3
Morco reserve the right to vary specification without notice
CONTENTS
SECTION ...............................................................................PAGE
1 GENERAL .........................................................................5
1.1 Introduction ........................................................................5
1.2 Operation ...........................................................................5
1.3
Safe Handling ....................................................................5
1.4
Optional Extra Kits .............................................................5
1.5 Safety ................................................................................6
1.6
Safe Handling of Substances ............................................6
1.7
Boiler Dimensions, Services & Clearances ......................7
1.8
Boiler Assembly - Exploded View ......................................8
2 INSTALLATION .................................................................9
2.1
Determining the Flue Length .............................................9
2.2
Determining the Flue Length ..........................................10
2.3
Cutting Horizontal Flue Terminal
RSF303 (600MM Long) ..................................................10
2.4
Installing the Flue ............................................................ 11
2.5
Flue Extensions RSF341 (Optional) ................................12
2.6
Flue Deflector Kit RSF300 (Optional)
..............................12
2.7
90º KIT RSF315 (Optional) .............................................12
2.8
Fitting the Optional Roof Flue Kit
RSF345 (Optional) - Flat or Pitched- ...............................13
2.9
Assembling the Roof Flue Kit ..........................................13
2.10 Condensate Drain............................................................14
2.11 Wiring Diagram ................................................................16
3 SERVICING .....................................................................17
3.1
Servicing Schedule ..........................................................17
3.2
Boiler Upper & Lower Front Panel
Removal / Replacement ..................................................18
3.3
Fan & Venturi Assembly Removal and Cleaning .............18
3.4
Burner Removal & Cleaning ............................................19
3.5
Cleaning The Condensate Trap/Siphon ..........................19
3.6
Cleaning The Heat Exchanger ........................................20
3.7 Reassembly .....................................................................20
3.8
Replacement Of Components .........................................21
3.9
Fan Replacement ............................................................21
3.10 Burner Injector Replacement ..........................................22
3.11 Burner Replacement........................................................22
3.12 Ignition/Flame Electrode Replacement............................23
3.13 Spark 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 ..........................29
SECTION ...............................................................................PAGE
3.24 Diverter Valve Body Assembly Replacement .................29
3.25 DHW Plate Heat Exchanger Replacement ......................30
3.26 Pump Head Replacement ...............................................30
3.27 CH Water Pressure Switch Replacement .......................30
3.28 DHW Filter & DHW Flow Regulator
Cleaning/Replacement ....................................................31
3.29 Flow Thermistor Replacement ........................................31
3.30 Return Thermistor Replacement ....................................31
3.31 Heat Engine Replacement ..............................................32
3.32 Expansion Vessel Recharging & Replacement .............33
3.33 Boiler Sealing Panel Seal Replacement .........................33
4
FAULT FINDING .............................................................34
4.1
Operation Modes .............................................................34
4.2
Service Mode...................................................................34
4.3
Fault Codes .....................................................................36
4.4
Fault Finding Chart Main Menu .......................................37
4.5
‘L1’ - Flow Temperature Overheat Lockout ......................38
4.6
‘L2’ - Ignition Lockout .......................................................38
4.7
Alternating ‘L’ and ‘5’ - 5 Resets Within 15 mins ..............39
4.8
‘L6’ - False Flame Lockout .............................................39
4.9
‘F1’ - Low Water Pressure ...............................................39
4.10 ‘F2 OR Fn OR Ln’ - Flame Loss ......................................40
4.11 ‘F3’ - Fan Fault ................................................................40
4.12 ‘F4 OR L4’ - Flow Thermistor Fault..................................41
4.13 ‘F5 OR L5’ - Return Thermistor Fault ..............................41
4.14 ‘F6’ - Outside Sensor Fault ..............................................42
4.15 No CH Operation but HW Works OK ...............................42
4.16 No HW but CH On ...........................................................43
4.17 No Display .......................................................................43
