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SECTION 7 - ROUTINE SERVICING INSTRUCTIONS
7 SERVICING SCHEDULE
For the very latest copy of literature for specication, 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.
Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS EN 50379-
3:2012 and BS 7967:2015.
To ensure the continued safe and efcient operation of the appliance it is recommended that it is checked at regular intervals and
serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at
least annually.
It is the law that any service work must be carried out by a Gas Safe Registered Engineer, or in other countries a qualied and
competent Gas Installer.
7.1 INSPECTION
1. Light the boiler and carry out a pre-service check, noting any
operational faults.
2. Check the ue terminal (and terminal guard if tted) is
undamaged and clear of any obstruction.
3. Check all water and gas joints for signs of leakage. Remake
any suspect joints ensuring a gas tightness check is carried
out if applicable and the water system is correctly relled,
vented and re-pressurised.
7.2 CLEANING PROCEDURE
Note. In order to carry out either servicing or replacement of
components the boiler upper and lower front panels must
be removed. Refer to Section 7.5.
1. Clean the main burner. Refer to Section 7.7.
2. Clean the heat exchanger & condensate trap/siphon. Refer to
Sections 7.8 & 7.9.
3.
Check the main injector for blockage or damage. Refer to
Section 7.6.
4. Check that the ue terminal is unobstructed and that the ue
system is sealed correctly.
The cleaning procedures are covered more fully in Sections 7.5-
7.11 and MUST be carried out in sequence.
IMPORTANT.
5. 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.
6. When work is complete the front panels MUST be correctly
retted, ensuring that a good seal is made.
Do NOT OPERATE the boiler if the upper front
panel is not tted.
7. If, for any reason, the condensate trap/siphon has been
removed ensure the trap is relled with water before
reassembling.
8. Check the gas consumption if on metered installations.
9.
Check combustion by connecting the ue gas analyser to the
ue gas sampling point as shown in the diagram and measure
CO & CO
2
. (Refer to Section 9).
If the CO/CO
2
ratio is greater than 0.004 AND the integrity of
the complete ue system and combustion circuit seals have
been veried and the inlet gas pressure have been veried,
then contact Morco.
7.3 GENERAL
Please Note: During routine servicing, and after any maintenance
or change of part of the combustion circuit, the following must be
checked:
- The integrity of the ue system and the ue seals,
- The integrity of the boiler combustion circuit and the relevant seals
- The operational (working) gas inlet pressure at maximum rate.
Turn on one or more DHW taps.
- The combustion performance.
7.4 COMPETENCE TO CARRY OUT THE
CHECK OF COMBUSTION PERFORMANCE
Note: BS 6798:2014 Specication for selection, installation,
inspection, commissioning, servicing and maintenance of gas-red
boilers of rated input not exceeding 70 kW net advises that:
- The person carrying out a combustion measurement should have
been assessed as competent in the use of a ue gas analyser and
the interpretation of the results.
- The ue gas analyser used should be one meeting the
requirements of BS EN 50379-3:2012 and BS 7967:2015 and
be calibrated in accordance with the analyser manufacturers
requirements.
Flue Sampling Point
Air Sample
Point
Ensure all caps and seals
are re-fitted after use
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