Morco 24CPM and 30CPM User Instructions and Installation Manual For Caravan Holiday Homes and Park Homes Domestic Hot water Output Central Heating Output Model Gas Type 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 ........~ ....--.... .
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.
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.
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).
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 .----Heating OFF Service Mode ,--------+---Heating ON MIN MAX. 4. DHW Temperature control knob This has 3 functions: 1. Set the DHW target temperature between 35 deg C and 60 deg C 2.
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 10.6L/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).
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.
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.
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 17- Automatic air vent 18- Air inlet pipe 19- Expansion vessel ( 7 litres) 20- Siphon (Condensate Trap) 21-
3- TECHNICAL DATA 24CPM Gas Category* Boiler Type Type of gas II II 2H3i> CrJ<~J· Ci*l• C4:3<¥lt C.s:JW, C,)(:(,)t Cal(xJ Unit JOCPM c IJCxh 21m C:Jl!.liol• c4l(X)• Cnt«>t C'i Ct~(~ G 20 G 31 G20 031 Performances CH Min. Heat Output (80160 °C) CH Max. Heat Output (80160 °C) CH Min. Heat Output (50/30 °C) CH Max. Heat Output (50130 °C) CH Min. Heat Input CH Max. Heat Input 6,6 22.
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.
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24CPM 30CPM Wiring Diagrams INFORMATION I In I clgD 031 D D rn1 30 'A 32 I I X10 II liiiil II 27 [Q] B2s 26 33 23 @) 22 21 @) ~ X2B I X2A I I -Brown 4 -Grey 18 -Yellow - YellowGreen -White I 20 ~ XlB I XlA 14 CUI-off 160"C 15 Flue gas NTC sensor 16 PWM Fan control 17 Water pressure sensor 18 DHW Flow turbine 19 Boiler chip card (BCC) port 20 Fuse4A 21 Power switch 22 CH potentiometer 23 24 25 26 27 -Blue -Orange -Pink - Purple -Red XlC PENLPENL - Black I 24 1 2
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.
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.
Position of air vents High Level Low level Air from an internal source 13000 sq. Mm 1300 sq. Mm Air from an external source 7500 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.
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%.
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 unless separate arrangements are made for expansion water.
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: 1. CH Flow-%" BSP 2. 3. 4. 5. DHW Outlet- %" BSP Gas Inlet-%" BSP DHW Inlet (mains)-%" BSP CH Return - %" BSP 6. Condensate Drain 7.
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.
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.
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.
- --· · -.·· ~ ''"-= 1 y ~f/J22 ~500 0 0 ~ ' AI 4 5 - ----1"'· .-----..::..---~...; 7 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 7.
6. COMMISSIONING During commissioning the appliance, the following should be checked: 1. 2. 3. 4. 5. 6. 7. Gas Supply Water Supply CH Circuit Condensate Trap Flue Connections Electrical Circuit 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.
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.
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.
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.
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 frequency 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.
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.
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.
1 - - - Boiler Load {Fan Speed) a) Flow Adjustment - - - Boller Load {Fan Speed) b) Offset Adjustment FEEDBACK CONNECTION FlOW(CO) ADJUSTMENT SEALING L A B E L \ - - : ,' OFFSET ADJUSTMENT _/ - -- l SEALI NG lABEL , 7.4 Service Mode • • • • • 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.
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.
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.
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.
