646339

Morco 30CPM Handleiding

34
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Pagina terug
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Pagina verder
Morco 24CPM and 30CPM
User Instructions and Installation Manual
For Caravan Holiday Homes and Park Homes
Domestic Hot
water
Model
Gas
Type
Output
Central Heating
Output
Morco
24CPM
LPG
26kW 24kW
Morco
30CPM
LPG
31kW
30kW
Morco
24CPM Nat
Gas
26kW 24kW
Morco
30CPM Nat
Gas
31kW 30kW
EC-TYPE EXAMINATION CERTIFICATE 177208
MORCO
PRODUCTS
LTD
Morco
House,
Riverview
Road,
Beverley,
East
Yorkshire,
HU17
OLD
Tel: 01482 325456
Fax:
01482 212869
www.morcoproducts.co.uk
~
...
~.....-....~......-......-....
.-..-.
..__
-
....
.._
--~-
~~--
-
--
.
~
.....
--
....
~
HEATING
&
HOT
WATER
'-..____/
1. USER INSTRUCTIONS
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1998 (AS AMENDED)
It
is
the law that all gas appliances are installed by a registered person,
in
accordance with the above regulations. Failure to install appliances correctly could
lead to prosecution. It
is
in
your own interest, and that
of
safety, to ensure that the
law
is
complied with.
Read these instructions carefully before attempting to operate the appliance.
Comply with all applicable warnings.
Do
not interfere with any sealed components,
and use the appliance only
in
accordance with these instructions.
This manual should
be
left with the owner of the boiler.
1.1
Introduction
The Marco 24CPM and 30CPM condensing combination boilers are wall hung,
room sealed, fan assisted, microprocessor controlled, fully modulating boilers
capable of supplying both central heating (CH) and instantaneous hot water (DHW).
The boiler can
be
set to work
in
a number of ways:
• DHW supply only
•
CH
supply only
• Both
CH
and DHW supply
The temperature of the
CH
and DHW supply can
be
set by using the knobs
on
the
control panel.
DHW Comfort Mode
The boiler has a "Comfort Mode" for hot water delivery only, that can
be
selected
on
the front panel.
In
this mode the boiler "learns" your hot water requirements and "pre-
heats" water prior to use to ensure faster delivery. With this mode switched
on
the
boiler will fire periodically even when
no
hot tap
is
opened-
this
is
normal operation.
With this mode switched off the boiler will only fire for hot water delivery when a tap
is
opened. This
is
called "economy mode"
LCD Display
Depending
on
the boiler status and user interaction with buttons and dials
on
the
control panel the following can
be
displayed
on
the LCD panel:
• Temperatures of water
in
the
CH
circuit-
both actual and target
• Temperature
of
DHW-
target only
• Fault
Codes-
in
the event of a problem
• Pressure
in
the
CH
circuit
3
1.2
CONTROL
PANEL
1 . On/off switch
2.
LCD display panel and yellow status LEOs
3.
Central heating temperature control knob
4.
Domestic hot water temperature control knob
5.
Central heating pressure test button
6.
Reset push button/burner LED
4
1.
On/off switch
This knob is used to turn the boiler
on
and
off-
it will NOT reset the
boiler after a fault code has been displayed
2.
LCD
display and yellow status
LEOs
The table below shows the various combinations
of
displays and
LED lights that give the boiler status at that point
in
time
Stand-by Mode: When there is no heat demand for
central heating
(CH) or domestic hot water (DHW).
LCD
display shows actual
CH
flow temperature
(default).
CH
mode: LCD display shows actual
CH
flow
temperature and status
LED CH is
ON.
DHW
mode: While DHW mode is active, status
LED
DHW
is
ON.
Setpoint mode:
LCD
display shows target
CRJDHW temperature when adjusting
CHIDHW
control knobs. Left dot is flashing. After I 0 seconds,
display shows actual CH Temperature.
Pressure mode:
CH
water pressure (bar) can be seen
on the LCD display
by
pressing the pressure
test-
button.
It
remains active for I 0 seconds.
Comfort
mode:
If
comfort mode is active, status
LED Comfort is ON.
Error
mode: A fault code appears automatically
on
the LCD display. The fault code is flashed and
Burner LED turns D.
Service mode:
If
service mode
is
active, status LED
Service is ON.
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5
3.
CH
temperature
control
knob
This has 3 functions:
1.
Set the CH target temperature between 30 deg C and 80 deg C
2.
Select heating mode ON
or
OFF
3.
The service mode is set by turning the knob fully
clockwise-
this
is only for use
by
engineers
Service
Mode
MAX.
4.
DHW
Temperature
control
knob
This has 3 functions:
.----Heating
OFF
,--------+---Heating
ON
MIN
1.
Set the DHW target temperature between 35 deg C and 60
deg C
2. Select comfort/economy mode - change between these
modes by turning the knob fully clockwise and then back
within 3 seconds.
3. The DHW supply can be switched off by turning the knob
fully anti-clockwise.
Comfort/ECO
Mode
Selection
5.
CH
Pressure
test
button
--...-..-.~...-..
=--===:;;=
-
·==-
···~--
..
~
----t--Hot
Water OFF
'------------.--
Hot Water ON
MIN
COMFORT
'
This is used to see what pressure is held
in
the CH circuit - it should
read between1.0 -1.4 bar. In order to see the pressure on the LCD display,
push the button. The value will be displayed for approximately 10 seconds.
6.
Reset push button/ burner LED
This is used to reset the boiler after
any
fault codes are displayed on the LCD panel.
In addition the colour
of
the LED indicates the following:
• Red LED - the boiler is in fault mode and a code should be visible on the LCD panel
• Blue
LED-
the boiler is operating normally and the burner is ignited
6
1.3
GENERAL
GUIDANCE
ON
HOT
WATER
DELIVERY
The temperature
of
the hot water is governed by both the ambient temperature
of
the cold water supply and its flow rate through the boiler.
In
the case
of
the
24CPM model at a flow rate
of
1 0.6L/min there will be a maximum rise
of
35°C
above ambient.
At
a flow rate
of
6.8L/min there will be a rise
of
sooc
above
ambient, (the slower the flow rate, the greater the temperature rise).
The flow rate
of
the hot water
is
controlled
by
the hot outlet tap, until the max flow
allowed by the boiler is achieved.
The temperature selector knob on the boiler is effective only when there is either
a low water flow rate
or
a high ambient water temperature.
- The boiler can theoretically supply more than one outlet simultaneously
However in practice the tap which is nearest will receive the most hot water. If
the shower is
in
use and a kitchen tap
is
opened virtually all the hot water will be
diverted to the kitchen as it offers the least resistance.
- If
an
outlet
is
too restrictive it will slow down the flow rate and increase the
temperature. For example, ensure the shower head
is
free from blockages
caused
by
scale.
-
If
a tap or shower head is too restrictive due to a fault
or
blockage, the flow rate
will be reduced to below the rate
at
which the boiler
is
able to operate, resulting
in a wide swing
in
temperatures. Either fix the restriction or turn the temperature
selector on the boiler down.
A eaution:The boiler can
produce
water at
over
1o·c when in central
heating
mode.
If
you
run a
hot
tap
when
the
boiler
has been
heating
the
radiators,
the
initial
flow
through
the
hot
tap
could
be
very
hot.
DO NOT
PLACE
YOUR
HANDS
under
the
tap
or
use
the
shower
until
this
initial
flow
has passed.
-Allow
time
(30
seconds)
for
the
temperature
to
stabilise
after
making
an
adjustment
at
the
tap
before
making
further
adjustments.
7
8
1.4
GENERAL
ADVICE
ANTI PUMP SEIZURE DEVICE
When central heating
is
not being used, but the boiler
is
in
the summer setting (for
domestic hot water only) the pump will automatically run for 30 seconds every 23
hours to prevent it
seiz1ng.
If the appliance has been shut down with the electrical
supply switched off for a period, this device will not work. The pump may
be
found to
have
jammed
when the appliance
is
switched back on. If so, consult your installer or
Gas Safe Registered
Eng1neer.
NOTE: Seized pumps are not covered under warranty.
ROUTINE SERVICING
To ensure continued safe and efficient operation
of
the appliance it
is
recommended
that it
is
checked and serviced as necessary at
re_gular
intervals. The frequency
of
servicing will depend upon the particular installation conditions and usage but
in
general once a year should
be
regarded as a minimum even if only occasional usage
nas occurred.
It
is
the law that any service work MUST
be
carried out by a competent Gas Safe
Registered Engineer.
SAFETY
It
is
essential that these instructions are strictly followed for the safe and economical
operation of this appliance. The appliance
is
a fan-assisted room sealed gas boiler and
therefore the flue terminal MUST NOT
BE
OBSTRUCTED under any circumstances. If
it
is
damaged, turn off the appliance and consult your installer, or service engineer. If it
is
known or suspected that a fault exists
on
the appliance it MUST NOT
be
used until
the fault has been rectified by a competent Gas Safe Registered Engineer.
THERMOSTATS/TIMERS/PROGRAMMERS
This appliance may
be
fitted with one of the above devices to control the central heating
function
in
the home. These devices may override the controls of the boiler. For
example: the boiler will not fire
in
CH
mode when a
room
thermostat senses its set point
temperature has been reached or a time clock
is
outside of the time zone selected for
CH
to operate.
If
the boiler is installed in a Caravan Holiday Home, refer
to
the user manual
for
the
home,
for
the positions
of
all drain plugs.
Note: There
are
no
drain plugs fitted
to
the
actual
boiler.
-Leave
all
taps
and
plugs open until the boiler
is
next needed for service. This will allow
any residual water
to
continue
to
drain.
NOTES ON FROST PROTECTION
The heating circuit and radiators should contain the correct level
of
antifreeze
to
prevent damage during freezing conditions and should not
be
drained down.
Opening the hot and cold water drain cocks should be sufficient
to
drain all the
water from the boiler.
However in some installations
it
rna}!
be
necessary
to
blow through the system
with
air
to
ensure the water has drained. The filling loop valve below the boiler may also
be
used as an extra drain point.
ALL
FROST DAMAGE IS OUTSIDE OF THE
WARRANTY
2. GENERAL SPECIFICATION
The Marco 24-CPM and 30-CPM are a range
of
high efficiency condensing combination
boilers that use premix technology and achieve a grade A rating
in
SAP 2009. They are
designed to provide both Domestic Hot Water (DHW) and Central Heating (CH), although
the CH does not operate while the DHW is being used. The boilers are designed to be
wall hung and are room sealed, that is they obtain the air for combustion from outside
the dwelling and a fan returns the products
of
combustion to the outside. The range is
particularly suited to use
in
Caravan Holiday Homes and Park Homes. The boilers can
be supplied ready to run on either LPG
or
Natural Gas.
Both horizontal and vertical flues can be used and various elbows can be used to
accommodate a more complex route between the boiler and the outside
of
the dwelling.
The main printed circuit board provides all the functionality and safety features for
the boiler.
The board operates the gas valve, fan, pump,3-way valve and flame supervision.
The safety systems built into your appliance provide entire safety for you and your
appliance. The safety systems are:
> Flue Gas Over-heat Safety System (105 °C)
> Flame Failure Supervision
> Boiler Over-heat Safety thermostat 2 levels: 95 °C and 105 °C)
> DHW (Domestic Hot Water) Over-heat thermostat
> CH Over Pressure Protection (3 bar)
> CH Low Water Pressure Protection (0,8 bar)
> High Voltage Protection System (260 VAC)
> Low Voltage Protection System (160 VAC)
> EMC (Electromagnetic Compatibility) Filter
> Thermal Accumulation Protection (with by-pass circuit and "pump over-run")
> Water Flow Supervision
> Pump Run Protection (0,4 bar)
> Pump Anti-sticking Function
> 3
Way
Valve Anti-sticking Function
> Automatic Air Vent
> Expansion Vessel (7 litres)
9
1-
Stainless steel heat exchanger
2-
Air I gas manifold
3-
Fan
4-
Pump
5- Hydraulic
circuit-
flow manifold
6- Gas
valve
7-
Water
pressure
transducer
8-
CH
tlo\v
NTC
sensor-
immersion
type
9-
CH
return
NTC
sensor - surface type
10-
DHW tlow turbine
11-
Air I gas mixer box
10
12-
Igniter
13-
Ignition electrodes
14-
Ionization electrode
15- Flue gas
NTC
sensor
16-
Hydraulic
circuit-
return manifold
1 7- Automatic air
vent
18-
Air
inlet
pipe
1 9-
Expansion
vessel ( 7 litres)
20- Siphon(Condensate Trap)
21- Plate heat exchanger
22- Thermal
cut-off
160
°C
3-TECHNICAL
DATA
24CPM
JOCPM
Unit
Gas
Category*
I I
2H3i>
II
21m
Boiler
Type
CrJ<~J·
Ci*l•
C4:3<¥lt
c
IJCxh
C:Jl!.liol•
c4l(X)•
C.s:JW,
C,)(:(,)t
Cal(xJ
Cnt«>t
C'i<xl>
Ct~(~
Type
of
gas
G 20 G
31
G20
031
Performances
CH
Min. Heat Output (80160
°C)
6,6
7,9
8, I
9,6
kW
CH
Max. Heat Output (80160 °C)
22.2
22,2
27,3
27,3
kW
CH
Min. Heat Output (50/30 °C)
7,3
8,8
9
10,8
kW
CH Max.
Heat
Output (50130 °C)
24
24
30
30
kW
CH
Min. Heat Input
6,8
8,2
8,4
10
kW
CH
Max. Heat Input
22,8
22,8
28
28
kW
DHW
Min. Heat Output
6,7
8
8,2
9,7
kW
DHW Max. Heat Output
26
26
31
31
kW
DHW
Min. Heat lnput
6,8
8,2
8,4
10
kW
DHW
Max. Heat Input
27
27
32
32
kW
Gas
Consumption**
Natural Gas (Max. Load)
2,38 2,92
m
3
lh
Natural Gas (Min. Load)
0,71
0,88
m3/h
Propane (Max. Load)
1,77 2,17
kglh
Propane (Min. Load)
0,64
0,77
kglh
Gas
Supply
Pressure
20 20
mbar
Natural Gas (G 20)
37
37
mbar
Propane (G 31)
Domestic
Hot
Water
Min. Flow
Rate
For Activating
3 3
Jtr/min
Max.
Flow
Rate
12
(~t=JI
•c)
14
(~t=32
.,C)
I trim in
Flow rate at 35
°C
temp. rise
10,6 12,7
ltr/min
Min. Operating Pressure
0,2 0,2
bar
Max. Operating Pressure
7
7
bar
Set Temperature Range
35-60 35-60
oc
Central
Heating
0,8 0,8
Min. Operating Pressure
bar
Max. Operating Pressure
3 3
bar
Set
Temperature Range
30-80 30-80
oc
General
Electrical Supply
230V AC- 50Hz 230V AC- 50Hz
VAC/Hz
Fuse Rating
4A
4A
A
Electrical Power Consumption
115
115
watt
Expansion Vessel
7 7
ltr
Dimensions (HxWxL)
775 x454x370 775 x454x370
mm
Weight (Net)
40 40,5
kg
Seasonal Efficiency (SEDBUK)
90,0-NG
I 91,3-LPG 90,1-NG I 91,6-LPG
%
IP rating
IPX40
IPX40
**For gas
consumption-
Calorific Value (Net) Natural gas: 34.52 MJim
3
Propane: 78.5 MJim
3
}>
c type boilers
(Crl(XJ,
c33(s),
c43{xh
CsJ(x),
c63(x),
C8J(x))
are air independent gas appliances. Air required for
combustion is provided from outside via air
supp!yducts
with products
of
combustion, discharged by flue
gas
ducts.
Only
M
OR
CO
supplied
flue options
may
be
used.
I
11
MAIN BOARD PCB
Main
board
has
different
parameters
such
as
fan
speeds
according
to
the
boiler
types
(24 kW,
30
kW, Natural gas, Propane,). A
main
board
can
be
converted to another type
by
installing
an
appropriate
(Boiler Control Card) to
the
main
board.
Main Board - Technical and Functional Specifications
General
Power supply range (standard):
195-253
VAC
!Power supply frequency:
50Hz
Working temperature range:
0
oc-
60
oc
Fusing: 4A
Inputs
Water pressure switch: 0,5 - 2,5 V
de
(0,0 - 4,0 bar)
DHW flow turbine
Max.
14
1/min
CH flow NTC sensor:
10
k0hm@25
°C
CH return NTC sensor:
10
k0hm@25
°C
Flue gas NTC sensor:
10
k0hm@25
oc
Thermal cut-off:
160
oc
Room thermostat:
24VDC
Ionization current: min.
11-lA
Outputs
Gas valve: 230 VAC
Igniter:
230 VAC
Pump: 230 VAC
Fan:
230 VAC
3 way electrical valve 230 VAC
12
13
30 sec
3 MIN
24CPM
30CPM
Wiring
Diagrams
I
In
rn1
'A
I I
X10
clgD
031
I
liiiil
II
I I I
30
32
27
D D
33
24
[Q]
B 2s
26
20
21
~
~
23
22
@)
@)
X2B
I
X2A
I
I XlC I XlB I XlA
PENLPENL
-
Black
-Blue
-Brown
4
-Grey
-Orange
-Pink
- Purple
-Red
-Yellow
18
~~~====:::::::::=.~
-
YellowGreen
-White
INFORMATION
1
230
VAC
Room
thermostat
(Optional)
2
230
VAC
Power supply
3
230
VAC Pump
4
230
VAC
Gas valve
5
230
VAC Igniter
6 Ignition electrodes
7 Ionization electrode
8 230VAC Fan
9 230
VAC
3
way
divertar valve
1 0
PC
communication/ e-Bus port
12
CH
ratum
NTC
sensor
13
CH
flow
NTC
sensor
14
CUI-off
160"C
15
Flue
gas
NTC
sensor
16 PWM Fan control
17 Water pressure sensor
1 8 DHW Flow turbine
19 Boiler
chip
card
(BCC)
port
20 Fuse4A
21
Power
switch
22
CH
potentiometer
23 DHW potentlonmeter
24 Reset button
25 Flame LED (blue)
26 Error
LED
(red)
27 Connector
MICS20
28 Pressure button
29 Status
LED
CH
30
Status
LED
DHW
31
Status
LED
Comfort
32 Status LED Service
33 LCD2x7
34
Terminal
35
24VDC
RT
/Opentherm
RT(Optlonal)
36 Outside temp. sensor (Optional)
.q-
.-
4. GENERAL INSTALLATION
FOR
THE
USER
This appliance must be installed, adjusted
or
adapted for use with another type
of
gas, only by a qualified and competent person.
A correct installation will ensure that your boiler works properly.
GAS SAFETY (INSTALLATION
AND
USE) REGULATIONS 1998 (As
amended).
It
is
the law that all gas appliances must be installed by a registered person,
in
accordance with the above regulations.
Failure to install appliances correctly may lead to prosecution.
It is
in
your own interest, and that
of
safety, to ensure that the law is complied
with.
In
addition to the above regulations, this appliance must be installed
in
accordance
with the current:
• lEE Wiring regulations,
• Heath and Safety Document No 635 'The Electricity at Work Regulations.
It should also be
in
accordance with the relevant recommendations
in
the current
editions
of
all relevant National Standards. Your particular attention is drawn to the
following standards relevant to an installation
in
Caravan Holiday Homes:
• BS 5482 part 2 Installations
in
caravans and non permanent dwellings.
• BSEN721 Leisure accommodation vehicles ventilation requirements.
• BSEN 1949 Installation
of
LPG System for Habitational Purposes in Leisure
Accommodation Vehicles.
For Park Home installation refer to:
• BS3632 Specifications for Residential Park Homes
• BS5440 Flueing and Ventilation
IMPORTANT: Manufactures instructions must NOT be taken in
any
way
as
over-riding statutory regulations.
4.1
BOILER LOCATION
In
positioning the boiler, the following limitations MUST be observed:
• The position must allow
for
a suitable flue termination to be made.
• The combination boiler must be installed on a flat vertical wall capable
of
supporting its weight.
• If the boiler is
in
a room containing a bath or shower, the boiler controls and
power supply must be so situated that they can not be touched by the person
using the bath
or
shower. Attention is drawn to the current lEE Wiring
Regulations, and
in
Scotland the electrical provisions
of
the Building
Regulations applicable
in
Scotland. (See 4.8).
• A compartment used to enclose the appliance MUST be designed and
constructed specifically for the purpose. An existing cupboard,
or
compartment,
may be used provided it is modified accordingly.
• Minimum clearance as stated
in
the technical data must be observed (see
4.3)
15
4.2 FLUE TERMINAL POSITION
• The boiler MUST
be
installed so that the terminal
is
exposed to the external
air.
• It
is
important that the position
of
the terminal allows free passage
of
air
across it at all times.
• Where the terminal
is
fitted
in
a position to which children, the elderly, or
disabled people have access (less than 1.5m above steps, decking or ground),
a suitable terminal guard should
be
fitted.
•
In
certain weather conditions the terminal may emit a plume
of
steam.
•
It
is
ESSENTIAL TO ENSURE, that products of combustion discharging from
the terminal cannot re-enter the building, or vehicle, through ventilators,
windows, or other sources of natural air infiltration, such
as
other flues etc, with
the exception of doors, but not the opening windows thereof.
• The minimum acceptable dimensions from the terminal to obstructions and
ventilation openings
is
as follows:
Directly below
an
opening fixed vent, windows, etc.
300mm
Adjacent to
an
opening fixed vent, windows, etc. 300mm
Below gutters 75mm
Below eaves
200mm
From a vertical drain pipe or soil pipe 75mm
From
an
internal or external corner 300mm
Vertically from a terminal
on
the same wall
1500mm
Horizontally from a terminal
on
the same wall 300mm
For domestic and Park Home applications please refer to BS5440.
4.3 MINIMUM CLEARANCES
• Minimum clearances of 25mm
on
each side and the front of the boiler must
be
observed. However full access from the front
in
the form of
an
opening door,
must
be
given to allow access to the controls
and
for servicing.
• 200mm above the top
of
the boiler case
is
required for the flue assembly.
• 300mm
is
required below the boiler to allow easy access to the gas isolation
cock and filling loop.
• If the boiler
is
to
be
installed into a small cupboard or compartment (i.e. at the
minimum clearances) and overheating can
be
foreseen (i.e. close proximity
to another heat source such as a cooker or fire) it
is
recommended that
ventilation
be
installed
in
the cupboard for cooling. The following table gives
the minimum effective areas
of
the vents:
16
Position
of
air Air from an internal Air from an external
vents source source
High Level
13000 sq.
Mm
7500 sq.mm
Low level
1300 sq.
Mm
7500 sq.mm
4.4
ELECTRICITY
SUPPLY
A 3 amp fused three pin plug for use with 230V-50Hz is supplied fitted to the
appliance.
It should be used with a shuttered socket outlet complying with BS 1363
THIS APPLIANCE MUST
BE
EARTHED
4.5
GAS
SUPPLY
• A Propane gas supply at 37mbar is required or a 20mbar for natural gas
• Ensure the regulator is
of
sufficient capacity to carry the maximum boiler
input plus the demand for any other installed appliances.
• Ensure the connection between the supply/bottle and the caravan holiday
home or park home
is
designed so that no pressure drop occurs.
• No more that 3 m
of
15mm pipe should be used. Where the supply exceeds
3 m the pipe should be suitably sized only reducing to 15mm before the boil-
er
• A full bore isolation cock must be fitted
in
the supply close to the boiler or
use Marco part number FW0391.
• If using bottled propane the bottle size must be taken account of.
• The complete installation must be tested for gas soundness.
4.6
CENTRAL
HEATING
SYSTEM
This appliance
is
designed for connection to sealed central heating water
systems only.
Requirements
for
Sealed
Water
Systems
The heating system design should be based
on
the following information:
A heating by-pass should
be
fitted. If thermostatic radiator valves are to
be
installed, at least one radiator should be fitted with lock shield valves (usually the
bathroom radiator or towel rail).
17
18
A sealed system must only be filled by a competent person using an approved filling
loop connected between the mains water supply pipe and the central heating return
pipe. Once filled the loop should be disconnected and left adjacent to the boiler.
Antifreeze/Inhibitor
The sealed CH circuit should, at all times be filled with the correct concentration of a
suitable antifreeze/inhibitor. Marco recommend Fernox Alphi
11
at a concentration
of
at least 25%. This will provide protection
on
the CH CIRCUIT ONLY down to
-11
deg Celsius and sufficient protection from corrosion.
Expansion Vessel
The following table gives the maximum system volume that the integral 7 litre
expansion vessel can sustain.
Vessel charge/initial
system
pressure
(bar)
0.5 1 1.5
Total
water
content
of
CH
system
(litres)
83
64
44
If the total water content exceeds that shown, an additional expansion vessel must
be fitted and connected to the heating system primary return pipe as close as
possible to the appliance. If an extra vessel is required, ensure that the total
capacity
of
both vessels is adequate. If the pressure display on the boiler control
panel indicates 2.2 bar
or
greater when the appliance is at maximum temperature
with all radiators
in
circulation an extra expansion vessel is required.
Pressure Relief Valve
A pressure relief valve set 3 bar (43.5psi)
is
fitted and a discharge pipe
is
routed to the
outside
of
the appliance. This discharge pipe should be extended to terminate safely
away from the appliance to a point where a discharge would not cause damage to
persons or property but would
be
detected. The pipe should
be
able to withstand
boiling water, be a minimum
of
15mm
in
diameter, and not include any upward pipe
runs or horizontal runs prone to freezing.
4.7
DOMESTIC
WATER
SYSTEM
Check that mains supply pressure is within the prescribed range
of
0.2 - 1
Obar.
If it
exceeds this limit, a pressure reducing valve should be fitted to the mains supply
before the inlet connection.
The final 1 000 mm
of
the mains supply pipe to the boiler and the hot water outlet
must be
in
15mm copper.
If the appliance is installed where the temporary hardness of the water is high,
say over 150 ppm (as defined by BS 7593 1993 Table 2), the fitting of an in line
scale inhibitor is required. This must be comply with the requirements of the local
water company.
Devices capable of preventing the flow of expansion water: e.g. non return valves
and/or loose - jumpered stop cocks should not be fitted u
nless separate
arrangements are made for expansion water.
If a non-return valve is fitted in the incoming water supply - e.g. in line with scale
inhibitor then a D.H.W. expansion vessel MUST be obtained and fitted.
4.8 INSTALLATION IN A BATHROOM
The appliance is rated IPX4D
The boiler may be installed in any room or internal space, although particular
attention is drawn to the requirements of t
he current IEE (BS.7671) Wiring
Regulations and, in Scotland, the electrical provisions of the building regulations
applicable in Scotland, with respect to the installation of the boiler in a room or
internal space containing a bath or shower. For IE reference should be made to
the current ETCI rules for electrical installations and I.S. 8 13:2002
If the appliance is to be installed in a room cont
aining a bath or shower then the
appliance can be installed in Zones 1 & 2, as detailed in BS. 7671. Although
consideration must also be given when fitting boilers within bathrooms to adhere
to the current gas safety regulations.
19
20
5.2 GAS AND WATER CONNECTIONS
Connect the boiler up in such a way as to leave the connecting pipes self supporting
and free from any stress. The Gas pipe must
be
supported by a clip to the bulkhead.
Check the gas pipe complies with the requirements in section 4.5.
Gas and water connections are made to the boiler as
in
the diagram below:
I
®
'
CD
'
®
0
171
2
~
3
0
4
1.
CH
Flow-%"
BSP
2.
DHW
Outlet-
%"
BSP
3.
Gas
Inlet-%"
BSP
4.
DHW Inlet
(mains)-%"
BSP
5.
CH
Return -
%"
BSP
6.
Condensate Drain
7.
Pressure Relief- 15mm copper stub pipe
0 7
0
5
21
5.3
WIRING
INSTRUCTIONS
Warning: observe the usual precautions to ensure that the electricity supply is
isolated before commencing any installation
or
service work.
The appliance is fitted with a 3 amp. fused 3 pin plug for use with 230
V-50Hz.
It
should be fitted to a shuttered socket outlet complying with BS 1363. If the
appliance needs to be wired to a fused spur (for example
in
a bathroom) then the
3 pin plug should be removed and fitted to a double pole type
3A
fused spur.
WARNING: THIS APPLIANCE MUST BE EARTHED.
Room ThermostatfTime Clock/Programmer
This appliance may be used
in
conjunction with an external control device.
This device MUST HAVE a volt free contact used to switch the boiler
on
and off. If
mains voltage enters the boiler via the control device terminals then BOILER
DAMAGE WILL OCCUR. If
in
doubt contact a qualified electrician.
For the connection
of
a control device proceed as follows:
1.
Remove front casing
2. Lower control box by removing the 2 side screws
3. Undo the 2 screws securing the connection cover panel.
4. Remove the link wire (coloured blue as below)
5. Connect volt free heating control switch wire
If fitting a room thermostat. it must be installed on a wall which is free from any
objects and free from sunlight
or
draughts.
X7A
I erminal
Block--
Room
stat
N L
It is possible to fit a 230VAC Thermostat!Time Clock/Programmer - Please
contact Marco for advice on
how
to install.
22
5.4 AIR/FLUE SYSTEM
The flue system
is
a
p~rt
of
the appliance and
is
approved as such. Use only flue
systems supplied by Marco that are approved for use with this boiler.
Both horizontal and vertical flues can
be
used with these boilers. The following
maximum flue lengths apply. These are based
on
the use
of
one elbow for the
horizontal flue and
no
elbows for the vertical flue.
Flue Type
Model
Maximum Flue Length
Horizontal 24CPM 7m
Horizontal
30CPM 4m
Vertical 24CPM
8m
Vertical 30CPM
Sm
Each 90 degree elbow added to the flue decreases the maximum length available
by 1m. Eacfl 45 degree elbow added to the flue decreases the
max1mum
len_gth
ayailable by 0.5m. Please contact Marco for more details when designing true
kitS.
The horizontal flue pipe may
be
cut down to the length required.
The flue must
be
fitted with a
2°
or
3°
downwards incline towards the boiler to
ensure condense flows back into the boiler.
In
cold or humid weather, water vapour
in
the flue gas may condense when
leaving the flue terminal. Care must
be
taken when locating the boiler to avoid
pluming causing nuisance to the occupier of the adjacent property.
The installer must ensure that an adequate seal
is
formed between the inner and
outer pipe and the corresponding part
in
any elbow or connector. The connection
can
be
eased by the use of silicon based lubricant. Normal grease/oil or sealant
are not allowed.
The black glastic terminal must
be
positioned with the rain shield to the top
on
the
horizontal flue system.
The air/flue terminal must
be
exposed to the external air and allow free passage
of air across it at all times.
The minimum acceptable dimension between the terminal and
obstructions/oQenings are outlined
in
chapter 4.2. For domestic and Park homes
refer to BS5440.
23
5.5
CONDENSATE
TRAP
All condensing boilers generate condensate discharge. The amount
of
condensate water depends on the working conditions
of
your appliance. This
can be up to
1.
7 litres per hour.
A plastic discharge pipe should be fitted to the outlet pipe
of
the condensate
trap using the black rubber connector provided and the pipe should run into
the drain point. Only plastic materials are suitable.
If the pipe work
is
not terminated within the Caravan Holiday Home
or
Park
Home any external pipes must be insulated against freezing and increased to
a 32mm diameter. Pipe work runs should be kept to the minimum possible.
All horizontal pipes must be connected at a slight 2 or 3 degree downwards
incline to ensure a good flow.
Before connecting the flue the condensate trap must be filled with water. This
is achieved by tipping 1 litre
of
water into the INNER flue terminal on top
of
the boiler as below. This prevents the risk
of
products
of
combustion
escaping into the dwelling. Take care when filling the condensate trap if the
drain pipe is not already connected.
5.6
CONDENSATE
DRAIN
TERMINALS
National and local requirements
for
the connection
of
the condensate trap to
drains should be taken account of. There are
2 suggested ways
of
draining
the condensate
for
a Caravan Holiday
or
Park Home. One is to drain into the
waste pipe under the home as below and the other is to drain into a soak
away, details
of
which are on the following page.
24
-
-
-·
·
-
.
··
~
''"-=
Soak
Away
Key
1.
Condensate pipe
2.
Section
of
pipe above or below ground
3.
100mm diameter pipe
4.
Bottom sealed
5.
Limestone chippings
6.
Two rows
of
12mm holes at 25mm centres
1
y
~f/J22
~500
4
5
-
----1"'
·
.---
--..::..
---
~
...;
7. Minimum hole size 400mm deep x 300mm wide
0
0
~
'
AI
7
25
6.
COMMISSIONING
During commissioning the appliance, the following should be checked:
1.
Gas
Supply
2.
Water
Supply
3. CH Circuit
4.
Condensate
Trap
5. Flue Connections
6. Electrical Circuit
7. Flue
gas
Analysis
IMPORTANT: Open all
doors
and
windows,
extinguish
naked lights, and
DO
NOT SMOKE
whilst
purging
the
gas
line.
Before commencing the commissioning procedure, ensure that the central heating
system and the domestic hot and cold water system have been flushed. This will
remove contamination which could block the filters fitted to the cold inlet and C.H.
return connections resulting
in
incorrect functioning
of
the boiler.
6.1
GAS
SUPPLY
The
whole
gas
installation including the
meter
(if fitted)
MUST
be purged and
tested
for
gas
soundness.
Check
the
supply
inlet pressure to the boiler is correct
for
the type
of
gas
used.
6.2
DOMESTIC
HOT
WATER
• Turn on the mains cold
water
isolation valve.
• Fill and
vent
the installation
by
turning on hot and cold
water
taps.
• Make sure that there are no leaks
in
the installation.
6.3 CENTRAL HEATING CIRCUIT
GAS PRESSURE
TEST
PO
INT
In
order
for
the boiler to function correctly, the pressure in the central heating
circuit
must
be between 1.0 and 1.4
bar
when cold. This can be seen by
pressing the button on the control panel and reading the value on the LCD
display.
The
pressure can be increased by the use
of
the filling loop - refer to
4.6.
The
central heating circuit should be filled with a
mix
of
water
and at least
25% antifreeze/inhibitor. In environments
were
temperatures drop
below
-11 deg
Celsius this percentage should be higher, with a maximum concentration
of
40%.
The
concentration d anti freeze I inhibitor should be checked using a refracto-
meter.
26
Both the boiler and the central heating installation should have been purged
of any air
in
the
CH
circuit which may cause noise/malfunctions/damage to
the boiler. The boiler
is
fitted with two automatic air vents:
1.
One
is
located
on
the pump
AUTOMATIC
AIR
VENT
......
......
2.
The other
is
located externally on top
of
the boiler
AUTOMATIC
AIR
VENT
Always ensure that both the caps on the automatic air vents are
loose prior
to
commissioning.
6.4 CONDENSATE TRAP
Ensure the trap
is
full with 1 litre of water. (See 5.5.)
Ensure all connections are water tight and that the condensate discharge pipe
is correctly installed (see 5.6.).
6.5 FLUE CONNECTIONS
Ensure that the flue has a fall
of
2-3 degrees back towards the
boiler.
Make sure that the air intake and the flue outlet are not blocked.
27
28
6.6 ELECTRICAL CONNECTIONS
Checks to ensure electrical safety should be carried out by a qualified person
ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity,
polarity, resistance to earth and short circuit using a suitable test meter.
6.7 FLUE GAS ANALYSIS
If the boiler is on a metered gas supply carry out a gas rate test at the gas meter. The
boiler needs to be in s
ervice mode which is achieved by turning the CH knob on the
front panel fully clockwise and the service LED will now be on. Turn the knob counter
clockwise and then fully clockwise again and the service LED will flash. The boiler is
now set in “high-rate” service mode. Turn on the hot water tap and carry out a gas rate
test at the gas meter. The gas consumption should be as below within a toleranc
e of
5%. If the reading is outside of this range then, with the use of a flue gas analyser,
refer to gas valve adjustment in chapter 7.
Gas Consumption
24CPM
30CPM
Unit
Natural Gas (max load)
2.38
2.92
m³/hour
Natural Gas (min load)
0.71
0.88
m³/hour
Propane (max load)
1.77
2.17
kg/hour
Propane (min load)
0.64
0.77
kg/hour
If no meter is available or the boiler is on bottled gas then, with the use of a flue
gas analyser, refer to gas valve adjustment in the chapter 7.
6.8 INITIAL OPERATION
Domestic hot water
To turn on the boiler follow the user instructions at the front of this manual.
Whenever a hot tap is opened the boiler automatically fires up to deliver hot water. The
temperature selector control should be se
t at maximum. If the ambient water
temperature is high (as in a hot climate) then the hot water temperature may be reduced
by using this knob.
Central heating
Set the timer/thermostat/programmer so that the boiler will fire in CH mode. Refer to
chapter 1 User Instructions to operate the CH circuit.
The central heating temperature control knob allows water temperature of between 30
and 80°C to be
selected. The boiler will remain on until:
• The temperature selected on the thermostat/programmer is reached
• The temperature selected on the boiler CH control knob is reached
• The timer switches the boiler off.
6.9 FAULT CODE/LOCK OUT
If the boiler develops a fault the reset button will show red and a fault code will show
on
the LCD panel. See Fault codes
in
chapter 9 for further details.
To reset the boiler after a fault, press the reset button and it should change from red
to either:
• Clear if the boiler is unlit or
• Blue if the boiler is lit.
6.10 FINAL CHECKS
• Re-light and test for gas soundness
• Set the C.H. and D.H.W. temperature selectors to the required settings.
• Ensure that the timer/thermostat/programmer are set to the required settings.
6.11 USER INSTRUCTIONS
Upon Commissioning
of
the boiler the engineer should:
• Give the 'users Instructions' to the owner and emphasise their responsibilities
under the "Gas Safety (Installation and Use) Regulations 1998"
• Explain and demonstrate the lighting and shut down procedures.
• Advise the owner
on
the efficient use
of
the system, including the use and
adjustment of all system controls for both D.H.W. ana
C.
H.
• Advise the user
of
the precautions necessary to prevent damage to the system,
and
tq
the home,
in
the event
of
the system remaining inoperative during frost
cond1t1ons.
• Explain the function
of
the boiler safety devices, fault codes and how to reset
them. Emphasise that if fault codes and lock outs persist, the boiler should be
turned off and a Gas Safe Engineer consulted.
• Stress the importance
of
an
annual service by a competent Gas Safe Registered
Engineer.
29
30
7.
ROUTINE SERVICING
To ensure continued efficient operation
of
the appliance, it
is
recommended
that it
is
checked and serviced as necessary- at regular intervals. The frequen-
cy
of
servicing will depend upon the particular installation conditions and usage
but
in
generar once a year should be adequate.
It
i~
the law that any service work must be carried out by a gas safe
reg1stered engmeer.
7.1
Front Cover Removal
Remove 2 screws at the bottom
of
the front panel
Pull forward at the bottom to disengage catches then lift the cover
off
the
pins at the top
of
the boiler .
.....
...
..
7.2
Servicing Schedule
...
..
......
Before commencing any service operation, ISOLATE the mains electric supply,
and TURN OFF the gas supply at the main service cock. Service the appliance
by following the full procedure aetailed below.
1.
Run the boiler
in
DHW mode and
CH
mode and carry out a pre service
check, noting any operational faults.
2.
Check the combustion performance whilst running
in
DHW mode at
maximum output, if suitable equipment for flue gas analysis
is
available.
(Note: the flue sampling point can
be
found on the flue turret elbow.
For correct boiler operation
the CO/C02 ratio
should
not
be
greater than
0.004).
If
this is not the case then refer to gas valve
adjustment
in
section 7.3
3.
Check that the DHW filter is not blocked.
4.
Check that the flue terminal is unobstructed and that the flue system is sealed
correctly.
5.
Remove the fan and burner assembly. Inspect, and if necessary, clean the
main burner using a soft brush
or
vacuum cleaner. Do not use a wire brush or
any abrasive materials.
6.
Remove ignition and ionization electrodes. Inspect and clean as necessary
using a soft brush. If either
of
the electrodes show signs
of
damage or wear,
replace the electrode and its gasket. Measure electrode separation as below:
7.
Remove the fan and burner assembly. Inspect the inside
of
the combustion
chamber and if necessary clean the inside
of
the tubes with a soft brush. Do
not brush the insulation at the rear, check the combustion chamber insulation
panels for damage and replace
if
necessary
a.
Remove the burner injector/gas restrictor.lnspect the injector for blockage
or
damage and clean/replace as necessary.
9. Remove the condensate trap bottom cleaning nut. Drain/clean as necessary
Important
Notes:
In
order to carry out servicing or replacement
of
parts the boiler front panel and
sealing panel must be removed, care must be taken to refit and seal correctly.
After completing the servicing
or
exchange
of
gas components, always test for gas
soundness
of
any disturbed joints or test points by means
of
a tightness test
or
leak
detection fluid as appropriate.
When work is complete the boiler front panel
& sealing panel must be replaced,
ensuring a good seal is made.
31
7.3
Gas
Valve
Adjustment
• Connect the flue gas analyser to the sampling point which is located
on
the turret
of
the air/flue system
• Operate the boiler at maximum load (see section 7.4 Service Mode).
• Be sure that boiler is running at maximum load
(---+
maximum fan speed).
• Wait approximately 4 minutes for the stabilisation
of
the values.
• Check the
C02
value against the Setting Values Table below
• If the
C02
value is not
in
the range (±0.2), gas valve adjustment
is
necessary.
• Turn the flow adjustment screw (see figure below) with 2.5 mm allen key counter-
clockwise (in direction +ve) to increase or clockwise (in direction -ve) to decrease
gas flow
(C02
value) to the burner.
• Adjust the required
C02
value (±0.1) according to the setting values table.
• Wait for the stabilization
of
the values
• Operate the boiler at minimum load (see section 7.4, Service Mode).
• Be sure that boiler is running at minimum load (---+minimum fan speed).
• Wait approximately 4 minutes for the stabilization
of
the values.
• Check the
C02
value against the Setting Values Table below
• If the
C02
value is not
in
the range (±0.2) gas valve adjustment is necessary.
• Turn the offset adjustment screw with 2.5 mm allen key clockwise (in direction
+ve) to increase or counter-clockwise (in direction -ve) to decrease minimum
C02
value.
• Wait for the stabilization
of
the values.
• Recheck the values at maximum load and minimum load because each
adjustment changes the previous setting value (See the flow adjustment and
offset adjustment graphs below.
Setting Values
Boiler Model
Natural Gas Propane
Fan Speed (rpm)
C02
(%)
02(%)
Fan Speed (rpm)
C02
(%)
Morco24CPM
1620 8,7 (±0,1) 5,6 (±0,2) 1860
10,0
(±0,1)
4680
9,3 (±0,1) 4,5 (±0,2)
4440
10,8
(±0,1)
Morco 30CPM
1620 8,5 (±0,1)
6,1
(±0,2) 1860
9,7
(±0,1)
4800
9,0 (±0,1)
5,1
(±0,2)
4440
10,8
(±0,1)
32
02(%)
5,7 (±0,2)
4,4 (±0,2)
6,2 (±0,2)
4,4 (±0,2)
---
Boiler Load
{Fan Speed)
a) Flow Adjustment
SEALING
LABEL\--
_/
,'
:
- l
OFFSET
- - ,
ADJUSTMENT
7.4
Service
Mode
1
---
Boller Load
{Fan Speed)
b) Offset Adjustment
FEEDBACK
CONNECTION
FlOW(CO)
ADJUSTM
E
NT
SEA
LI
NG
lAB
EL
• Turn the
CH
knob fully clockwise. Status LED Service will be
ON
• After the soft start time ends, the boiler will run
at
the minimum load.
• To operate the boiler
at
the maxmum load, turn the
CH
knob to the off position
and back again to the service mode position within 3 seconds. (If the
CH knob
stays
in
off position, the main board will cancel the service mode). The
status LED Service will blink
to
indicate the maximum load.
• Service mode will be inactive after 10 minutes.
• It is possible cancel the soft start function by turning the
CH
knob to the
off position and back again to the service mode position within 3 seconds.
33
8.
COMMON PROBLEMS AND FAULT CODES
8.1
Common
problems
• Hot water temperature at the taps is reduced. This may be because the temperature
of
the mains cold water supply is colder during the winter period.
• The gas supply to the boiler has run out,
or
is
about to run out. Near empty propane
gas bottles will supply enough gas to run low power appliances such as cookers and
gas fires, but will fail to supply high powered appliances such as the combination
boiler.
• During busy periods, the mains cold water supply to the boiler may be subjected to
variations
in
pressure, this will result
in
fluctuations
in
the hot water temperature at
the hot water outlet.
• If the mains power supply to the boiler has been interrupted
or
turned off, then the
time clock/programmer (if fitted) must be reset to the correct time, if the boiler is to
be operated
in
the timed sequence
in
central heating mode.
8.2 Fault
Codes
The Marco 24 CPM and 30 CPM Boilers have a self diagnostic system built into their
printed circuit board. Should a fault for safety related
or
other reasons occur, then the
boiler will failsafe by locking out, which
is
indicated by the
red
LED
on
the control panel.
The fault can be identified by the code
in
the LCD display. The electronic failsafe
is
also
backed by a mechanical means
of
protection, should the electronics fail to detect a fault.
These mechanical forms
of
protection will protect and ensure the safe shut down of the
boiler. The software protection built into the P.C.B. will
run
a system check
on
components
which are essential to the safe operation of the boiler. This occurs before any ignition
sequence takes place, if any component
is
found to
be
faulty or out of a predetermined
range, the boiler will lockout with the fault code displayed
on
the LCD screen. Each Fault
will comprise a number.
NOTE: The red LED stays on constantly until the reset button
is pressed.
Fault conditions can be divided
in
2 groups:
1. Lockout Conditions
• Lockout flue gas over heat
• Lockout boiler over heat
• No flame signal
• Flame loss
• Flame simulation
• Failure flow-return supervision
• Failure gas valve circuit
V1N2
• Failure fan speed
34
These fault codes can only be cleared by pressing the reset push-button, then display
panel will be
in
stand-by mode. While
in
lockout conditions, Burner LED will turn RED.
2.
Blocking Conditions
• Boiler over heat
• Failure
CH
flow sensor (NTC)
• Failure flue gas sensor (NTC)
• Failure
CH
return sensor (NTC)
• Failure power supply
• Failure water pressure
These fault codes will reset as soon as the cause
of
the problem disappears. For
example, when
CH
water pressure is out
of
operating range, blocking condition will be
generated and keep the system off until the pressure
is
within operating range again.
8.3
Lockout
Conditions
and
Solutions
-
Error
Cause
Solution - Check list
code
NO
Power
supply connections. Check
lCD
Lack
of
electricity.
;....
On
I
off
switch is
ON
display
)-
3
amp
fuse in fuse spur
or
4amp
fuse PCB
Lack
of
circulation, Check
Lockout flue gas
overheat
;;;.
Flow & Return isolation valves are open.
01
~
Ful1
TRV
system have a by-pass
The
flue gas sensor sensed
.,.
By-pass settings
(over
105
°C.)
,.,
Pump
failure
or
set to maximum 3 setting
I
,
.,
Faulty Flue-gas
NTC
or
wire detached
- Lack
of
circulation, Check
Lockout
boiler overheat
j;.
Flow & Return isolation valves are open.
01
.
~
Full
TRV
systems have a by-pass
CH
flow temp. has exceeded t 05 °C
~
By-pass settings
or
CH
return temp. exceeds
90
°C
,.
Pump tai lure
or
set
to maximum3 setting
:..
Faulty Flow I return NTC
or
wire
detached
Boiler overheat
06
CH flow temp has exceeded 95
°C
,..
Boiler will remain
in
this error mode until
or
return temp. exceeds 90°C,
flow temperature drops into operating range.
Heat exchanger
overheat
stat
12
);.
Check
Thermal
cut
out in heat exchanger for
Thermal
cut-off
160
°C
may have continuity.
operated.
If
boiJer is cold -
13
;...
Check
wiring has not become disconnected
or
Flue gas NTC Open circuit
Sensor has been damaged.
~
Replace NTC
35
36
9 . WARRANTY CONDITIONS
The boiler
is
guaranteed against manufacturing defects for a period of one year from the
date
of
first commissioning. However the guarantee is subject to proof
of
commissioning
in
accordance with the gas safety (Installation and Use) act. 1998.
The guarantee does NOT cover the following issues:
• Frost damage to any part
of
the boiler containing water during freezing conditions.
• The removal
of
sludge or hard water scale due to lack
of
antifreeze/inhibitor or water
quality.
• Damage to electronics caused by a defective electrical supply.
• Damage or failure caused by insect contamination or blocked water filters.
• Loss off pressure within the heating system not caused directly by the boiler.
• Incorrect operation of the boiler caused by defective outlets such as thermostatic
mixers or mono block mixer taps.
• Damage caused by unauthaurised modifications to the boiler from original spec-
ifications.
For more detailed servicing information, workshop manuals, technical advice, spare
parts, product training, please contact us at the address below.
MORCO PRODUCTS LTD
Marco House, Riverview Road, Beverley, East Yorkshire HU17
OLD
TEL: 01482 325456
FAX: 01482 212869
EMAIL: sales@morcoproducts.co.uk
www.
morcoproducts.co.uk
37
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