Morco GB24 Technical Instructions Download

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Technical Instructions

GB24 & GB30

Series II

Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD

Morco Products Ltd

Tel: 01482 325456 Fax: 01482 212869

Website: www.morcoproducts.co.uk

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)

To Central Heating:

GB24/30 Minimum 8.0 kW (27,296 Btu/h)

GB24/30 Maximum 24.2 kW (82,570 Btu/h)

BOILER OUTPUT

preheat

min

max

mode

reset

off

status

burner

max

BOILER OUTPUT

Series

GB24

UIN 212458 A08

July 2018

Summary of Contents for GB24

Page 1: ...morcoproducts co uk 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 To Central Heating GB24 30 Minimum 8 0 kW 27 296 Btu h GB24 30 Maximum 24 2 kW 82 570 Btu h BOILER OUTPUT preheat preheat min min max mode reset off status burner max e BOILER OUTPUT Series II GB24 UIN 212458 A08 July 2018 ...

Page 2: ...n Boiler Destination Country BE Belgium CH Switzerland CZ Czech Republic DE Germany ES Spain FR France GB UK GR Greece IE Ireland IT Italy NL Netherlands PL Poland PT Portugal SI Slovenia Morco GB24 GB30 Series II ...

Page 3: ...TENTS SECTION PAGE 1 GENERAL 4 Technical Data 4 Introduction 5 Boiler Dimensions Services Clearances 7 Boiler Assembly 8 2 INSTALLATION 9 Fluing 9 Condensate Drain 14 Wiring 16 3 SERVICING 17 4 FAULT FINDING 34 Operating Modes 34 Fault Codes 35 Fault Finding Charts 36 ...

Page 4: ... Q Nett CV kW 24 3 24 3 8 0 8 0 Btu h 82 912 82 912 27 296 27 296 Gross CV kW 26 4 26 4 8 7 8 7 Btu h 90 077 90 077 29 684 29 684 Gas Consumption m3 h 1 00 1 25 0 329 0 329 ft3 h 35 33 44 20 11 62 11 62 kg h 1 83 2 26 0 58 0 58 Boiler Output Non Condensing kW 24 2 24 3 8 00 8 00 70o C Mean Water temp Btu h 82 570 82 570 27 296 27 296 Condensing kW 25 6 25 6 8 5 8 5 40o C Mean Water temp Btu h 87 3...

Page 5: ...boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW 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...

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: ...lled is less than the 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 f...

Page 8: ...UE MANIFOLD TOP 227 CLAMP RETAINING FLUE TURRET 228 HOSE CONDENSATE INTERNAL 229 SIPHON TRAP 231 CONDENSATE OUTLET CONNECTION 302 PRIMARY PCB 303 CUI BOARD 306 ELECTRODE IGNITION 307 ELECTRODE DETECTION 308 IGNITER UNIT 309 FLOW THERMISTOR 313 IGNITION LEAD 314 CONTROL BOX LENS 324 CONTROLS BOX LID 325 CONTROL BOX FRONT 326 MECHANICAL TIMER 401 HEAT ENGINE 503 WALL MOUNTING BRACKET 504 FRONT PANEL...

Page 9: ...uct 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 screw cap...

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: ... 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 u...

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: ... 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 point or purpose designed soak away If an external system is chosen then the following measures must be adop...

Page 15: ...onnection 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 75 Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Visible air break at plug hole Min Ø 19mm Internal pipe Sink basin bath or shower with integral overflow and 75mm trap Minimu...

Page 16: ... 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 Water Flow Turbine p bk r bk Water pressure Switch PCB Flow Thermistor Return Thermistor Earth bk bk b b br y g Service Connector blue black brown red pink yellow white yellow green grey orange violet b bk br r p y w y g g or v KEY p y Flame Sensor Electrode Fan bk bk b y g br y g y g Spark Electrode Spark Generator bk Gas Valve b bk v br bk b Divertor Valve Pump...

Page 17: ...l valve 7 When work is complete the front panels MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the upper front panel is not fitted 8 If for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before reassembling 9 Check the gas consumption if on metered installations 10 Check combustion by connecting the flue gas...

Page 18: ...anel 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 2 6 1 7 3 5 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 d...

Page 19: ...urner 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 r...

Page 20: ...Check that the ignition and detection gaps are correct Refer to Frames 3 12 3 13 1 Ignition Electrode Earth Wire Flame Detection 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 ...

Page 21: ...er Refer to Frame 3 21 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 9 FAN REPLACEMENT 1 Refer to Frame 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas control valve 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 remove venturi ass...

Page 22: ...ged or deteriorating sealing gasket 8 Reassemble in reverse order 9 Check the operation of the boiler 6 1 Refer to Frame 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas valve to venturi pipe 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 in...

Page 23: ...t 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 FLAME DETECTION ELECTRODE REPLACEMENT Flame Detection Electrode 12 5mm Straight edge 1 Refer to Frame 3 8 2 Remove the burner Refer to Frame 3 10 3 Unplug the flame detection lead from the electrode 4 Remove the 2 screws retaining the dete...

Page 24: ... and disconnect the earth wire 3 Remove the outlet gas valve clip and slide the pipe upwards 4 Undo the gas inlet pipe union at the inlet to the gas control valve 5 Undo the single screw fixing the gas valve to the mounting bracket and withdraw the valve forwards To gain access temporarily move the seal 6 Fit the new gas control valve ensuring that the o ring and sealing washer are in place Replac...

Page 25: ...that the switched live to the boiler is off and that all DHW taps are shut and that pre heat is switched off c Hold the mode knob in the reset position for more than 10 secs d The display will alternate between d and U and the actuator will move into the mid position e The divertor valve will initially drive all the way out this may cause the spindle to become detached from the body If this occurs...

Page 26: ...tions to the PCB including the ribbon cable 6 Spring out the two side retaining clips and pull the PCB upwards to clear the retaining posts 7 Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 24kW or 30kW Note Ensure the correct orientation of BCC by placing TOP side up 8 Re connect all plug connections 9 Reassemble in...

Page 27: ...SER CONTROL PCB REPLACEMENT 3 Potentiometer spindle Control Knobs to be in vertical position PCB 4 1 Refer to Frame 3 8 2 Swing the boiler lower front panel into the service position Refer to Frame 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 7 Fit programmer and retain with 4 screws previously removed 8 ...

Page 28: ...the boiler close tap close the drain valve and open all system isolating valves re pressurise as appropriate 5 Check operation of the boiler CENTRAL HEATING CIRCUIT 1 Refer to Frame 3 8 2 Close all the CH water isolating valves on the boiler inlet 3 To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point 4 After replacing any component on ...

Page 29: ... Reassemble in reverse order ensuring the retaining clip is correctly fitted and the pipe compression fitting retightened 9 Refill the boiler with specified anti freeze Check operation of the boiler 1 Refer to Frame 3 8 2 Drain the boiler Refer to Frame 3 21 3 Remove the return thermistor Refer to Frame 3 32 4 Using a suitable screwdriver positioned between the air vent dust cap and the plastic pr...

Page 30: ...anifold 17 Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly 18 Fit the new diverter valve body assemble and replace the two fixing screws 19 Refit the DHW manifold fit the assembly back to the boiler and reassemble in reverse order 20 Refill the boiler and add the correct volume of anti freeze Check operation of the boiler 3 27 DHW PLATE HEAT EXCHANGER...

Page 31: ...Drain the boiler Refer to frame 3 21 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 5 Clean or replace filter as necessary 6 Reassemble in reverse order 7 Refill the boiler 8 Check operation of the boiler 3 4 1 Refer to Frame 3 8 2 Drain down the boiler Refer to Frame 3 21 3 Unplug the electrical lead 4...

Page 32: ...t and transfer bracket to the new heat exchanger 11 Undo the inlet pipe union nut swing the pipe and pull down to remove from heat exchanger 12 Pull out the flow pipe spring clip pull the pipe down to remove from heat exchanger 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 replac...

Page 33: ... 3 Recharge the tank pressure to 0 75 bar 4 Re assemble in reverse order 5 Check operation of the boiler Refer to Frames 28 29 REPLACEMENT 6 Refer to Frame 3 8 7 Drain the boiler CH circuit Refer to Frame 3 21 8 Remove the retaining clip on the vessel connection pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the boiler and remove Note the...

Page 34: ... appliance has reached the desired temperature set on the boiler The boiler has a call for 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 pre heat mode The water in the cental heating circuit is less than 5ºC If heating is switched on this display code will change to c The boiler is operat...

Page 35: ...atively a Gas Safe Registered Engineer if outside of the warranty period In all other countries contact a Registered Gas Installer 1 Check other gas appliances in the home are working to confirm a supply is present in the property 2 If other appliances do not work or there are no other appliances check the gas supply is on at the meter Gas Cylinder and or pre payment meter has credit If the boiler...

Page 36: ...YES Check spark generator and associated harness for continuity and visual condition Refer to Frame 3 14 Are these functioning correctly YES Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 3 12 Are these functioning correctly NO Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check w...

Page 37: ...Electrode YES NO Check routing and integrity of internal boiler wiring RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 4 5 ALTERNATING L AND 5 5 RESETS WITHIN 15 MINS Turn power off and on 4 7 ALTERNATING F AND 1 LOW WATER PRESSURE Are the Boiler and CH System filled with water and all isolation and radiator valves open check pres...

Page 38: ... Refer to Frame 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 Ignition Electrode and associated harness as necessary NO Replace Gas Valve NO Note d...

Page 39: ...n the PCB and the Thermistor Fit a new Thermistor NO Check and replace wiring as necessary 4 11 ALTERNATING F AND 5 RETURN THERMISTOR FAULT YES NO YES Replace PCB Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 o C expect 9 700 10 300 Ohms At 60 o C expect 2 400 2 600 Ohms At 85 o C expect 1 000 1 100 Ohms Is the Thermistor value correct Is th...

Page 40: ... and c0 being shown reset boiler Note Ensure the correct orientation of BCC by placing TOP side up Replace the BCC with a new BCC that is correct for the boiler After switching power on and c0 being shown press reset Is c2 still shown Replace PCB YES RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting RESET PROCEDURE To reset boiler t...

Page 41: ...n Are the Timer and the Room Thermostat switched on YES NO Switch the Timer and Room Thermostat On Are the Radiator Valves Open YES NO Open the Radiator Valves Is there 230Vac at A YES NO There is no Voltage from the Timer Room Stat This is not boiler fault Ensure Voltage is supplied to boiler by rectifying external wiring Replace the Divertor Valve A ...

Page 42: ...a tap is on NO YES Are the flow rates correct Is the wiring between the PCB and the diverter valve actuator connected YES YES Check diverter head fully engaged onto waterset body YES Is diverter stuck in the CH position YES Check and replace diverter valve actuator head Is Boiler DHW OK NO Change diverter valve assembly NO Adjust flow rates to achieve 35º temp rise and check filter fitted in turbi...

Page 43: ...43 NOTES ...

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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