cold. Both the boiler and the heating installation must be correctly purged,as air in the water pipes can cause excessive noise and malfunctioning.
  • Page 8 t e c h n i c a l Description of functioning Description and function of the hydraulic components: Compact hydraulic unit: (Part number MCB2190) This unit consists of various hydraulic components: circulating pump, safety valve, drain valve, plate heat exchanger, 3-way valve, fl ow restrictor, automatic drain valve and automatic bypass.
  • Page 9 t e c h n i c a l Description of functioning Drain valve: This component allows the heating circuit to be drained. Finger operated located to the right hand side of the safety valve. (Part number MCB2180) MCB2180 3 Way valve: Integrated within hydraulic unit, operates whenever a hot tap is opened.
  • Page 10 t e c h n i c a l Description of functioning Expansion vessel: (Part number MCB2005) The expansion vessel is a hermetically closed receptacle with two chambers separa- ted by an SBR membrane. One chamber contains nitrogen (air) and the other is fi lled with the water from the heating circuit.
  • Page 11 18v dc return LPS 18v dc out LPS TIME CLOCK RETURN 18vdc TIME CLOCK 0UT 18 v dc DHW ANTI-FREEZING RELAY (J24) (NOT USED ON FEB-24ED) GAS VALVE 1 RELAY. EV1 (J25) (220VAC) GAS VALVE 2 RELAY. EV2 (J25) (220VAC) PUMP RELAY (J17) FAN RELAY (J18) “Opto triac”...
  • Page 12 t e c h n i c a l Description of functioning Anti Freeze Safety: When the temperature (read by heating thermistor) falls to 6ºC the pump will run until the temperature reaches to 9ºC. If the temperature continues to fall and the heating thermistor reads less than 3 ºC the boiler will light up at minimum power until the heating circuit temperature reaches 20º...
  • Page 13 t e c h n i c a l Description of functioning Output Time If the heating selected temperature is achieved in less than 5 minutes. The next heating cycle will result in the minimum burn period to be extended to 5 mins. If the burner continues to burn at minimum power for 5 minutes without restarting the Modulation process can then start to increase the burner power if required.
  • Page 14 t e c h n i c a l Description of functioning 92º C Security (without DHW demand) If heating thermistor value arrives to 92º C, the pump will run making cycles of 10 se- cond starting and stopping. If the temperature remains high the pump will continue cycling until a lower temperature is detected.
  • Page 15 t e c h n i c a l Description of functioning Note: When the heating is working and within the range shown in the table below If the thermistor is out of range the boiler will lock out, automatically “resetting” again when the working range is entered.

  • Page 16: Gas Circuit

    t e c h n i c a l Description of functioning 3.1.3.- Gas Circuit Characteristics of the gas components: Gas valve: (Part number FCB1130) This is one of the most important components of the boiler. It regulates output power, gas consumption, combustion, mo- dulation.
  • Page 17 Description of functioning MAIN BOARD PUSH BUTTON FEB-24ED: Installation Menu. To enter in the Installation menu, with the left knob out of the O position and the right knob must be placed in to the middle, more or less at 75ºC, after the boiler must be turned off,...
  • Page 18 t e c h n i c a l Description of functioning Gas Type Maximum Power Minimum Power Natural Gas Propane Step 2. Maximum Heating Power. The display shows “P2” and the value selected alternatively. When the right knob (CH) is in summer position, the display shows the stored value of the selected step.
  • Page 19 t e c h n i c a l Description of functioning The table below shows the gas pressure values at the burner for each model of boiler: OUTPUT (kcal/h) BURNER PRESSURE IN mb OF WATER GAUGE BOILER 24KW Natural Propane 20382 18.0...

  • Page 20: Air Circuit

    t e c h n i c a l Description of functioning 3.1.4- Air Circuit Characteristics of the air circuit components: MCB2105 Fan: (Part number MCB2030) The function of the fan is to draw in air from the outside and evacuate the burnt gases produced during combustion.The 24kW boiler fan has a power of 35W.
  • Page 21 t e c h n i c a l Description of functioning 3.2- Troubleshooting A.S.S. Control It’s an appliance connected to BMF net from the main control board of the boiler, it’s used by the A.S.S. (After Sales Service) to confi gure and adjust the boiler parame- ters.
  • Page 22 t e c h n i c a l Description of functioning The different groups are the following: - D.H.W. Set point and temperature (tap symbol). - Central Heating set point and temperature (radiator symbol). - D.H.W. Temperature (ºC) and gas valve power (%). - D.H.W.
  • Page 23 t e c h n i c a l Description of functioning - Input and output temperature in the exchanger ( No NTC at the output appears “- -”) AUTOTEST. A.S.S. TEST. Parameters adjust. It has 7 different steps: - Step 1. Switch ON/OFF the pump and 3-way valve. The display shows P1. Light button: When pressed, display shows D.H.W.
  • Page 24 t e c h n i c a l Description of functioning - Step 3. Maximum DHW Power Regulation. Display shows P3 and electrical value. Limited between 56 and 99. - Light button: When pressed, display shows D.H.W. Temperature and electrical value of this step.
  • Page 25 t e c h n i c a l Description of functioning First 2 digits indicate the boiler type depending on type of water pressure detector, if the boiler uses water pressure switch, the boiler will be 00 and if the boiler uses water pressure sensor (digital pressure gauge) the boiler will be 04.
  • Page 26 t e c h n i c a l Description of functioning Second digit from “YY” External probe (SE) Without probe Curve A Curve B Curve C Curve D - Step 2. Latest Faults. Shows an historical with fi fty last faults of the boiler. At fi rst its shown “FAI”...
  • Page 27 t e c h n i c a l Description of functioning - Step 5. External Probe. Display shows “SE” and “X” the selected curve. If SE=0 no external probe will be connected. In all the other cases it will be selected the best option for the external probe.
  • Page 28 t e c h n i c a l Description of functioning - Step 8. Maximum DHW Power Regulation. Only displays the selected value in AUTOTEST (P1 XX). - Step 9. Minimum DHW Power Regulation. Only displays the selected value in AUTOTEST (P2 XX).
  • Page 29 Description of functioning seconds time, the opposite option will be chosen and the display will show “- -” to indicate that a different option has being stored and after it will show the sto- red option. In case fl oor heating (SU) is selected, the set point must be stored.
  • Page 30 t e c h n i c a l Description of functioning - Step 3. Maximum DHW Power Regulation. Display shows t3 and the electrical value alterna- tely. When the right knob (CH) is in summer posi- tion, the display shows the stored value and tur- ning clockwise the right knob the selected value can be changed.
  • Page 31 t e c h n i c a l Description of functioning red value, it can be stored pushing the main board button, then the display shows “- -”to indicate that the value has being stored. The electrical value is limited from 20 to 99 when heating circuit is radiators (RA) and from 20 to 70 when heating circuit is fl...
  • Page 32 t e c h n i c a l Description of functioning Second digit from “YY” External probe (SE) Without probe Curve A Curve B Curve C Curve D I.E. A boiler that shows “Cn” “00” “3B” in this step means that is a boiler type 00 (with pressure switch) and it is confi...
  • Page 33 t e c h n i c a l Description of functioning - Step 5. External Probe. Display shows “SE” and “X” the selected curve alternatively. If SE=0 no external probe will be connected. In all the other cases it will be selected the best option for the external probe.
  • Page 34 t e c h n i c a l Description of functioning Failures and Fault Finding: The different type of failures the boiler will show with a lockout light: The boiler trys 3 times to establish the fl ame: each sequence lasts 6 seconds between each sequence the stop time is 5 seconds If the ionisation electrode fails to detect a flame the boiler will lock out (F1)
  • Page 35 t e c h n i c a l Description of functioning In the lighting up process the PCB checks if the air pressure switch contacts are open prior to the fan starting,if after 3 minutes if the air pressure switch contacts remain closed then the boiler will lockout F2 (F21 IN HISTORICAL FAULTS) In the lighting up process the PCB checks if the air pressure switch contacts are closed.If after 6 minutes the air pressure switch contacts remain open the boiler locks out...
  • Page 36 t e c h n i c a l Description of functioning This fault that occurs when there is a problem with the gas valve or PCB. As the burner shuts down the solenoids on the gas valve. These close one at a time until the fl...
  • Page 37 t e c h n i c a l Description of functioning This may be caused by a poor connection of the 5-way cable joining the two PCB's; “Err” may also appear very briefl y on the display when the boiler is plugged into the mains or when entering auto-test mode;...
  • Page 38 Description of functioning Fault Finding: Boiler FEB-24ED FEB-24ED DISPLAY DEMAND Go to 1 Heating Works? D.H.W. Works? Go to 2 Heating Go to 3 Works? Pump Go to 4A Works? Fan Works?
  • Page 39 t e c h n i c a l Description of functioning LIGHTING UP INCORRECT Left knob in TURN IT ON Position ON? Check electrical There are 230 VAC in connection (Mains cable) connectors J12-J13? Replace main PCB 5 VDC in connector J26 between extreme pins? Check the wiring and connections between...
  • Page 40 t e c h n i c a l Description of functioning DHW WORKS BUT HEATING DOESN´T WORK CH control knob in the It´s the right knob out Turn it to winter position of summer position? winter setting ? Room thermostat contacts Check Room Thermostat Room thermostat close? closed and calling for heat ?
  • Page 41 t e c h n i c a l Description of functioning PUMP DOESN´T WORK Is the pump ON? Check the connections There are 230 Vac in J17 at the PCB if all OK then replace the main PCB Unseize the pump impelor or Unseize up the pum or replace the pump replace the paump...
  • Page 42 t e c h n i c a l Description of functioning PUMP AND FAN WORK BUT THERE IS NO SPARK Air pressure switch Is there enough is closed? pressure differential (J4-black wires) at the air pressure swich? Check the venturi and the Check the pressure switch flue/ air intake pipes connections, P+ &...
  • Page 43 6. SPARK WORKS BUT NO FLAME/FLAME FAILS AFTER IGNITION. Is there a 230v Check the ac supply to the wiring & gas valve connections at solenoids, EV1 J25 on PCB, if Regulated gas Flame & EV2 J25 PCB ok replace supply to inlet black/red? main PCB.
  • Page 44 t e c h n i c a l Description of functioning DOESN´T MODULATE CORRECTLY Heating DHW modulates modulates correcty? correcty? Check water Regulate Always at Pump works? pressure or check minimum minimum? 230Vac on J17 Check gas valve Configure Check SU/RA Regulate regulation and...
  • Page 45 t e c h n i c a l Description of functioning BOILER MAKES NOISE Has the boiler an Fit air restrictor What kind of air restrictor ring in tha air intake, if noise? fitted? is necesary WATER Check the Check th minimum burner pressure...
  • Page 46 t e c h n i c a l Description of functioning 3.3- Assembly and disassembly instructions PLEASE NOTE THAT THE HYDRAULIC UNIT CONTAINS A FLOW RESTRICTOR. THIS IS LOCATED IN THE COLD WATER INLET PORT WITHIN THE UNIT. FAILURE TO REFIT THIS PART WILL ALLOW AN EXCESSIVE FLOW FROM THE BOILER.
  • Page 47 t e c h n i c a l Description of functioning tions, i.e. the 3-way valve micro switch and the thermistor connections. - Remove the heating outlet pipe (2) from the hydraulic unit. - Remove the pressure sensor from the heating return pipe, for ease of handling. - Remove the heating outlet pipe (3) from the heat exchanger for ease of handling.
  • Page 48 t e c h n i c a l Description of functioning Changing the Pump : - Drain the heating circuit and the domestic circuit. - Remove the four Allen screws holding the pump body to the hydraulic unit, and remo- ve the pump.
  • Page 49 Description of functioning 3.4.- Lighting up Sequence and Electrical Circuit DHW start sequence FEB-24ED Low pressure DHW DEMAND Lock out F-3 switch closed 3 Min.Lock out F-2 Air pressure FAN OFF...
  • Page 50 Description of functioning Heating start sequence FEB-24ED HEATING Low pressure Lock out F-3 DEMAND switch closed? Heating temperature < PUMP ON Heating Set Point-5ºC? Heating temperature < Heating Set Point-5ºC? 3 Min.Lock out F-2...
  • Page 51 Description of functioning RE-start sequence FEB-24ED FROM START GAS VALVE CLOSED SPARK OFF SEQUENCE FAN 5 SEC.ON PUMP ON Open gas valve at SPARK Maximun 6 Open EV1 and EV2 lighting pressure seconds.
  • Page 52 Description of functioning DHW Service: FEB-24ED START SEQUENCE DHW Temp. <DHW Set point - 4º C? DHW Temp. <DHW Set point (45 sec.)? Is there F-11? ON-OFF MODULATION MODULATION: DHW Temperature regulated by Heating Dwh Temp.<DHW Set point + 4ºC (15 sec)?
  • Page 53 Description of functioning HEATING SERVICE FEB-24ED START SEQUENCE 30 second FUZZY LOGIC: minimum power 5 min. Minimum power HEATING MODULATION: Heating Temp. = 102ºC? keep the temperature at selected value by user LOCK OUT F-4 PUMP 1MIN.ON...
  • Page 54 t e c h n i c a l Description of functioning Working mode change sequence: from Heating to DHW. Pump Cycling OFF Pump Cycling ON Heating working: Heating working BURNER ON BURNER ON FAN ON FAN ON PUMP ON PUMP ON DHW DEMAND DHW DEMAND...
  • Page 55 Description of functioning Electrical Circuit diagrams: FEB-24ED 1.- Mains connection (230v ac) 15.- High limit stat 16.- DHW thermistor 2.- Earth 3- Fan (230v ac) 17.- Central Heating thermistor 4.- Pump (230v ac) 18.- CH low Pressure switch...
  • Page 56 MORCO PRODUCTS LTD Morco House Riverview Road Beverley East Yorkshire HU17 OLD Sales Telephone:01482 325456 Technical Helpline 01482 386586 Fax:01482 212869 email: sales@morcoproducts.co.uk web: www.morcoproducts.co.uk...
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