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Morco II Series - User Manual

Morco II Series
44 pages
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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
preheat
min
min
max
mode
reset
off
status burner
max
e
BOILER OUTPUT
Series IIGB24
UIN 212458 A08
July 2018
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Summary

SECTION 1 - GENERAL

1.1 INTRODUCTION

Overview of the Morco GB Series II boilers: fanned flue, high efficiency, condensing gas boilers.

OPERATION

Describes how the boiler operates for central heating and domestic hot water demands.

SAFE HANDLING

Precautions and guidelines for safely moving and installing the boiler unit.

OPTIONAL EXTRA KITS

Lists and describes optional accessory kits for flue installation and extensions.

SAFETY

Covers gas safety, electrical safety, and regulatory compliance for installation and use.

SAFE HANDLING OF SUBSTANCES

Information regarding the absence of hazardous substances like asbestos, mercury, or CFCs.

1.2 BOILER DIMENSIONS, SERVICES & CLEARANCES

Details boiler dimensions, required clearances for installation, and service access.

1.3 BOILER ASSEMBLY - Exploded View

An exploded view illustrating the boiler components with numbered references.

SECTION 2 - INSTALLATION

2.1 DETERMINING THE FLUE LENGTH

Guidance on calculating and installing the correct flue length for safe operation.

2.2 DETERMINING THE FLUE LENGTH

Provides diagrams and formulas for calculating flue length for rear and side installations.

2.3 CUTTING HORIZONTAL FLUE TERMINAL RSF303 (600 MM LONG)

Step-by-step instructions for cutting the horizontal flue terminal to the correct size.

2.4 INSTALLING THE FLUE

Detailed instructions for fitting the flue through the wall and securing the turret assembly.

2.5 FLUE EXTENSIONS RSF341 (OPTIONAL)

Instructions for assembling and installing optional flue extension kits.

2.6 FLUE DEFLECTOR KIT RSF300 (OPTIONAL)

Details on fitting the flue deflector kit for horizontal deflection of flue products.

2.7 90° KIT RSF315 (OPTIONAL)

Information on using the 90° elbow kit for flue installations, including length calculations.

2.8 FITTING THE OPTIONAL ROOF FLUE KIT RSF345 (OPTIONAL) - Flat or Pitched-

Instructions for fitting the optional roof flue kit, including weatherproofing.

2.9 ASSEMBLING THE ROOF FLUE KIT

Steps for assembling the roof flue kit, including the vertical connector and clamp.

2.10 CONDENSATE DRAIN

Details on the condensate trap system, pipework requirements, and drainage connection methods.

2.11 WIRING DIAGRAM

Schematic diagram showing the boiler's electrical connections and components.

SECTION 3 - SERVICING

3.1 SERVICING SCHEDULE

Provides a schedule for routine servicing and maintenance of the boiler.

GENERAL

Key checks to perform during routine servicing or after component changes.

COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE

Specifies requirements for personnel performing combustion analysis.

SERVICE MODE

Instructions on how to access and use the boiler's service mode for diagnostics.

3.2 BOILER UPPER & LOWER FRONT PANEL REMOVAL; REPLACEMENT

Step-by-step guide for removing and refitting the boiler's front panels.

3.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

Procedure for removing, cleaning, and inspecting the fan and venturi assembly.

3.4 BURNER REMOVAL AND CLEANING

Instructions for safely removing and cleaning the boiler's burner assembly.

3.5 CLEANING THE CONDENSATE TRAP;SIPHON

Procedure for draining and cleaning the condensate trap or siphon.

3.6 CLEANING THE HEAT EXCHANGER

Steps for thoroughly flushing and cleaning the boiler's heat exchanger.

3.7 REASSEMBLY

Guidance on reassembling the boiler components after servicing or replacement.

3.8 REPLACEMENT OF COMPONENTS GENERAL

General precautions and steps before replacing any boiler component.

3.9 FAN REPLACEMENT

Detailed procedure for replacing the boiler's fan assembly.

3.10 BURNER INJECTOR REPLACEMENT

Instructions for replacing the burner injector unit.

3.11 BURNER REPLACEMENT

Procedure for removing and replacing the main burner assembly.

3.12 IGNITION ELECTRODE REPLACEMENT

Steps for safely removing and replacing the ignition electrode.

3.13 FLAME DETECTION ELECTRODE REPLACEMENT

Procedure for removing and replacing the flame detection electrode.

3.14 SPARK GENERATOR REPLACEMENT

Instructions for replacing the spark generator unit.

3.15 GAS CONTROL VALVE REPLACEMENT

Procedure for safely removing and replacing the gas control valve.

3.16 DIVERTER VALVE ACTUATOR REPLACEMENT

Steps for removing and replacing the diverter valve actuator motor.

3.17 CONDENSATE TRAP;SIPHON REPLACEMENT

Procedure for replacing the boiler's condensate trap or siphon.

3.18 MAIN PCB REPLACEMENT

Instructions for replacing the main printed circuit board (PCB) and boiler chip card.

3.19 USER CONTROL PCB REPLACEMENT

Procedure for replacing the user control printed circuit board (PCB).

3.20 REPLACING THE MECHANICAL TIMER

Steps for removing and replacing the mechanical timer unit.

3.21 DRAINING THE BOILER

Detailed procedures for draining the central heating and domestic hot water circuits.

3.22 DHW FLOW TURBINE SENSOR REPLACEMENT

Instructions for replacing the domestic hot water flow turbine sensor.

3.23 PRESSURE GAUGE RENEWAL

Procedure for replacing the boiler's pressure gauge.

3.24 SAFETY RELIEF VALVE RENEWAL

Steps for removing and replacing the safety relief valve.

3.25 PUMP AUTOMATIC AIR VENT REPLACEMENT

Procedure for replacing the automatic air vent on the pump.

3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT

Instructions for removing and replacing the diverter valve body assembly.

3.27 DHW PLATE HEAT EXCHANGER REPLACEMENT

Procedure for replacing the domestic hot water plate heat exchanger.

3.28 PUMP HEAD REPLACEMENT

Steps for removing and replacing the boiler's pump head.

3.29 CH WATER PRESSURE SWITCH REPLACEMENT

Procedure for replacing the central heating water pressure switch.

3.30 DHW FILTER & DHW FLOW REGULATOR CLEANING;REPLACEMENT

Instructions for cleaning or replacing the DHW filter and flow regulator.

3.31 FLOW THERMISTOR REPLACEMENT

Procedure for removing and replacing the flow thermistor.

3.32 RETURN THERMISTOR REPLACEMENT

Steps for removing and replacing the return thermistor.

3.33 HEAT ENGINE RENEWAL

Procedure for removing and replacing the heat engine assembly.

3.34 EXPANSION VESSEL RECHARGING & REPLACEMENT

Instructions for recharging or replacing the expansion vessel.

3.35 BOILER SEALING PANEL SEAL REPLACEMENT

Procedure for replacing the boiler's front panel sealing strip.

SECTION 4 - FAULT FINDING

4.1 OPERATION MODES

Explains the different display codes and their corresponding boiler operating modes.

4.2 FAULT CODES

Lists common fault codes, their descriptions, and recommended actions.

4.3 ALTERNATING L AND 1 - FLOW TEMPERATURE OVERHEAT LOCKOUT

Troubleshooting guide for flow temperature overheat lockout faults.

4.4 ALTERNATING L AND 2 - IGNITION LOCKOUT

Troubleshooting guide for ignition lockout faults.

4.5 ALTERNATING L AND 5 - 5 RESETS WITHIN 15 MINS

Troubleshooting guide for boilers resetting five times within 15 minutes.

4.6 ALTERNATING L AND 6 - FALSE FLAME LOCKOUT

Troubleshooting guide for false flame lockout faults.

4.7 ALTERNATING F AND 1 - LOW WATER PRESSURE

Troubleshooting guide for low water pressure issues.

4.8 ALTERNATING F AND 2 - FLAME LOSS

Troubleshooting guide for flame loss faults.

4.9 ALTERNATING F AND 3 - FAN FAULT

Troubleshooting guide for fan faults.

4.10 ALTERNATING F AND 4 - FLOW THERMISTOR FAULT

Troubleshooting guide for flow thermistor faults, including resistance checks.

4.11 ALTERNATING F AND 5 - RETURN THERMISTOR FAULT

Troubleshooting guide for return thermistor faults, including resistance checks.

4.12 ALTERNATING F AND 7 - LOW MAINS VOLTAGE

Troubleshooting guide for low mains voltage issues.

4.13 ALTERNATING F AND 9 - PCB FAULT

Troubleshooting guide for main PCB faults, including checking the Boiler Chip Card (BCC).

4.14 ALTERNATING C AND 0 - BCC ACTIVATION FAULT

Troubleshooting guide for BCC activation faults.

4.15 ALTERNATING ‘c AND ‘2 - BCC FAULT (BOILER CHIP CARD)

Troubleshooting guide for BCC faults, focusing on correct insertion and replacement.

4.16 NO CH OPERATION BUT HW WORKS OK

Troubleshooting guide for scenarios where central heating is not working but hot water is.

4.17 NO HW BUT CH ON

Troubleshooting guide for scenarios where hot water is not working but central heating is.

4.18 NO DISPLAY

Troubleshooting guide for when the boiler display shows no information.

Morco II Series Specifications

General IconGeneral
IgnitionElectronic
ModelII Series
Fuel TypeLPG
Gas pressure (mbar)37
Safety FeaturesFlame failure device, overheat thermostat

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