Morco FEB-24ED 3 Star Technical Documentation Manual Download

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FEB-24ED 3 STAR TECHNICAL DOCUMENTATION

29-05-13 version 1.0

Summary of Contents for FEB-24ED 3 Star

Page 1: ...FEB 24ED 3 STAR TECHNICAL DOCUMENTATION 29 05 13 version 1 0 ...

Page 2: ...hotograph 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 32 3 5 Trouble shooting Flow charts 36 3 6 Assembly and disassembly hydraulic unit 44 3 7 Functional flow charts 47 3 8 PCB Schematic drawing 53 ...

Page 3: ...with gas installation regulations Boiler installation must comply with the conditions described by in the user and installation manual provided with the appliance I Important Please read the user and installation manual for this boiler carefully 1 PLEASE NOTE THAT THE FAULT CODES AND SOFTWARE DIFFER FROM THE FEB24E ED FAULT CODES ALWAYS USE THIS MANUAL FOR FAULT FINDING AND TROUBLE SHOOTING ON THE...

Page 4: ... power of between 7 7 kW and 24 5 kW 26 291 07 83 653 41 Btu h FEB 24ED 3 STAR 1 3 5 7 8 9 4 6 2 12 10 16 15 13 11 14 1 a 2 Air pr ur th h 3 tur 4 tra h at th r t r 5 Copper heat exchanger 6 h t th r tat 7 a 8 u t ha r 9 at tr 10 Circulation Pump with automatic ir ent 11 Modulating gas valve 12 tra h at r ur t h 13 ur r r ur t t t 14 r t h 15 rau a at h at ha r 16 tra h at r tur th r t r 17 u Aut ...

Page 5: ...tural G 20 m3 h 2 69 Propane G 31 kg h 2 03 Electrical supply V Hz 230V 50Hz Maximum Power Consumption W 120 Combustion product s Temperature C 100 Combustion product s Mass Flow g sec 11 858 Height 680 Width 390 Depth 254 Top 200 Bottom 150 Sides 5 Front 5 Gas Inlet BSP Domestic cold water inlet BSP D H W outlet BSP Central heating flow BSP Central heating return BSP Net weight kg 30 Type of gas ...

Page 6: ...Pump 3 Low pressure switch 4 Flow thermistor 5 Three way valve 6 High limit stat 7 Air pressure switch 8 Venturi 9 Fan 10 Sealed air box 11 Copper heat exchanger 12 Combustion chamber 13 Ignition electrodes 14 Main burner 15 Ionisation electrode 16 Modulating gas valve 17 Gas inlet 18 Return thermistor 19 Hot water outlet 20 Plate heat exchanger 21 C H Flow 22 Cold water inlet 23 C H Return 24 Saf...

Page 7: ... is no leakage from the installation or boiler Check all the con nections thoroughly Domestic Hot Water Functioning DHW Water begins to circulate through the domestic circuit of the boiler The cold water flows through the 3 way valve this action ports the 3 way valve and micro switch into DHW mode Water heated in the primary circuit flows through the plate heat exchanger to heat up the water comin...

Page 8: ...valve MCB2185 Low Pressure Switch FCB1480 Flow restrictor MCB2240 All these parts together form a compact unit Circulating pump head Part number MCB3120 Operates in both CH and DHW mode Circulation of the primary circuit either to the radiators or to the plate heat exchanger when operating in DHW mode Pump combines a manual and automatic anti blocking system The capacity of this pump has a mamomet...

Page 9: ...rass diaphragm housing Activation occurs when the white switch tip which sits on the diaphragm push rod in CH mode is released as the diaphragm push rod ports the 3 way valve to DHW This action places the PCB into DHW mode allowing the boiler to commence the ignition sequence Part number MCB2320 Flow restrictor Located within the hydraulic unit between the brass inlet union and the cold inlet port...

Page 10: ...it Automatic bypass The bypass is located inside the hydraulic unit It joins the heating outlet and return It is preset only opening when the pressure between the bypass inlet and outlet exceed 0 3 bar Its purpose is to assist when there is a large loss of load in the circuit and the pump consequently has difficulty in moving the water When the bypass opens an amount of water which was flowing tow...

Page 11: ...NAL PROBE 15 J22 OR J23 DISPLAY PCB 3 PURPLE WIRES OR BLACK WHITE BROWN 16 J16 MODULATING GAS VALVE 18VDC 17 J27 PORT FOR SOTWARE PROGRAM 18 AUTO TEST PORT 19 SUPPRESSION FILTER 20 SUPPRESSION FILTER 21 MAIN ELECTRICAL SUPPLY CONECTORS 230V 50Hz 9 J18 J17 J25 N N L L L L N N L FAN 230V ac PUMP 230V ac MAINS SUPPLY 230Vac GAS VALVE EV1 230V ac EV2 230V ac SPARK 230V ac 85v ac 18v dc return micro sw...

Page 12: ...re and if the temperature is lower than 3 degrees the burner will relight Pump Antiblock safety If during the last 23 hours the pump has not run the PCB will run the pump for 30 seconds Overheating If the flow thermistor detects a lower temperature than 50ºC and there is a higher output than 95 after 5 minutes the boiler will shut down then relight Fuzzy logic This program operates only in central...

Page 13: ...r starts to work in ON OFF cycling mode While the boiler is in ON OFF mode the boiler starts at least 8 seconds and stops working for at least 4 seconds and always working at the minimum power The boiler comes out of this ON OFF mode when DHW temperature is lower than DHW set point 4º C or when DHW temperature is lower than DHW set point during more than 45 seconds and the boiler begins to regulat...

Page 14: ...lly closed When the thermostat is activa ted the boiler will lock out F4 block The thermostat resets automatically although the F4 fault will need resetting from the control panel Thermistors MCB2245 There are two thermistors incorporated into the boiler The flow thermistor is located top left on the primary heat exchanger and is responsible for most of all boiler functions along with the return t...

Page 15: ...is entered In case DHW is working the boiler continues to work even if the LED displays fault The boiler uses the return thermistor and temperature selected to regulate DHW temperature Relation between Temperature Voltage and Thermistor nominal Resistance Temperature ºC Voltage Volts Resistance k 85 0 92 1 44 80 1 01 1 65 75 1 15 1 91 70 1 28 2 21 65 1 41 2 57 60 1 54 2 99 55 1 71 3 51 50 1 93 4 1...

Page 16: ... Burner pressure can also be tested at the inlet pipe to the burner Spark generator A B This component has 2 functions the 1st is to create a high tension voltage at the spark electrodes The unit also provides a connection for the 230v ac from the PCB to the twin gas valve solenoids EV1 EV2 Part number MCB3055 Gas pressure modulation This is a progressive modulation type boiler i e it automaticall...

Page 17: ...e selected step And it is pushed the main board button when a new value wanted to be stored then the display shows to indicate that the value has being stored To leave installation menu it can move the right knob back to the O position These are the 7 Installation Menu s Steps Step 1 Select gas type The display shows P1 and the value selected 6n or LP 6n is for Natural Gas and LP for propane butan...

Page 18: ...iator or SU floor heating Using right knob CH RA radiators or SU floor heating can be selected In case floor heating SU is selected the set point must be stored Using the right knob CH it can be selected the value between 40 and 60 ªC and using the main board button the value will be stored and the display will show again to indicate that the value has being stored When this option SU is chosen th...

Page 19: ... values should be equal or lower never higher For example if you are making a maximum natural gas regulation the table says 18 0mb so you achieve 18 0 mb or less than 18 0mb I Changing the gas This boiler is designed to function using PROPANE GAS or NATURAL GAS GAS To change the type of gas used the only com ponents that need to be changed are the injec tors The injectors corresponding to the gas ...

Page 20: ...ated at a differential pressure of 120Pa 1 2 mb and deactivated at 100Pa 1 0 mb To measure the differential pressure first measure the pressure using the manometer on one of the pressure ports and then with the manometer on the other The result will be the sum total of both This data is to be taken as an approximate value only as variations of a few Pascals occur in the measurements while the fan ...

Page 21: ...s must be used ON OFF Shows boiler status WINTER Adjust boiler parameters AUTOTEST Comfort Configure the boiler Showing boiler status The symbols from the top of the display show the actual state of the different inputs outputs and with both 7 segment displays show set points temperatures water flow pressure and power of the boiler The values of visualization are shown in groups of two and using t...

Page 22: ... 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 Temperature and Central Heating Temperature tap and radiator symbol Water flow and pressure symbols l min y bar NOT AVAILABLE ON FEB24ED 3 STAR 20 ...

Page 23: ... shows P1 Light button When pressed display shows D H W Temperature and C H Temperature D H W set point increase button Pump ON OFF D H W set point decrease button Change 3 way valve Step 2 Switch ON OFF the fan and sparks system The display shows P2 Light button When pressed display shows D H W Temperature and C H Temperature D H W set point increase button Fan ON OFF D H W set point decrease but...

Page 24: ... Limited between 20 and 55 Step 5 Start up Pressure Regulation Display shows P5 and electrical value To adjust this value use the same instructions that are used in Step 3 Limited between 20 and 60 Step 6 Check the boiler operation sets the DHW temperature to 42ºC Display shows P6 No action possible in this step Pushing light button DHW tempe rature and hundred percent value of the gas valve are s...

Page 25: ...pressure switch the boiler will be 00 and if the boiler uses water pressure sensor digital pressure gauge the boiler will be 04 Second 2 digits are explained in following tables First Number from YY Heating Circuit Type CA Heating Plumb Delay Tpb Plumb Cycling PC rA SU 1min 2 99min OFF ON 0 x x x 1 x x x 2 x x x 3 x x x 4 x x x 5 x x x 6 x x x 7 x x x 23 ...

Page 26: ... of boiler From 00 to 03 means that the boiler has water pressure switch and if its from 04 to 13 the boiler has water pressure sensor To store the selected value use the comfort button Step 4 Type of heating circuit radiators or floor heating The display will show CA as it s shown in the picture and the selected option RA radiator or SU floor hea ting Using increase decrease CH set point buttons ...

Page 27: ...t point until 99 minutes To store the selected value use the comfort push button Step 7 Pumb Cycling Display shows PC and On or OF depending on the state of the pump cycling function Select the desired value using increase decrease CH se point buttons and store it with the comfort push button When the boiler is working in central heating function at a high temperature if a tap is opened very hot w...

Page 28: ...n hours h days d or weeks w Step 14 State of manufacture EF XX Step 15 Main board software version i e CC 1 1 Step 16 Front panel control software version i e CP 2 3 HEATING SELECTION WITHOUT EXTERNAL AUTO TEST 26 Selection of heating mode radiators under floor heating The boiler can be configured for either heating radiators rA or under floor heating SU 2 configuration methods are available via t...

Page 29: ...switched on it shows the selected value in the display for a few seconds if the heating circuit is radiator it will show rA and if the hea tingcircuit is floor heating it will show SU Adjusting boiler s parameters AUTOTEST To enter in the AUTOTEST function menu both knobs must be place to minimum to the left DHW knob in O position and CH knob in summer position and then push the main board button ...

Page 30: ...n board button then the display shows to indi cate that the value has being stored The electri cal value is limited from 20 to 55 LPG VALUE 46 Step 5 Start up Pressure Regulation Dis play shows t5 and the electrical value alternately When the right knob CH is in summer position the display shows the stored value and turning clockwise the right knob the selected value can be changed Once it s selec...

Page 31: ... shows the stored value of the selected step The configuration button must be pressed when a new value is to be stored then the display shows to indicate that the value has being stored To leave configuration menu both knobs must be moved to the O position These are the different Configuration Steps Step 1 Main Configuration Viewer It can not be modified Alternately shows in the display Cn XX YY w...

Page 32: ... alternately ti and the number of the type of boiler selected If the value stored is 00 to 03 means that the boiler has presotat and if the value is 04 to 08 means that it has pressure sensor With the right knob at the summer position the value stored is shown and using this knob we can select the desired va lue to store it just push the main board button and will be displayed meaning that the val...

Page 33: ...e the selected value use the main board push button Step 7 Pump Cycling Display shows alterna tively PC and On or OF when right knob is in summer position depending on the state of the pump cycling function Select the desired value using right knob CH and store it with the main board push button When the boiler is working in central heating mode at high temperature if a hot tap is opened the initi...

Page 34: ...n electrode fails to detect a flame the boiler will lock out F1 locked When the boiler is working and the flame fails due to a malfunction of the gas valve or ionisation electrode after 1 second without flame detection the boiler will shut down gas valves The boiler will then attempt to relight if no flame is detected the boiler will lock out F1 lapoouuuuuuuuuuuuuuuuuuuuufdfd no oiuuuuuuuuuuuuuuAC...

Page 35: ...e venturi Faulty PCB F03 If the heating circuit s pressure falls below 0 5 b or the central heating low pressure switch fails contacts open the boiler locks out F31 OR 32 HISTORICAL FAULTS F04 If the high limit thermostat activates at 102ºC or fails contacts open the boiler locks out F05 If there is any failure in the software protections of the boiler control program the boiler gets locked The us...

Page 36: ...ited If this fault ocours the heating mode will work normally and the DHW mode will also work but using the heating thermistor as reference to heat the DHW This fault will auto reset when the thermistor is in range F13 It s a failure of the heating thermistor that it is out of range open or short circuited If this fault occurs the boiler blocks This fault auto reset when the thermistor returns wit...

Page 37: ...cour after a maximun time of 6 minutes if the contacts remain open F22 F 31 Fault on water circuit of the boiler The heating circuit is empty or the pressure detec ted is lower than 0 5 bar F 32 Fault on water circuit of the boiler The central low heating pressure switch is faulty or disconnected F 51 F 52 F 53 F 54 F 55 F56 F 57 F 58 These faults are internal electronic faults of the main control...

Page 38: ...rectly Go to 1 OUT Yes No No No No No No No No No No Heating Works DEMANDYes Go to 2 Go to 3 Go to 5 Go to 6 Go to 7 Go to 8 Makes noise Go to 4A Go to 4B D H W Works Heating Works Pump Works Sparks at electrode Spark works but no flame or flame fails after ignition Fan Works FEB 24ED DISPLAY ON 36 ...

Page 39: ...connector J26 between extreme pins Check electrical connection Mains cable Replace main PCB Check the wiring and connections between main control circuit and front panel circuit if it is OK replace the front control PCB TURN IT ON 37 No lights on front display Remove both wires off the High Limit Thermostat If front display lights up Replace faulty High Limit Thermostat MCB2250 ...

Page 40: ...he main control circuit No Check Room Thermostat connections and select heating enought temperature IN No Yes Yes OUT There are 2l min at the opened tap Does the 3 way valve connector turns off j7 wires blue brown Check the wiring and connections if it is OK replace the front panel circuit or main control circuit Check the filter 3 way valve operating water presure No Check wiring and connection o...

Page 41: ...se contacts closed black wires Check wiring and conections if it is OK replace the main control circuit Replace air pressure switch connections or pressure switch Yes There are 230 Vac in J18 wires blue brown No Check wiring and connections if it is OK replace the main control circuit Unseize the pump impelor or replace the pump 39 Check the connections at the PCB if all OK then replace the main P...

Page 42: ...ial at the air pressure swich 230 Vac on J25 wires brown blue Take off the wires of t Replace main PCB R Check the wiring and connections if it is OK replace the ignition electrode Check the venturi and the flue air intake pipes Check the pressure switch connections P P connections If it s OK replace the air pressure switch Remove wires from spark gen erator is there are spark 40 Replace spark gen...

Page 43: ...ut locking out Replace front control panel PCB Replace solenoids EV1 EV2 or spark generator as required Replace the gas valve adjust the new valve to the correct gas pressures Check the ignition pressure 8 0mbar if ok check all the main burner jets for blockages boiler works Simulate the ionisation signal with a diode or replace ionisation electrode Boiler works Check the min burner pressure remov...

Page 44: ...int Regulate mechanically and electricaly the gas valve Check gas valve regulation and electrical values of configuration in AUTOTESTIt s OK Check water pressure or check 230Vac on J17 Yes Yes Heating modulates correcty Always at minimum Check SU RA OK Check heating electrical value OK Thermistor values are OK Always Same Set Point Replace Main Control Circuit Regulate minimum Configure main contr...

Page 45: ...ting installation Set the pump to no 2 speed Check the heating circuit pressure check by pass and check the pump works in 3rd position Sound of boiling water in the heat exchanger Sound of water in the DHW installation T filling tap of the in Fit air restrictor in tha air intake if is necesary NO GAS WATER Check the minimum burner pressure Reduce the cold water mains pressure 43 ...

Page 46: ...t 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 main heat exchanger for ease of handling Remove the screws holding the hydraulic unit to the boiler base they are on the underside Release the hydraulic unit from the lower connectors DHW inlet and outlet and heating inlet and outlet The water inta...

Page 47: ...or ease of handling Remove the screws holding unit 1 to the boiler base they are on the underside Release unit 1 from the lower connectors DHW inlet and outlet and heating outlet The water intake connectors do not need to be removed Changing the plate heat exchanger Remove the four screws holding the plate heat exchanger to unit 1 be very careful with the O rings they should be changed Changing th...

Page 48: ...o the hydraulic unit and remo ve the pump Remove the pump electrical connection to the PCB Changing the drain valve Drain the heating circuit Remove the pump and remove the clip holding the drain valve in place Changing the safety valve and drain valve Safety valve or drain valve 2 and 3 1 Drain the heating circuit 2 Remove the clip and pull out the valve 2 3 GGGGG 46 ...

Page 49: ...TART SEQUENCE DHW MODULATION Wait until Heating temperature goes down FAN ON PUMP OFF Lock out F 3 3 Min Lock out F 2 FAN OFF PUMP OFF 6 Min Lock out F 2 FAN OFF PUMP OFF Flame detection before 6 seconds Open EV1 and EV2 Open gas valve at lighting pressure SPARK MAX 6 SECS Heating Temp DHW set point 20º C Heating Temp DHW set point 20º C PUMP ON Air pressure switch closes FAN ON Air pressure switc...

Page 50: ...k out F 2 FAN OFF PUMP OFF 6 Min Lock out F 2 FAN OFF PUMP OFF Flame detection within 6 seconds Open EV1 and EV2 Open gas valve at Inigtion pressure SPARK Maximun 6 seconds Air pressure swich closed FAN ON Air pressure switch opened Heating temperature Heating Set Point 5ºC Heating temperature Heating Set Point 5ºC PUMP ON PUMP ON Heating start sequence FEB 24ED 3 STAR 48 ...

Page 51: ...efore 6 seconds Open EV1 and EV2 Open gas valve at lighting pressure SPARK Maximun 6 seconds FAN 5 SEC ON PUMP ON GAS VALVE CLOSED SPARK OFF Flame detection before 6 seconds FAN 5 SEC ON PUMP ON Open EV1 and EV2 Open gas valve at lighting pressure SPARK Maximun 6 seconds HEATING OR DHW MODULATION BURNER OFF FAN 7 SEC ON PUMP OFF RE start sequence FEB 24ED 3 STAR 49 ...

Page 52: ...nt 4ºC 15 sec or DHW Temp DHW Set point 8ºC DHW Temp DHW Set Point HEATING DEMAND Heating Temp 102ºC LOCK OUT F 4 PUMP 1MIN ON FAN OFF BURNER OFF END OF DHW DEMAND HEATING MODULATION FAN 5 SEC ON PUMP OFF BURNER OFF PUMP CYCLING ON Heating Temp 92ºC FAN ON PUMP ON 10secs OFF 1sec BURNER OFF PUMP ON BURNER OFF Heating Temp 88ºC Heating Temp 92ºC Thermistor s in range MODULATION DHW Temperature regu...

Page 53: ...LING next page Heating Temp 102ºC FAN 5s ON PUMP ON BURNER OFF LOCK OUT F 4 PUMP 1MIN ON FAN OFF BURNER OFF DHW DEMAND FAN 5 SFC ON PUMP ON during Tpb BURNER OFF END OF DHW DEMAND Heating Temp heating Set Point 5ºC PUMP ON FAN ON PUMP ON 10s OFF 1s BURNER OFF Heating Temp 92ºC Heating Temp 92ºC 30 second minimum power FUZZY LOGIC 5 min Minimum power YES YES YES YES YES 51 YES HEATING SERVICE FEB 2...

Page 54: ...AN ON PUMP ON DHW DEMAND BURNER ON FAN ON PUMP ON DHW MODULATION DHW Temperature Heating working BURNER ON FAN ON PUMP ON DHW DEMAND Heating Temp DHW Set Point 20ºC BURNER OFF FAN ON PUMP CYCLING Heating Temp DHW Set Point 20ºC BURNER ON FAN ON PUMP ON DHW MODULATION DHW Temperature Pump Cycling OFF Pump Cycling ON NO YES 52 ...

Page 55: ...d 1 230v ac 7 Gas valve solenoid 2 230v ac 8 Front panel control 9 3 way valve micro switch 10 Air pressure switch 11 Room stat optional 12 Clock connection 13 Modulating solenoid valve 14 Ionisation electrode 15 High limit stat 16 Return thermistor 17 Flow thermistor 18 CH low Pressure switch 19 External Probe Not Used 20 Clock 230 v ac 53 1 7 5 6 4 3 13 14 9 10 15 18 19 17 16 11 8 2 12 20 ...

Page 56: ...RODUCTS 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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