Morco GB24 User & Installation Instructions Manual
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Morco GB24 User & Installation Instructions Manual

Combination boiler
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User & Installation Instructions
BOILER OUTPUT
To Domestic Hot Water:
GB24/30 Minimum 8.0 kW (27,296 Btu/h)
GB24 Maximum 24.2 kW (82,570 Btu/h)
GB30 Maximum 30.3 kW (103,384 Btu/h)
UIN 209783 A03
April 2014
GB24 & GB30
off
max
reset
min
preheat
mode
To Central Heating:
GB24/30 Minimum 8.0 kW (27,296 Btu/h)
GB24/30 Maximum 24.2 kW (82,570 Btu/h)
Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD
Morco Products Ltd
Tel: 01482 325456
Website:
www.morcoproducts.co.uk
status
burner
e
min
max
preheat
GB24
Fax: 01482 212869

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Summary of Contents for Morco GB24

  • Page 1 GB24 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) GB30 Maximum 30.3 kW (103,384 Btu/h)

  • Page 2: Combination Boiler

    Morco GB24 & GB30 Destination Country: BE = Belgium Combination Boiler CH = Switzerland CZ = Czech Republic ES = Spain FR = France GB = UK GR = Greece IE = Ireland IT = Italy NL = Netherlands PL = Poland...

  • Page 3: Table Of Contents

    CoNTENTS SECTIoN PAGE Users Instructions ............................4 General Specifications ...........................8 Technical Data ...............................10 General Installation Requirements.........................12 Installation Instructions ..........................14 Commissioning Instructions ...........................23 Routine Servicing Instructions ........................25 Fact Sheets ..............................31 Fault Codes..............................32 Combustion Ratio Check ..........................34 Warranty ................................36...

  • Page 4: Users Instructions

    SECTION 1 - USERS INSTRUCTIONS FoR ANy qUERIES PLEASE RING THE MoRCo CoNSUMER HELPLINE : 01482 325456 NoTE. BoILER RESET PRoCEDURE - To reset boiler, turn mode control knob to reset position and immediately turn knob back to required setting. Minimum Clearances Introduction Clearances of 165mm (6...

  • Page 5: Control Of Water Temperature

    SECTION 1 - USERS INSTRUCTIONS To shut down the boiler Operation Set the mode knob control to oFF Winter conditions - i.e. CH and DHW required. To relight the boiler ensure the mode knob control (A) is set to winter ( Repeat the procedure detailed in ‘To light the boiler’.

  • Page 6: Loss Of System Water Pressure

    SECTION 1 - USERS INSTRUCTIONS Loss of system water pressure To unblock a frozen condensate pipe; The pressure gauge indicates the central heating system 1. Follow the routing of the plastic pipe from its exit point on the pressure. If the pressure is seen to fall below the original appliance, through its route to its termination point.

  • Page 7: Troubleshooting

    SECTION 1 - USERS INSTRUCTIONS PoINTS FoR THE BoILER USER Note. In line with our current warranty policy we would ask that you check through the Troubleshooting guide to identify any problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.

  • Page 8: General Specifications

    Automatic Bypass use. Daily Pump and Diverter Valve exercise maximum heat output in either heating or hot water for the GB24 mechanical 24hr Timer is 24.2kW (82,570 Btu/hr) The boiler temperature controls are visible, located in the control maximum heat output in heating mode for the GB30 is 24.2 kW...
  • Page 9 SECTION 2 - gENERAL SPECIFICATIONS 2.2 WIRING DIAGRAM...

  • Page 10: Technical Data

    section 3 - tecHnicAL DAtA Table 1 - General Data Morco GB Gas supply - G31 - 37mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 3.75 3.75 Inlet Connection Domestic hot Water outlet Connection Domestic hot Water Flow Connection Central heating Return Connection Central heating...
  • Page 11 section 3 - tecHnicAL DAtA BoILER DIMENSIoNS, SERVICES & CLEARANCES The boiler connections are made on the boiler bulkhead fittings. (24”). Where the space into which the boiler is going to be installed is less than the length of flue required the flue must The following minimum clearances must be maintained for be fitted from the outside. operation and servicing. Installation from inside oNLy Additional space will be required for installation, depending upon site conditions.

  • Page 12: Boiler Location & Flue Terminal Position

    SECTION 4 - gENEral INSTallaTION rEquIrEmENTS 4.1 RECoMMENDATIoNS CoMPARTMENT INSTALLATIoNS A compartment used to enclose the boiler should be designed Current Gas Safety (Installation and Use) Regulation or Rules in and constructed specially for this purpose. Force. An existing cupboard or compartment may be used, provided The boiler is suitable only for installation in the specified countries that it is modified for the purpose.

  • Page 13: Air Supply

    SECTION 4 - gENEral INSTallaTION rEquIrEmENTS 4.4 AIR SUPPLy 4.9 REqUIREMENTS FoR SEALED WATER SySTEMS 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 At maximum CH output 24.24kW at a 20ºC differential and flow it necessary to ventilate a cupboard or compartment in which the rate 17.3 l/min a 3.4m wg head is available for the system...

  • Page 14: Installation Instructions

    section 5 - installation instructions 5.1 BoILER PACKAGING 5.4 INTERNAL WIRING The boilers are supplied in different packagings: The boiler has been pre-fitted with a 3 amp fused approved moulded 3 pin and flying lead for use with 230V 50Hz. • Boiler If the supply cord is damaged, it must be replaced by the • Flue System (separate) manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. •...
  • Page 15 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). Turret Part No. RSF303 The minimum cut length is 138mm (includes 30mm into elbow) The maximum allowable length using extensions (RSF341) is: GB24 - 8m (minus any flue kit options) GB30 - 7m (minus any flue kit options)

  • Page 16: Determining Flue Length

    section 5 - installation instructions 5.7 DETERMINING THE FLUE LENGTH ImPoRTANT. The boiler must be installed in a vertical position in accordance to the installation instructions. STANDARD FLUE KITS Horizontal Flue Terminal RSF303 (600mm long) - contains: Flue turret, non telescopic single piece 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.
  • Page 17 section 5 - installation instructions 5.8 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 18: Installing The Flue

    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 17mm min aluminium spinning at least 17mm. Note.
  • Page 19 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.

  • Page 20: Assembling The Roof Flue Kit

    section 5 - installation instructions 5.14 FITTING THE oPTIoNAL RooF FLUE KIT (RSF345) (Pitched) Note. A 5º or 14º pitched roof plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both 5º and 14º pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.
  • Page 21 section 5 - installation instructions 5.16 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 Condensate Condensate such as an internal soil and vent stack or kitchen or bathroom Drain Drain waste pipe etc.
  • Page 22 section 5 - installation instructions 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 sealed...

  • Page 23: Commissioning Instructions

    SECTION 6 - COMMISSIONING INSTRUCTIONS 6.2 CENTRAL HEATING CIRCUIT Before commissioning the boiler, the whole gas installation including the meter (if fitted) MUST be purged and tested for gas soundness. Fill the siphon in the condense pipework prior to operating. Purge air from the gas installation by the approved methods only. 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 WARNING.

  • Page 24: Final Checks

    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. Standby, no demand for heat present.

  • Page 25: Routine Servicing Instructions

    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.
  • Page 26 SECTION 7 - ROuTINE SERvICINg INSTRuCTIONS 7.2 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 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.

  • Page 27: Burner Removal And Cleaning

    SECTION 7 - ROuTINE SERvICINg INSTRuCTIONS 7.4 BURNER REMoVAL AND CLEANING 1. ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 28: Cleaning The Heat Exchanger

    SECTION 7 - ROuTINE SERvICINg INSTRuCTIONS 7.6 CLEANING THE HEAT ExCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition electrode Flame Detection Frames 7.5. 1. Remove ignition and flame detection electrodes. Refer to Frames 7.9 & 7.10. 2. It is advisable to replace the sump cover prior to the water flush process.

  • Page 29: Burner Removal

    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. 4. Remove the 2 front fixing screws and loosen the 2 rear extended nuts. 4.
  • Page 30 SECTION 7 - ROuTINE SERvICINg INSTRuCTIONS 7.10 FLAME DETECTIoN ELECTRoDE 1. Remove the burner. Refer to Frame 7.8. 2. Check dimensions are correct as in diagram below. 3. Reassemble in reverse order. Flame Detection electrode FoR REMoVAL: 1. Unplug the ignition lead and remove the earth lead.

  • Page 31: Fact Sheets

    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...

  • Page 32: Fault Codes

    SECTION 9 - faulT COdES 9 FAULT CoDES DESCRIPTIoN ACTIoN DISPLAy CoDE oN BoILER outside Sensor Failure Reset the appliance - if the boiler fails to operate then please contact morco (if under warranty) or alternatively a Gas Safe Registered Engineer, or in other countries a qualified and competent Gas Installer if outside of the warranty period.

  • Page 34: Combustion Ratio Check

    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.
  • Page 35 SECTION 10 - COMBUSTION CHECK Start Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow (by fully turning on hot tap) set boiler to readings to stabilise.

  • Page 36: Warranty

    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: 1.

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Gb30

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