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Ideal Heating GB24, Technical Instructions

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23

SECTION 3 - SERVICING

Spark Generator

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.

4.

  Remove the earth lead from the ignition 

electrode.

5. 

Remove the 2 screws holding the ignition 

electrode to the combustion chamber.

6.

  Remove the electrode.

7.

  Fit the new ignition electrode, using the 

new gasket supplied. Check dimensions 

as shown.

8.

  Reassemble in reverse order.

9. 

Check the operation of the boiler. 

           

Ignition Electrode

3mm

Straight edge

Spark Gap

3.5mm

3.13 SPARK GENERATOR REPLACEMENT

1. 

Refer to Section 3.8.

2. 

Disconnect the leads from the spark 

generator.

3.

  Pull the spark generator to unclip 

from the mounting bracket.

4.

  Fit the new spark generator and re-

assemble in reverse order ensuring 

that the the earth lead is replaced. 

5.

  Check operation of the boiler.

3

Summary of Contents for GB24

Page 1: ...s co uk 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 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 BOILER OUTPUT min m...

Page 2: ...2 Combination Boiler Destination Country GB UK IE Ireland Ideal GB24 GB30 Series III ...

Page 3: ...park Generator Replacement 23 3 14 Gas Control Valve Replacement 24 3 15 Divterter Valve Actuator Replacement 24 3 16 Condensate Trap Siphon Replacement 25 3 17 Main PCB Replacement 26 3 18 Replacing The Mechanical Timer 27 3 19 Draining The Boiler 27 3 20 DHW Flow Turbine Replacement 27 3 21 Pressure Gauge Replacement 28 3 22 Safety Relief Valve Renewal 28 3 23 Pump Automatic Air Vent Replacement...

Page 4: ...erformance Data Domestic Hot Water Required for maximum flow rate Boiler operates down to 2 l min DHW delivery Ideal GB Series III 24 30 Gas Supply I3P G31 37mbar Gas Supply Connection 15mm copper compression Injector Size mm 3 3 3 75 Inlet Connection Domestic Hot Water G Outlet Connection Domestic Hot Water G Flow Connection Central Heating G Return Connection Central Heating G Flue Terminal Diam...

Page 5: ...draw off of 24 9 9 l min at 35 o C temperature rise 30 12 4 l min at 35 o C temperature rise The DHW draw off rate specified above is the nominal that the boiler flow regulator will give Due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rate the maximum temperature is limited to 65 o...

Page 6: ... Gas Installer In the approved country the boiler is installed this must be in accordance with their current rules in force Detailed recommendations are contained in the following British Standard Codes of Practice BS 5482 Part 1 2005 Code of Practice for domestic butane and propane gas burning installations in permanent dwellings residential park homes and commercial premises BSEN1949 2011 A1 201...

Page 7: ...he length of flue required the flue must be fitted from the outside Installation from inside ONLY b If a core boring tool or hole cutter is to be used inside the dwelling the space in which the boiler is to be installed must be at least wide enough to accommodate the tool In either of the above cases safe external access is required to allow the addition of sealant to seal the flue to the aluminiu...

Page 8: ...ECTOR ASSEMBLY 214 VENTURI 215 FAN 217 BURNER 218 GASKET BURNER 219 SUMP CLEAN OUT COVER 223 FLUE MANIFOLD 224 FLUE MANIFOLD TOP 227 CLAMP RETAINING FLUE TURRET 228 HOSE CONDENSATE INTERNAL 229 SIPHON TRAP 231 CONDENSATE OUTLET CONNECTION 232 TOP FLUE MANIFOLD SEAL 302 PCB 306 IGNITION FLAME IONISATION ELECTRODE 308 IGNITER UNIT 309 FLOW THERMISTOR 313 IGNITION LEAD 324 CONTROLS BOX LID 325 CONTRO...

Page 9: ...e air duct MUST be sealed with sealant to create an adequate seal WALL Aluminium Flue Collar RSF 060 Fill with sealant 17mm min Internal Sealing Flubber Fill with sealant 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 RSF305 has an upper combustion sample point with a sc...

Page 10: ... outer edge to aid assembly Centre of turret to edge of turret 100mm Turret 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 NOTES REAR Fit towall A Flue length measured from outer terminal lip to end of outer flue A or B 47mm SIDE Fit towall B Minimum clearance 2 5mm WALL WALL FI...

Page 11: ... 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 ...

Page 12: ...he boiler and its flue system Note The resistance of the deflector is equivalent to 1 metre of flue length Ensure this is used when calculating the maximum allowable flue length 2 Choose the direction required to deflect the flue products horizontally left or right only 3 Push the deflector elbow onto the angled flue outlet of the terminal in the desired position and ensure the deflector is pushed...

Page 13: ...balcony 500 mm Below velux windows 2000mm Above or side of velux windows 600mm 2 9 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 2 Ensure that if the length needs to be adjusted to allow an additional 30mm added to the outer air tube length and 14mm added to the inner flue length This allows corre...

Page 14: ...ating 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 Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge...

Page 15: ...ipe Water Weather proof insulation Max 3m external pipework Limestone chippings 500 300 25 2 rows of three Ø12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Minimum connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min Ø 19mm Internal pipe Min Ø 30mm Internal pipe Water weather proof insulation Figure 3 Connection of a ...

Page 16: ...VE DHW LIVE X3 PUMP GND X9 X8 OWC OWC OPENTHERM OPENTHERM CHIP COM BUS TX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE IONISATION FLOW DHW DHW X7 3 5 2 1 1 2 3 4 5 6 2 WPS SIGNAL WPS GND FLUE FLUE RETURN RETURN 1 black grey red green blue brown green yellow orange pink violet yellow white bk gy r g b br g y o p v y w KEY DIVERTOR VALVE F...

Page 17: ...cleaning procedures are covered more fully in Sections 3 3 3 7 and MUST be carried out in sequence IMPORTANT 6 After completing the servicing or exchange of components always ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve 7 When work is complete the front panels MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the bo...

Page 18: ... onto the top retaining clips 5 Retain the upper panel with the two fixing screws previously removed ensuring a good seal is made 6 Swing the lower front panel up and retain with the two screws 7 Close the lower front panel access panel 1 Disconnect the electrical leads from the fan 2 Remove the clip from the gas control valve outlet and ease the pipe upwards rotate and then ease down to remove 3 ...

Page 19: ...ner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may be on the ceramic with a SOFT brush 7 Inspect the sealing gasket around the burner for any signs of damage Replace as necessary Note Ensure condensate trap is fully drained before removal 1 Pull off the rub...

Page 20: ...gnition gap is correct Refer to Sections 3 12 3 13 1 Ignition Electrode Earth Wire Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of water 2 Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence A B C D shown below 3 Refit the fan venturi assembly ensuring the retaining ta...

Page 21: ... to Section 3 19 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 9 FAN REPLACEMENT 1 Refer to Section 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas control valve and the gas pipe 4 Remove the extended nut retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to remov...

Page 22: ... any damaged or deteriorating sealing gasket 8 Reassemble in reverse order 9 Check the operation of the boiler 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 Loosen the screw retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the 2 injector ...

Page 23: ...e the electrode 7 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Ignition Electrode 3mm Straight edge Spark Gap 3 5mm 3 13 SPARK GENERATOR REPLACEMENT 1 Refer to Section 3 8 2 Disconnect the leads from the spark generator 3 Pull the spark generator to unclip from the mounting bracket 4 Fit the...

Page 24: ...UATOR REPLACEMENT Refer to Section 3 8 To remove the motor 1 Remove the condensate trap siphon Refer to Section 3 16 2 Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator 3 Before replacing the diverter valve actuator proceed as follows a Ensure that the switched live to the boiler is off and that all DHW taps are shut and that pre heat is switched off b Press a...

Page 25: ...l 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 6 Check operation of the boiler 3 16 CONDENSATE TRAP SIPHON REPLACEMENT 2 ...

Page 26: ...guide and secure this to the new PCB 9 Insert the new PCB and secure all electrical connections Ensure control knobs are correctly aligned with PCB 10 Reassemble in reverse order If programming of the spare PCB is required then proceed as follows 11 a Turn power on display shows uP Rotate all three dials fully anti clockwise b Press RESTART display shows oF c Turn power off d Turn power on display...

Page 27: ...will be experienced during replacement of components 3 After replacing any component on the boiler DHW circuit re fill as appropriate 4 Check operation of the boiler CENTRAL HEATING CIRCUIT 1 Refer to Section 3 8 2 To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point or use filling loop re fill point on the return pipe 3 After replacing...

Page 28: ...freeze Check operation of the boiler 5 7 4 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 Enuring there is no pressure in the system unclip the C clip from the flow manifold port and remove the capillary connection together with o ring 5 Releasing the two retaining clips on...

Page 29: ... 7 Remove the pump electrical connection Refer to Section 3 26 no 3 8 Remove DHW Turbine electrical connection Refer to Section 3 20 no 3 9 Remove the DHW plate heat exchanger note orientation Refer to Section 3 25 10 Undo the safety valve pipe compression fitting See No 5 Section 3 22 11 Remove the compression fitting above the pump and rotate the pipe 12 If required remove expansion vessel conne...

Page 30: ...ng a suitable tool pull out the metal retaining clip 5 Carefully withdraw the pressure switch 6 Fit the new pressure switch and re assemble in reverse order 7 Refill the boiler and add the correct volume of anti freeze 8 Check operation of the boiler 3 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 ex...

Page 31: ...panner should be used 5 Fit the new thermistor using the sealing washer provided 6 Reassemble in the reverse order 7 Refill the boiler and add the correct volume of anti freeze 8 Check the operation of the boiler 3 28 DHW FILTER DHW FLOW REGULATOR CLEANING REPLACEMENT 4 3 3 30 RETURN THERMISTOR REPLACEMENT 1 Refer to Section 3 8 2 Unclip the return thermistor from the return pipe and withdraw it f...

Page 32: ...llows clearance of the pipe from heat exchanger plugs Lift pipe and remove 13 Remove the two heat exchanger fixing screws 14 To remove the Heat exchanger slide out of location bracket 15 Remove the condensate rubber pipe from the sump 16 If replacement sump required Rotate heat exchanger assembly 180º Place new sump onto heat exchanger ensuring correct orientation and seal is in place Then gently ...

Page 33: ... pressure to 0 75 bar 5 Re assemble in reverse order re fill the boiler and add the correct volume of anti freeze 6 Check operation of the boiler REPLACEMENT 7 Refer to Section 3 8 8 Drain the boiler CH circuit Refer to Section 3 19 9 Remove the retaining clip on the vessel connection pipe 10 Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the bo...

Page 34: ...or hot water but the appliance has reached the desired temperature set on the boiler The boiler is operating in central heating mode The boiler is operating in domestic hot water mode The boiler is operating in frost protection Note that after the boiler has reached temperature it will show dH for 60s whilst it also protects the DHW circuit The boiler mode knob C is in the off position rotate full...

Page 35: ...ber letter refer to page 34 L Boiler is in lockout for a specific error Display will show L with a number or letter to show which error is detected F Boiler has a fault for a specific error Display will show F with a number or letter to show which error is detected Service Modes SH Service High SL Service Low Setting to Minimum Rate 1 Hold restart function buttons together for more than 5s 2 Last ...

Page 36: ...he house are working to confirm a supply is present in the property 3 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 IE contact a Registered Gas I...

Page 37: ... FAULT GO TO SECTION 4 13 RETURN THERMISTOR FAULT GO TO SECTION 4 14 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER NEGATIVE DIFFERENTIAL FLOW OR RETURN THERMISTOR FAULT PCB UNCONFIGURED FAULTY OR GAS VALVE SHORT CIRCUIT IF FAULT PERSISTS REPLACE PCB NO CH BUT HW OK NO HW BUT CH OK NO DISPLAY GO TO SECTION 4 15 GO TO SECTION 4 16 GO TO SECTION 4 17 LC 5 RESETS WITHIN 15 MINS T...

Page 38: ... Check wiring connection from gas valve to PCB for continuity If the wiring is OK then replace the PCB NO Replace Spark Generator and harness as necessary NO Replace ignition detection electrode and associated harness as necessary NO Replace Gas Valve YES Unplug gas valve Is resistance between outside pins between 120k Ω 20 YES Replace Gas Valve NO RESTART PROCEDURE to restart boiler press the res...

Page 39: ... Are the Boiler and CH System filled with water and radiator valves open check pressure gauge is between 1 to 1 5 bar NO NO YES Fill and vent the system and open all isolation valves YES Are connections on water pressure sensor secure Re fit connections Replace water pressure switch 4 7 ALTERNATING L AND 5 5 RESETS WITHIN 15 MINS 4 8 L6 FALSE FLAME LOCKOUT 4 9 F1 LOW WATER PRESSURE Turn power off ...

Page 40: ...electrode and associated harness for continuity visual condition and position Refer to Section 3 12 Are these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check wiring from gas valve to PCB for continuity If the wiring is OK then replace the PCB NO Replace Spark Generator and Harness as necessary NO Replace Igniti...

Page 41: ...r NO Securely connect the wiring to the PCB Is the wiring securely connected to the Flow Thermistor located in the top of the Heat Exchanger YES NO Securely connect the wiring to the Flow Thermistor NO 4 13 F5 OR L5 RETURN THERMISTOR FAULT Remove the Return Thermistor from the CH Return Pipe and disconnect the wires Check the resistance using a suitable multimeter connected across the thermistor s...

Page 42: ...K Disconnect the wires to the outside sensor Check the resistance using a suitable multimeter connected across the Outside Sensor s terminal pins At 0 o C expect 31 000 35 000 Ohms At 15 o C expect 15 000 16 500 Ohms At 30 o C expect 7 700 8 500 Ohms Is the Outside Sensor value correct YES Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor ...

Page 43: ...p rise and check filter fitted in turbine is not blocked with debris NO Reconnect wiring or replace wiring harness if no continuity NO Re engage diverter head NO Replace PCB Is hot and cold pipework crossed NO Is the wiring connected between PCB and DHW sensor Remove the turbine and check for debris in the turbine Replace turbine if necessary Is DHW OK YES NO Re connect wiring NO Replace turbine s...

Page 44: ...e 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 ...

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