1. Manuals
  2. Brands
  3. Ideal Heating Manuals
  4. Boiler
  5. III Series
  6. Technical instructions

Ideal Heating III Series Technical Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
BOILER OUTPUT
To Domestic Hot Water:
GB24-Propane Minimum 4.9 kW (16,600 Btu/h)
GB30-Propane Minimum 6.1 kW (20,700 Btu/h)
GB24-Propane Maximum 24.2 kW (82,570 Btu/h)
GB30-Propane Maximum 30.3 kW (103,384 Btu/h)
January 2021
UIN 221474 A03
GB24 & GB30
Series III
Propane
Technical Instructions
min
Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD
Morco Products Ltd
Tel: 01482 325456
Website:
www.morcoproducts.co.uk
off
88
e
max
min
max
restart
restart
mode
To Central Heating:
GB24-Propane Minimum 4.9kW (16,600 Btu/h)
GB30-Propane Minimum 6.1 kW (20.700 Btu/h)
GB24-Propane Maximum 17.2 kW (58,728 Btu/h)
GB30-Propane Maximum 20.4 kW (69,607 Btu/h)
Fax: 01482 212869

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the III Series and is the answer not in the manual?

Questions and answers

Related Manuals for Ideal Heating III Series

Summary of Contents for Ideal Heating III Series

  • Page 1 GB24 & GB30 Series III Propane Technical Instructions restart restart mode BOILER OUTPUT To Domestic Hot Water: To Central Heating: GB24-Propane Minimum 4.9 kW (16,600 Btu/h) GB24-Propane Minimum 4.9kW (16,600 Btu/h) GB30-Propane Minimum 6.1 kW (20,700 Btu/h) GB30-Propane Minimum 6.1 kW (20.700 Btu/h) GB24-Propane Maximum 24.2 kW (82,570 Btu/h) GB24-Propane Maximum 17.2 kW (58,728 Btu/h) GB30-Propane Maximum 30.3 kW (103,384 Btu/h)
  • Page 2 Ideal GB24 & GB30 Series III Destination Country: GB = UK IE = Ireland Combination Boiler...

  • Page 3: Table Of Contents

    CONTENTS SECTION ................PAGE SECTION ................PAGE GENERAL ................. 5 3.24 Diverter Valve Body Assembly Replacement ....29 Introduction ................ 5 3.25 DHW Plate Heat Exchanger Replacement ...... 30 Operation ................5 3.26 Pump Head Replacement ..........30 Safe Handling ..............5 3.27 CH Water Pressure Switch Replacement .......
  • Page 4 SECTION 1 - GENERAL Table 1 - General Data Ideal GB Series III Gas Supply - G31 - 37mbar Gas Supply Connection 15mm copper compression Injector Size 3.75 Inlet Connection Domestic Hot Water G ½ Outlet Connection Domestic Hot Water G ½...

  • Page 5: General

    SECTION 1 - GENERAL 1.3 SAFE HANDLING GENERAL This boiler may require 2 or more operatives to move it to its 1.1 INTRODUCTION installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler The Ideal GB Series III range of boilers are wall mounted, full may include the use of a sack truck and involve lifting, pushing and sequence, automatic spark ignition, low water content, fanned...

  • Page 6: Safety

    SECTION 1 - GENERAL 1.5 SAFETY Current Gas Safety (installation and use) regulations or rules in force: The appliance 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.

  • Page 7: Boiler Dimensions, Services & Clearances

    SECTION 1 - GENERAL 1.7 BOILER DIMENSIONS, SERVICES & CLEARANCES The following minimum clearances must be maintained for is less than the length of flue required the flue must be fitted operation and servicing. from the outside. Installation from inside ONLY Additional space will be required for installation, depending upon site conditions. b.

  • Page 8: Boiler Assembly - Exploded View

    SECTION 1 - GENERAL 1.8 BOILER ASSEMBLY - EXPLODED VIEW Note that item numbers are linked to the spares list PUMP HEAD PRESSURE GAUGE CONDENSATE OUTLET CONNECTION AIR VENT PUMP GAS COCK TOP FLUE MANIFOLD SEAL DIVERTOR VALVE MOTOR PIPE - GAS INLET DIVERTOR VALVE BODY GAS VALVE IGNITION/FLAME IONISATION ELECTRODE...

  • Page 9: Installation

    SECTION 2 - INSTALLATION INSTALLATION 2.1 DETERMINING THE FLUE LENGTH IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions. STANDARD FLUE KITS Horizontal Flue Terminal RSF303 (600mm long) - contains: Flue turret, non telescopic single piece flue incorporating a terminal and inner rubber wall seal. Extension Kit RSF341 - contains: 1 metre length of flue pipe (Functional length 900mm), 1 support bracket.

  • Page 10: Determining The Flue Length

    SECTION 2 - INSTALLATION 2.2 DETERMINING THE FLUE LENGTH FIGURE 1 REAR FLUE SIDE FLUE Cut flue length = distance from edge of turret to outside of Cut flue length = distance from edge of turret to outside of wall dimension A + 47mm. wall dimension B + 47mm. Note. Minimum dimension A which can be accommodated is Note. Minimum dimension B which can be accommodated is 91mm.

  • Page 11: Installing The Flue

    SECTION 2 - INSTALLATION 2.4 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 aluminium flue collar (RSF 060) at least 17mm. Note. If less than 50% of the length of the flue is internal the flue should be fitted from outside.

  • Page 12: Flue Extensions Rsf341 (Optional)

    SECTION 2 - INSTALLATION 2.5 FLUE EXTENSIONS RSF341 (OPTIONAL) For side outlet refer to section 1.2 before commencing any work. 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.

  • Page 13: Fitting The Optional Roof Flue Kit Rsf345 (Optional) - Flat Or Pitched

    SECTION 2 - INSTALLATION 2.8 FITTING THE OPTIONAL ROOF FLUE KIT RSF345 (OPTIONAL) - Flat or Pitched- Note. A 5º or 14º pitched roof plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both 5º and 14º pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

  • Page 14: Condensate Drain

    SECTION 2 - INSTALLATION 2.10 CONDENSATE DRAIN 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.
  • Page 15 SECTION 2 - INSTALLATION CONDENSATE DRAIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of Condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler...

  • Page 16: Wiring Diagram

    SECTION 2 - INSTALLATION 2.11 WIRING DIAGRAM...

  • Page 17: Servicing

    SECTION 3 - SERVICING SERVICING 3.1 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.

  • Page 18: Boiler Upper & Lower Front Panel Removal / Replacement

    SECTION 3 - SERVICING 3.2 BOILER UPPER & LOWER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Lift the lower front panel access panel. 4. Hook the upper panel onto the top retaining clips. 2. Unscrew the fixing screw, close the access panel to retain 5. Retain the upper panel with the two fixing screws the two screws and hinge the lower front panel down into previously removed ensuring a good seal is made.

  • Page 19: Burner Removal & Cleaning

    SECTION 3 - SERVICING 3.4 BURNER REMOVAL & CLEANING 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 20: Cleaning The Heat Exchanger

    SECTION 3 - SERVICING 3.6 CLEANING THE HEAT EXCHANGER Ignition Electrode Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Section 3.17. 1. Remove ignition electrode. Refer to Section 3.12. 2. It is advisable to replace the sump cover prior to the water flush process. 3. Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered.

  • Page 21: Replacement Of Components

    SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. Ensure all gas valve connections are gas tight with a gas When replacing ANY component soundness check up to the gas control valve. 1. Isolate the electricity supply. When work is complete, the front panels must be correctly 2.

  • Page 22: Burner Injector Replacement

    SECTION 3 - SERVICING 3.10 BURNER INJECTOR REPLACEMENT 1. Refer to Section 3.8. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve and ease the pipe upwards, rotate and ease down to remove. 4.

  • Page 23: Ignition/Flame Electrode Replacement

    SECTION 3 - SERVICING 3.12 IGNITION/FLAME ELECTRODE REPLACEMENT 1. Refer to Section 3.8. 2. Remove the burner. Refer to Section 3.10. 3. Unplug the ignition lead from the electrode. Ignition Electrode 4. Remove the earth lead from the ignition electrode. 5. Remove the 2 screws holding the ignition electrode to the combustion chamber.

  • Page 24: Gas Control Valve Replacement

    SECTION 3 - SERVICING 3.14 GAS CONTROL VALVE REPLACEMENT 1. Refer to Section 3.8. 2. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire. 3. Remove the outlet gas valve clip and slide the pipe upwards.

  • Page 25: Condensate Trap/Siphon Replacement

    SECTION 3 - SERVICING 3.16 CONDENSATE TRAP/SIPHON REPLACEMENT 1. Refer to Section 3.8. 2. Pull off the rubber pipe at the siphon. 3. Turn the siphon clockwise to disengage and lift to remove. 4. Reassemble in reverse order. 5. When reassembling ensure the trap is full of water.

  • Page 26: Main Pcb Replacement

    SECTION 3 - SERVICING 3.17 MAIN PCB REPLACEMENT *Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering spare PCBs programming may be required. Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis.

  • Page 27: Replacing The Mechanical Timer

    SECTION 3 - SERVICING 3.18 REPLACING THE MECHANICAL TIMER 1. Refer to Section 3.8. 2. Swing the boiler lower front panel into the service position. Refer to Section 3.2. 3. Remove the 4 fixing screws. 4. Disconnect the 4 push on connectors. 5. Remove programmer. 6. Re-fit 4 push on connectors to new programmer.

  • Page 28: Pressure Gauge Replacement

    SECTION 3 - SERVICING 3.21 PRESSURE GAUGE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the heating system. Refer to Section 3.19. 3. Remove the boiler front (See Section 3.8), lower the control panel and remove the  control box cover. 4.

  • Page 29: Pump Automatic Air Vent Replacement

    SECTION 3 - SERVICING 3.23 PUMP AUTOMATIC AIR VENT REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.19. 3. Using a suitable screwdriver positioned between the air vent dust cap and the plastic protrusion, turn the air vent carefully anti Dust Cap clockwise to disengage and lift to remove.

  • Page 30: Dhw Plate Heat Exchanger Replacement

    SECTION 3 - SERVICING 3.25 DHW PLATE HEAT EXCHANGER REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.19. 3. Remove the condensate siphon. Refer to Section 3.16. 4. Remove the two plate heat exchanger fixing screws. 5. Slide the plate heat exchanger to the left and push the plate back to disengage.

  • Page 31: Dhw Filter & Dhw Flow Regulator Cleaning/Replacement

    SECTION 3 - SERVICING 3.28 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.19. 3. Turn the housing anti clockwise and pull forward to remove the cartridge. 4. Using a pair of pliers, pull out the plastic filter/flow regulator.

  • Page 32: Heat Engine Replacement

    SECTION 3 - SERVICING 3.31 HEAT ENGINE REPLACEMENT Refer also to Section 1.3 - ‘Boiler Exploded View’ IMPORTANT - Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Section 3.8. 14. To remove the Heat exchanger slide out of location bracket. 2.

  • Page 33: Expansion Vessel Recharging & Replacement

    SECTION 3 - SERVICING 3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING 1. Refer to Section 3.8. Recharge Point 2. Drain the boiler CH circuit. Refer to Section 3.19. 3. Remove the charge point cover. 4. Recharge the tank pressure to 0.75 bar. 5.

  • Page 34: Fault Finding

    SECTION 4 - FAULT FINDING FAULT FINDING 4.1 OPERATION MODES DESCRIPTION DISPLAY CODE ON BOILER The boiler is in standby operation awaiting either a central heating call or hot water demand. The boiler has a call for central heating but the appliance has reached the desired temperature set on the boiler.

  • Page 35: Service Mode

    SECTION 4 - FAULT FINDING 4.2 SERVICE MODE THE DISPLAY The user control has two LEDs and two 7 segment displays to inform the user about the status. The display will show the status of the boiler. The LED will show the status of the flame. If no flame is detected the LED is off. When the flame is detected the LED will be lit permanently. Below is a list with display function in normal operation.

  • Page 36: Fault Codes

    SECTION 4 - FAULT FINDING 4.3 FAULT CODES DESCRIPTION ACTION DISPLAY CODE ON BOILER Low Water Pressure Check system water pressure is between 1 & 1.5bar on the system pressure gauge. To re-pressurise the system see Section 3. If the boiler still fails to operate then please contact Morco (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.

  • Page 37: Fault Finding Chart Main Menu

    SECTION 4 - FAULT FINDING 4.4 FAULT FINDING CHART MAIN MENU GO TO SECTION 4.5 - ‘L1’ FLOW TEMPERATURE OVERHEAT LOCKOUT GO TO SECTION 4.6 - ‘L2’ IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS - ‘LC’ TURN POWER OFF AND ON GO TO SECTION 4.8 - ‘L6’...

  • Page 38: L1' - Flow Temperature Overheat Lockout

    SECTION 4 - FAULT FINDING 4.5 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with anti-freeze/ Fill and vent the system and open all inhibitor solution and all isolation and radiator valves isolation valves, then restart boiler open? Has the pump impellor seized? Check by engaging Is the Flow/Return differential across the with a screwdriver pushing inwards and then turning boiler in excess of 30ºC...

  • Page 39: Alternating 'L' And '5' - 5 Resets Within 15 Mins

    SECTION 4 - FAULT FINDING 4.7 ALTERNATING ‘L’ AND ‘5’ - 5 RESETS WITHIN 15 MINS Turn power off and on 4.8 ‘L6’ - FALSE FLAME LOCKOUT Restart the boiler. Does the boiler No further action required. work OK? If prolem persists Remove flame detection plug from spark generator. Is Replace Spark Generator.

  • Page 40: F2 Or Fn Or Ln' - Flame Loss

    SECTION 4 - FAULT FINDING 4.10 ‘F2 OR FN OR LN’ - FLAME LOSS Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish? the Boiler Inlet (35 ±0.5 mbar)? rectify fault Check wiring from gas Is 24Vdc supply available at the...

  • Page 41: F4 Or L4' - Flow Thermistor Fault

    SECTION 4 - FAULT FINDING 4.12 ‘F4 OR L4’ - FLOW THERMISTOR FAULT Securely connect the wiring to the Flow Is the wiring securely connected to the Flow Thermistor Thermistor (located in the top of the Heat Exchanger?) Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected Fit a new Thermistor across the Thermistor’s terminal pins.

  • Page 42: F6' - Outside Sensor Fault

    SECTION 4 - FAULT FINDING 4.14 ‘F6’ - OUTSIDE SENSOR FAULT IMPORTANT: If no outside sensor is fitted & F6 fault is shown, replace PCB. Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.

  • Page 43: No Hw But Ch On

    SECTION 4 - FAULT FINDING 4.16 NO HW BUT CH ON Is hot and cold pipework crossed? Does the display show “dH” when a tap is on? Adjust flow rates to achieve 35º Are the flow rates correct as per Section 1.16. temp rise and check filter fitted in turbine is not blocked with debris. Is the wiring between the PCB and the diverter Reconnect wiring or valve actuator connected? replace wiring harness if Is the wiring connected no continuity.
  • Page 44 For more detailed servicing information, workshop manuals, technical advice, spare parts, product training, please phone us on 01482 325456 or contact us at the address below: MORCO PRODUCTS LTD Morco House, Riverview Road, Beverley, East Yorkshire HU17 0LD TEL: 01482 325456 FAX: 01482 212869 EMAIL: sales@morcoproducts.co.uk WEBSITE: www.morcoproducts.co.uk...

This manual is also suitable for:

Gb24Gb30

Table of Contents