Ideal Heating III Series Owner's manual

January 2021
UIN 221474 A03
Technical Instructions
GB24 & GB30
Series III
Propane
88
restart
Morco House, Riverview Road, Beverley, East Yorkshire, HU17 0LD
Morco Products Ltd
Tel: [phone] Fax: [phone]
Website: www.morcoproducts.co.uk
To Domestic Hot Water:
GB24-Propane Minimum 4.9 kW (16,600 Btu/h)
GB30-Propane Minimum 6.1 kW (20,700 Btu/h)
GB24-Propane Maximum 24.2 kW (82,570 Btu/h)
GB30-Propane Maximum 30.3 kW (103,384 Btu/h)
To Central Heating:
GB24-Propane Minimum 4.9kW (16,600 Btu/h)
GB30-Propane Minimum 6.1 kW (20.700 Btu/h)
GB24-Propane Maximum 17.2 kW (58,728 Btu/h)
GB30-Propane Maximum 20.4 kW (69,607 Btu/h)
BOILER OUTPUT
min max min max
mode
off
e
restart

2
Combination Boiler
Destination Country:
GB = UK IE = Ireland
Ideal GB24 & GB30 Series III

3
Morco reserve the right to vary specication 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Deector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

4
SECTION 1 - GENERAL
Note. Gas consumption is calculated using a
caloric value of 95.65 MJ/m3 (2569 Btu/ft3) gross
or 88 MJ/m3 (2360 Btu/ft3) nett
To obtain the gas consumption at a different
caloric value:
a. For l/s - divide the gross heat input
(kW) by the gross C.V. of the gas (MJ/m3)
b. For ft3/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
c. For m3/h - multiply l/s by 3.6.
Key to symbols
C13 C33 = A room sealed appliance designed for connection via ducts to a
horizontal or vertical terminal, which admits fresh air to the burner
and discharges the products of combustion to the outside through
oriceswhich,inthiscase,areconcentric.Thefanisupstreamof
the combustion chamber.
I3P = An appliance designed for use on 3rd Family gas, Group P only.
* The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from
whichithasbeencalculatedhavebeencertiedbyanotiedbody.
Table 1 - General Data
Maximum DHW Input : 24 30
Nett CV kW 24.3 30.4
Btu/h 82,912 103,725
Gross CV kW 26.4 33
Btu/h 90,077 112,596
Gas Consumption m3/h 1.00 1.25
ft3/h 35.33 44.20
kg/h 1.83 2.26
Maximum kW 24.2 30.3
DHW Output Btu/h 82,570 103,384
DHW Flow Rate l/min 9.9 12.4
at 35°C temp. rise. gpm 2.2 2.8
DHWSpecicRate  l/min 11.5 14.5
gpm 2.5 3.2
Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water
*Required for maximum ow rate. Boiler operates down to 2 l/min DHW delivery
Ideal GB Series III 24 30
Gas Supply I3P - G31 - 37mbar
Gas Supply Connection 15mm copper compression
Injector Size mm 3.3 3.75
Inlet Connection Domestic Hot Water G ½
Outlet Connection Domestic Hot Water G ½
Flow Connection Central Heating G ¾
Return Connection Central Heating G ¾
Flue Terminal Diameter mm 100
Average Flue Temp-Mass Flow Rate DHW 63ºC - 11g/s 68ºC - 13 g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)
Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) (kPa) 10.0 (145) (1000)
Minimum Domestic Hot Water Inlet Pressure* bar (lb/in2) (kPa) 0.8 (11.6) (80) 1.3 (18.9) (130)
Electrical Supply 230 V - 50 Hz.
Power Consumption W 79 79
Fuse Rating External : 3A Internal : T4H HRC L250 V
Water Content Central Heating litre (gal) 1.2 (0.26)
Domestic Hot Water litre (gal) litre (gal) 0.5 (0.11)
Packaged Weight kg 32.9 32.9
Maximum Installation Weight kg 30 30
Boiler Casing Size Height mm 700
Width mm 395
Depth mm 285
Max. Min.
Boiler Input : 24 30 24 30
Boiler Input ‘Q’ Nett CV kW 17.3 20.4 4.9 6.1
Btu/h 59030 69607 16720 20814
Gross CV kW 18.8 22.2 5.3 6.6
Btu/h 64148 75749 18084 22520
Gas Consumption m3/h 0.71 0.82 0.20 0.25
ft3/h 25.1 29.0 7.1 8.8
Boiler Output :
Non Condensing kW 17.2 20.4 4.9 6.1
70oC Mean Water temp. Btu/h 58688 16720 16720 20814
Condensing kW 18.2 21.6 5.15 6.45
40oC Mean Water temp. Btu/h 62100 73702 17572 22008
Seasonalefciency* SEDBUK 2005 24kW = 91.0 30kW = 91.1
Seasonalefciency* SEDBUK 2009 24kW = 88.9 30kW = 89.5
NOxClassication CLASS 6

5
SECTION 1 - GENERAL
1 GENERAL
1.1 INTRODUCTION
The Ideal GB Series III range of boilers are wall mounted, full
sequence, automatic spark ignition, low water content, fanned
ue,highefciency,condensing,combinationgasboilers.
Note. Due to the high efciency of the boiler a plume of water
vapour will form at the terminal during operation.
Central heating (CH) output is fully modulating with a range of:
24 4.9 to 17.2kW (16720 to 58728 Btu/h)
30 6.1 to 20.4kW (20814 to 69607 Btu/h)
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
24 24.2kW (82,570 Btu/h)
30 30.3kW (103,384 Btu/h)
The boiler is supplied fully assembled with DHW plate heat
exchanger, diverter valve, circulating pump, pressure gauge,
safety valve and CH expansion vessel.
VariableCHandDHWtemperaturecontrolsarettedonthe
user control.
The boiler includes as standard:
- Automatic bypass
- Daily pump and diverter valve exercise
- Mechanical 24hr timer
The boiler casing is of white painted mild steel.
The boiler temperature controls are visible located in the
control panel on the front of the boiler.
The heat exchanger is manufactured from cast aluminium.
The boiler is suitable for connection to fully pumped,
sealed heating systems ONLY. Adequate arrangements for
completely draining the system by provision of drain cocks
MUST be provided in the installation pipework.
Pipework from the boiler is routed downwards.
1.2 OPERATION
WithnodemandforCH,theboilerresonlywhenDHWis
drawn off.
When there is a demand for CH, the heating system is
supplied at the selected temperature of between 30oC and
80oC, until DHW is drawn off. The full output from the boiler is
then directed via the diverter valve to the plate heat exchanger
to supply a nominal DHW draw-off of
24 9.9 l/min at 35 oC temperature rise.
30 12.4 l/min at 35 oC temperature rise
TheDHWdrawoffratespeciedaboveisthenominalthat
theboilerowregulatorwillgive.Duetosystemvariations
andseasonaltemperatureuctuationsDHWowrates/
temperature rise will vary, requiring adjustment at the draw off
tap.
At low DHW draw-off rate the maximum temperature is limited
to 65 oC by the modulating gas control.
The boiler features a comprehensive diagnostic system which
gives detailed information on the boiler status when operating,
and performance of key components to aid commissioning
andfaultnding.
1.3 SAFE HANDLING
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler
may include the use of a sack truck and involve lifting, pushing and
pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when
performing these tasks and the following precautions should be
considered:
• Grip the boiler at the base.
• Be physically capable.
• Use personal protective equipment as appropriate, e.g. gloves,
safety footwear.
During all manoeuvres and handling actions, every attempt should
be made to ensure the following unless unavoidable and/or the
weight is light.
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
1.4 OPTIONAL EXTRA KITS
•Horizontal Flue Terminal (RSF305) - (900mm long)
•Horizontal Flue Terminal (RSF303) - (600mm long)
•Flue Extension Ducts (RSF341) - (980mm long)
24-upto8m(minusanyuekitoptions)
30-upto7m(minusanyuekitoptions)
• FlueDeectorKit(RSF300)
•
Roof Flue Kit (RSF345) (min. length 0.950m - max. length 7.5m)
• 90º Elbow Kit (RSF315)
• Flue Vertical Connector (RSF346)

6
SECTION 1 - GENERAL
1.5 SAFETY
Current Gas Safety (installation and use) regulations or rules
in force:
Theapplianceissuitableonlyforinstallationinthespecied
countries and should be installed in accordance with the rules in
force.
In GB, the installation must be carried out by a Gas Safe
Registered Engineer. It must be carried out in accordance with the
relevant requirements of the:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water byelaws in Scotland.
• The Current I.E.E. Wiring Regulations.
The appliance must be installed so that the electrical power socket
is not switchable.
If the supply cord is damaged, it must be replaced by the
manufacturer,itsserviceagentorsimilarlyqualiedpersonsin
order to avoid hazard.
Mains supply and system wiring must be through a common
isolator.
Wherenospecicinstructionsaregiven,referenceshouldbemade
to the relevant British Standard Code of Practice.
Inothercountriestheinstallationmustbecarriedoutbyaqualied
and competent Gas Installer. In the approved country the boiler
is installed, this must be in accordance with their current rules in
force.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5482: Part 1 2005 - Code of Practice for domestic butane
and propane gas burning installations in permanent dwellings,
residential park homes and commercial premises.
BSEN1949:2011+A1:2013-Specicationfortheinstallation
of LPG systems for habitation purposes leisure accomodation
vehicles and in other road vehicles.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT.TheseappliancesareCEcerticatedforsafety
and performance. It is, therefore, important that no external
controldevices,e.g.uedampers,economisersetc.,aredirectly
connected to these appliances unless covered by these Installation
and Servicing Instructions or as otherwise recommended by Morco
in writing. If in doubt please enquire.
Any direct connection of a control device not approved by Morco could
invalidatethecerticationandthenormalappliancewarranty.It
could also infringe the Gas Safety Regulations and the above
regulations.
1.6 SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the boiler
or its manufacture.

7
SECTION 1 - GENERAL
CH FLOW
DHW OUTLET
COND. DRAIN
GAS INLET
DHW INLET
CH RETURN
PRV
W A L L
Underside View - Dimensions to Wall
3952.5 2.5
from case
700
Side
flue
dim. A
285
86.5
17
155
43.5 65 28.5 28.5 60.5 75 39.554.5
WALL
103
34
9910399
103
1.7 BOILER DIMENSIONS, SERVICES & CLEARANCES
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending upon
site conditions.
Side and Rear Flue
a. Providedthattheueholeiscutaccurately,e.g.withacore
boringtoolorholecuttertheuecanbeinstalledfrominside
the dwelling where wall thicknesses do not exceed 600mm.
Where the space into which the boiler is going to be installed
islessthanthelengthofuerequiredtheuemustbetted
from the outside.
Installation from inside ONLY
b. If a core boring tool or hole cutter is to be used inside the
dwelling the space in which the boiler is to be installed
must be at least wide enough to accommodate the tool.
In either of the above cases safe external access is
requiredtoallowtheadditionofsealanttosealtheueto
thealuminiumuecollar(RSF060).
Front clearance
The minimum front clearance when
built in to a cupboard is 5mm from
the cupboard door but 450mm overall
clearance is still required, with the
cupboard door open, to allow for
servicing.
* Bottom clearance
Bottom clearance after installation
can be reduced to 5mm.
This must be obtained with an
easily removable panel, to provide
the 100mm clearance required for
servicing.
Max 30kW
Max 24kW
2.Foruelengthsrequiring“D”packextensions(RSF341),theuemustinclineby26mmper1Metreofuelength.

8
SECTION 1 - GENERAL
1.8 BOILER ASSEMBLY - EXPLODED VIEW Note that item numbers are linked to the spares list
108 PUMP HEAD
110 AIR VENT PUMP
111 DIVERTOR VALVE MOTOR
112 DIVERTOR VALVE BODY
113 PRESSURE RELIEF VALVE
114 PIPE - PRV OUTLET
115 PIPE - FLOW
116 PIPE - RETURN
117 PIPE - EXPANSION VESSEL
118 EXPANSION VESSEL
119 RETURN GROUP KIT
120 FLOW GROUP KIT
121 PLATE HEAT EXCHANGER
124 FLOW REGULATOR CARTRIDGE
127 FLOW SENSOR/TURBINE
128 RETURN THERMISTOR
131 WATER PRESSURE SWITCH
135 PRESSURE GAUGE
203 GAS COCK
204 PIPE - GAS INLET
205 GAS VALVE
206 PIPE - GAS INJECTOR
211 INJECTOR ASSEMBLY
214 VENTURI
215 FAN
217 BURNER
218 GASKET - BURNER
219 SUMP CLEAN OUT COVER
223 FLUE MANIFOLD
224 FLUE MANIFOLD TOP
227 CLAMP RETAINING FLUE TURRET
228 HOSE CONDENSATE INTERNAL
229 SIPHON TRAP
231 CONDENSATE OUTLET CONNECTION
232 TOP FLUE MANIFOLD SEAL
302 PCB
306 IGNITION/FLAME IONISATION ELECTRODE
308 IGNITER UNIT
309 FLOW THERMISTOR
313 IGNITION LEAD
324 CONTROLS BOX LID
325 CONTROL BOX FRONT
326 MECHANICAL TIMER
332 LIGHT GUIDE
401 HEAT ENGINE
503 WALL MOUNTING BRACKET
504 FRONT PANEL
506 BRACKET - GAS VALVE
507 BRACKET - EXPANSION VESSEL
510 ACCESS FLAP
211
206
205 204
506 401
218
217
306
308
219 229
504
313
215
309
214
223
510
326 325
324
231
302
203
118
507
224
227
503
228
332
232
135
110
114
113
121
131
127
124
120
119
117
112
115
116
108
111
128

9
SECTION 2 - INSTALLATION
2 INSTALLATION
2.1 DETERMINING THE FLUE LENGTH
IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions.
STANDARD FLUE KITS
Horizontal Flue Terminal RSF303 (600mm long) -contains:Flueturret,nontelescopicsinglepieceueincorporatingaterminal
and inner rubber wall seal.
Extension Kit RSF341 -contains:1metrelengthofuepipe(Functionallength900mm),1supportbracket.
When extension kits are used the ue duct must incline 1.5 degrees away from the appliance, to allow the condensate to drain back to
the boiler and out of the condensate drain. It is recommended that a support bracket is tted on every 1 metre of pipe work used and the
bracket is located as close to the collar as possible. The bracketing must ensure a 1.5 degree fall back to the appliance.
Only use water as a lubricant during assembly.
Thehorizontaluekitterminalisclassedaspartofthemaximumuelength.
OncetheueisinstalleditisIMPORTANTthatthewhiteairductprotrudesfromthealuminumuecollar(RSF060)byat
least17mm.Thegapbetweenthealuminiumuecollar(RSF060)andthewhiteairductMUSTbesealedwithsealantto
create an adequate seal.
WALL
Aluminium Flue
Collar (RSF 060)
Fill with
sealant
17mm min
Internal Sealing
Flubber
Fill with
sealant
ItisIMPORTANTthatallattachmentsarettedinaccordancewiththeinstallationinstructionsprovidedinthismanual.
The TURRET supplied in the Horizontal Flue Kits (RSF303 & RSF305) has an upper combustion sample point with a screw cap
seal and a lower air sample point with an air stopper seal. Ensure all caps & seals are in place.
Additional Termination Kits available for use with these Horizontal Flue Kits (RSF303 & RSF305)
FlueDeectorKit(RSF300) Theresistanceistheequivalentof1metreofuepipeandthereforemustbedeductedfrom
anymaximumuelength
Total Maximum Permissible Horizontal Concentric Flue Length combining both Horizontal Flue Kits and Extension Kits
(Measuredfromcentrelineoftheturrettotheoutsidefaceofthealuminiumuecollar(RSF060)
24 kW appliances TotalMaximum:8metres-minusanyuekitoptions
30 kW Appliances TotalMaximum:7metres-minusanyuekitoptions
Total Maximum Permissible Vertical Flue Length
24 & 30kW Appliances Total Maximum: 7.5 Metres - minus any 90º bends
Minimum Horizontal Flue Lengths (Centrelineofturrettooutsidefaceofthealuminiumuecollar(RSF060)
Rear Flue - 191mm
Side Flue - 236mm (with minimum 2.5mm clearance)

10
SECTION 2 - INSTALLATION
2.2 DETERMINING THE FLUE LENGTH
2.3 CUTTING HORIZONTAL FLUE TERMINAL RSF303 (600MM LONG)
1. Measurefromtheouterterminalliptoendofouterue.Markthe
required cut length (A or B + 47mm) around the circumference of the
outerueandcutfollowingthemarktoensureitscutsquare.
2. Dress the cut end to make sure all burr’s are removed and the cut
edge is in its original shape.
3. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure its cut square.
4. Remove all burrs and place a light chamfer on the outer edge to aid
assembly.
Centre of turret to edge of turret = 100mm
Turret has a ue insertion of 30mm
The white outer ue tube must protrude the wall by 17mm.
From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm
NOTES
REAR
Fit
to wall
A
Flue length measured from outer terminal lip
to end of outer ue
A or B + 47mm
SIDE
Fit
to wall
B
Minimum clearance 2.5mm
WALL
WALL
FIGURE 1
10mm
Mark cut length =
A or B + 47mm from terminal lip
REAR FLUE
Cutuelength=distancefromedgeofturrettooutsideof
wall dimension A + 47mm.
Note. Minimum dimension A which can be accommodated is
91mm.
SIDE FLUE
Cutuelength=distancefromedgeofturrettooutsideof
wall dimension B + 47mm.
Note. Minimum dimension B which can be accommodated is
136mm (with minimum clearance of 2.5mm).

11
SECTION 2 - INSTALLATION
2.4 INSTALLING THE FLUE
FITTING FLUE THROUGH THE WALL
1. Ensure the seam and the outlet terminal are at
thetopandttedasshown.
2. OncetheueisinstalleditisIMPORTANTthat
the white air duct protrudes from the aluminium
uecollar(RSF060)atleast17mm.
Note. If less than 50% of the length of the ue is
internal the ue should be tted from outside.
3. Fittheinternalsealingubbertotheue(leave
loose) and check protrusion externally of the
white air duct is 17mm.
4. Fit the turret as below
FITTING THE TURRET -Ensurethecondensatetrap/siphonislledwithwater
1. Ensuretherubbersealisttedcorrectlyontheappliancemanifoldandthatalluesealsareundamaged.
2. Holdtheuermlyandpushtheturretonuntilithastravelled30mmontotheuepipeandisfullyengaged.Makesurethe
uehasnotrotatedormovedforwardduringttingandtheueseamisuppermost.
3. Pushtheturretintothemanifoldensuringtheupperplasticlipisushwiththetopofthemanifold.
4. Fullyengagetheclamplocationsectionintothemanifoldlocationholes.Rotatedownontoturretange.
5. Secure clamp to appliance using securing screw.
6. Ensureallsamplepointsareaccessibleandallsampleplugsandcapsaretted.
7. Fullyengagetheueintotheturretandslideinternalubbertowall.
8. Thegapbetweenthealuminiumuecollar(RSF060)andthewhiteairductMUSTbesealedwithsealanttocreateaseal.
Flue Outlet
C
A
A - Duct Assembly
B - Flue Turret
C - Turret Clamp
D - Seal
Flue Outlet
D
B
Retaining
screw
Clamp Lugs
Sample points
WALL
Aluminium Flue
Collar (RSF 060)
Fill with
sealant
17mm min
Internal Sealing
Flubber
Fill with
sealant
5” hole

12
SECTION 2 - INSTALLATION
2.5 FLUE EXTENSIONS RSF341 (OPTIONAL)
2.6 FLUE DEFLECTOR KIT RSF300 (OPTIONAL)
For side outlet refer to section 1.2 before commencing
any work.
1.Makesurethat‘tophat’onthecollar(A)tsoverthe
rectangular form on the inner plastic pipe (B).
2. Ensurethattheatbaseofthecollar(C)is
positioned on the bottom lip of the pipe (D).
INNER PIPE ASSEMBLY INSTRUCTIONS
3. Slide the pipe and collar assembly back into the outer
housing (E), note that this can only be done at the female
end of the outer housing.
4. Whenttingsupportbrackets(F)makesuretheyare
positioned on the female side of the neck as shown.
A B
Top Hat
Rectangular
CD
E
F
Theuedeectorelbowcanbettedtotheueoutletofthe
standardterminalkitsRSF303orRSF305todeecttheueproducts
horizontally to the left or the right only.
1. RefertotheboilerInstallationandServicingInstructionsfortting
oftheboileranditsuesystem.
Note. The resistance of the deector is equivalent to 1 metre of ue
length. Ensure this is used when calculating the maximum allowable
ue length.
2. Choosethedirectionrequiredtodeecttheueproducts
(horizontally left or right only).
3. Pushthedeectorelbowontotheangledueoutletoftheterminal
inthedesiredpositionandensurethedeectorispushedupto
the shoulder to fully engage the rubber seal. Drill the terminal
throughtheholeinthedeectorwitha3.2mmdrillandsecurethe
deectorwiththeselftappingscrewprovided.
Note. Only use water as a lubricant during assembly. Do not use
mineral based oils.
Flue
Deector
WALL
2.7 90º KIT RSF315 (OPTIONAL)
This optional kit can be used on both horizontal and
verticaluekits
1. Use dimensions below for calculating total length
2. Whencuttingextensionsoruekitsalwaysallow
sufcient(+30mmairduct+14mmueduct)to
allowforcorrectengagementinthetting
3. 1 elbow reduces the maximum available length by
1m
Note. Only use water as a lubricant during assembly .
Do not use mineral based oils.
115
115

13
SECTION 2 - INSTALLATION
Note.
A 5º or 14º pitched roof plate (not supplied) is required before proceeding with the
installation of this kit.
This kit is suitable for both 5º and 14º pitched roof terminations, using a concentric
uetorunverticallyfromthetopoftheboilerandterminatingaboverooflevel.
Connection to the top of the boiler is made using a vertical connector (supplied in
the kit - RSF346).
WEATHER PROOFING
Wheretheuepassesthroughtherooflineanadequatesealmustbemade.This
is achieved by using a suitable sealant.
ACCESSORIES
FlueDuctExtensionKitsareavailableforuelengthsextendingbeyond1m.These
packs contain 1m extension ducts and may be cut to the desired length. If 90º
elbows are used (RSF315) they will reduce the overall height by 1m per elbow.
2.8 FITTING THE OPTIONAL ROOF FLUE KIT RSF345 (OPTIONAL) - Flat or Pitched-
Terminal Position Minimum Dimension
Directly below an opening,
air brick, windows, etc. 300 mm
Below plastic / painted gutters 300 mm
Painted surface 300 mm
Below eaves or balcony 500 mm
Below velux windows 2000mm
Above or side of velux windows 600mm
2.9 ASSEMBLING THE ROOF FLUE KIT
1. Positiontheroofplate(suppliedseparately)overtheholecutintheroofandinsertue
terminal from the roof end.
2. Ensure that if the length needs to be adjusted to allow an additional 30mm added
totheouterairtubelengthand14mmaddedtotheinneruelength.Thisallows
correct engagement into the vertical connector.
Note. Ensure a square cut. remove all burrs and sharp edges.
3. Fit the vertical connector (supplied in the kit) and secure the vertical connector by
applying downward pressure on the connector.
4. Positiontheclamponthetopfaceoftheuemanifoldandpushithorizontally
backwards.Locatebothclamplugsintotheuemanifoldandsecuretotheue
manifold clamp with the M5 retaining screw.
5. “Push”assemblyAintoverticalconnector.
Notes. Ensure turret sample points are servicable and all caps and plugs are tted.
Ensure condensate siphon/trap is lled with water.
6. Finally ensure the roof plate is correctly sealed to the roof.
Assembly A
5
3
Vertical
connector
4
5º & 14º
MAX LENGTH:
7.5m**
**minus any
90º bends
MIN LENGTH:
0.950m
BOILER
Flue Terminal
RSF050
14º
RSF051
5º
1
ASSEMBLY A

14
SECTION 2 - INSTALLATION
2.10 CONDENSATE DRAIN
137
47
156
Condensate
Drain
Thisapplianceisttedwithasiphonic75mmsealedcondensate
trapsystemthatrequiresllingbeforeoperatingtheappliancefor
the 1st time or after maintenance.
All condensate pipework should conform to the following:
a. Where a new or replacement boiler is being installed, access to
an internal ‘gravity discharge’ termination should be one of the
main factors considered in determining boiler location.
b. Plasticwithpushtorsolventconnections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD)
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipe work should be kept to a minimum
andinsulatedwithClass“O”waterproofpipeinsulation.
g. All installations must be carried out in accordance to the
relevantconnectionmethodsasshowninthe“Condensate
installationdiagrams”&BS6798:2009
h. Pipe work must be installed so that it does not allow spillage
into the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
ttings.
NB.Cliprunstopreventpipeworkdisconnectingdueto
vibration etc.
In order to minimise the risk of freezing during prolonged very cold
spells, one of the following methods of terminating condensate
drainage pipe should be adopted.
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.
CondensatePump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
specicationrecommendedbytheboilerorpumpmanufacturer
should be used terminating into a suitable internal foul water
discharge point such as an internal soil and vent stack or internal
kitchenorbathroomwastepipeetc.(g3).
External Drain Connections
The use of an externally run condensate drainage pipe should
only be considered after exhausting all internal termination options
as described previously. An external system must terminate at a
suitable foul water discharge point or purpose designed soak away.
If an external system is chosen then the following measures must
be adopted:
The external pipe run should be kept to a minimum using the most
directand“mostvertical”routepossibletothedischargepoint,with
no horizontal sections in which condensate might collect.
- For connections to an external soil/vent stack see Fig 4.
Insulation measures as described should be used.
- When a rainwater downpipe is used, an air break must be
installed between the condensate drainage pipe and the
downpipetoavoidreverseowofrainwaterintotheboiler
shouldthedownpipebecomeoodedorfrozen,seeFig5.
- Where the condensate drain pipe terminates in a purpose
designed soakaway (see BS 6798) any above ground
condensate drain pipe sections should be run and insulated as
described above. See Fig 6.
- Where the condensate drain pipe terminates over an open
foul drain or gully, the pipe should terminate below the grating
level,butabovewaterlevel,tominimise“windchill”attheopen
end. The use of a drain cover (as used to prevent blockage by
leaves) may offer further prevention from wind chill.
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas should be
treated as external pipe.
Ensure the customer is aware of the effects created by a frozen
condensate and is shown where this information can be found in
the user manual.
Boiler
with 75mm
sealed
condensate
trap Min Ø 19mm
Internal pipe
Minimum
connection
height up to 3
storeys
Soil & vent stack
≥ 450
Sink/basin/
bath or
shower
Boiler
with 75mm
sealed
condensate
trap
Min Ø 19mm
Internal pipe
Internal soil & vent stack
≥ 100
Figure 1 - Connection of Condensate Drainage Pipe to
Internal Soil & Vent Stack
Figure 2 - Connection of a Condensate Drainage Pipe
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil Vent Stack
continued . . . . .

15
SECTION 2 - INSTALLATION
CONDENSATE DRAIN - CONT’D.......
Visible air break
Condensate pump
(Install in accordance with manufacturers instructions)
Min Ø 19mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
75
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Air gap
External air
break
combined foul/
rain water drain
Terminated
and cut at 45º
43mm 90º male/
female bend
Water/
weather proof
insulation
68mm Ø PVCU
Strap on fitting
Boiler
with 75mm
sealed
condensate
trap
Boiler
with 75mm
sealed
condensate
trap
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe Water/Weather
proof insulation
Max 3m external
pipework
Limestone
chippings
≥ 500
≥ 300
≥ 25
2 rows of three Ø12mm holes
25mm centres, 50mm from
the bottom of the tube, facing
away from the house
Minimum
connection
height up to 3
storeys
Soil & vent stack
≥ 450
Boiler
with 75mm
sealed
condensate
trap
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Water/weather
proof insulation
Figure 3 - Connection of a Condensate Pump Typical
Method (see manufacturers detailed instructions)
Figure 4 - Connection of Condensate Drainage Pipe to
External Soil & Vent Stack
Figure 5 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater
drain)
Figure 6 - Connection of a Condensate Drainage Pipe to an
External Purpose Made Soak Away.

16
SECTION 2 - INSTALLATION
2.11 WIRING DIAGRAM
3 2 1 6 5 4 3 2 1 321 654321 654321 654321 87654321 54321 54321
SERVICE
CONNECTOR
2 3 4
1 2 3 4
5
1 2
Chassis
Earth
TIMER
1 2
321
234
1 2 3
321
1 2 3
PELV
X4
230V 50Hz Mains
NO. 2 B2 24V
NO. 5 A2 24V
NO. 6 B1
NO. 4 B3
NO. 3 A3
NO. 1 A1
X6
WPS 5V
X5
FLOW +
FAN FEEDBACK
FAN PWM
FAN GND
PUMP FEEDBACK
PUMP PWM
NC
GAS VALVE -
GAS VALVE +
TURBINE SIGNAL
TURBINEGND
X1
TURBINE 5V
CH LIVE
IGNITION LIVE
PE
X2
PUMP LIVE
DHW LIVE
X3
PUMP GND
X9X8
OWC +
OWC -
OPENTHERM +
OPENTHERM -
CHIPCOM BUS TX
CHIPCOM BUS 24V
CHIPCOM BUS GND
CHIPCOM BUS 5V
CHIPCOM BUS RX
MAINS LIVE
MAINSNEUTRAL
AUXILIARY LIVE
IONISATION
FLOW -
DHW +
DHW -
X7
35 2 1
1 2 3 4 5 6
2
WPS SIGNAL
WPS GND
FLUE +
FLUE -
RETURN +
RETURN -
1
black grey red green blue brown green/yellow orange pink violet yellow white
- - - - - - - - - - - -
bk gy
r
g b
br
g/y
o p
v y
w
KEY
DIVERTOR
VALVE
FAN
PUMP
DHW FLOW
TURBINE
WATER
PRESSURE
SWITCH
RETURN
THERM
FLOW
THERM
GAS
VALVE
SPARK
GENERATOR
IGNITION
ELECTRODE
br
g/y
g/y
g/y
b
r r
bk
bk
b
g/y
b
b
bk
b
gy
r
r
g/y
bk
rgy bk
bk
w brbbr
w
r
r
r
pbpbk y
ybk y p bk
b
bk
rp
r
o
bk bk bk bk
bk
y
v
vbk gy
bk
r
bk gy g
v v
rr

17
SECTION 3 - SERVICING
3 SERVICING
3.1 SERVICING SCHEDULE
Fortheverylatestcopyofliteratureforspecication,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BS7927.
Toensurethecontinuedsafeandefcient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qualiedand
competent Gas Installer.
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relled,ventedandre-pressurised.
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 3.2.
1. Clean the main burner. Refer to Section 3.4.
2. Clean the heat exchanger & condensate trap/siphon.
Refer to Sections 3.5 & 3.6.
3. Check the main injector for blockage or damage. Refer to
Section 3.10.
4. Checkthattheueterminalisunobstructedandthatthe
uesystemissealedcorrectly.
ALSO IF THE DHW FLOW RATE IS IN QUESTION :-
5. ChecktheDHWlterforblockage.RefertoSection3.28.
The cleaning procedures are covered more fully in Sections
3.3-3.7 and MUST be carried out in sequence.
IMPORTANT.
6. 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.
7. When work is complete the front panels MUST be
correctlyretted,ensuringthatagoodsealismade.
Do NOT OPERATE the boiler if the upper front
panel is not tted.
8. If, for any reason, the condensate trap/siphon has been
removedensurethetrapisrelledwithwaterbefore
reassembling.
9. Check the gas consumption if on metered installations.
10.
Checkcombustionbyconnectingtheuegasanalyserto
theuegassamplingpointasshowninthediagramand
measure CO & CO2.
If the CO/CO2 ratio is greater than 0.004 AND the integrity
ofthecompleteuesystemandcombustioncircuitseals
havebeenveriedandtheinletgaspressurehavebeen
veried,thencontactMorco.
Flue Sampling Point
Air Sample
Point
Ensure all caps and seals
are re-fitted after use
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.
COMPETENCE TO CARRY OUT THE CHECK OF
COMBUSTION PERFORMANCE
Please Note: BS6798:2009Specicationforinstallation
andmaintenanceofgas-redboilersofratedinputnot
exceeding 70kW 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 BS7927 or BS-EN50379-3 and be
calibrated in accordance with the analyser manufacturers
requirements.
SERVICE MODE
To access the service mode:
Press and hold the restart and function button for 5 seconds.
Thedisplaywillshowthelast3faulsfollowedby“S H”.

18
SECTION 3 - SERVICING
3.2 BOILERUPPER&LOWERFRONTPANELREMOVAL/REPLACEMENT
3.3 FAN & VENTURI ASSEMBLY REMOVAL AND CLEANING
REMOVAL
1. Lift the lower front panel access panel.
2. Unscrewthexingscrew,closetheaccesspaneltoretain
the two screws and hinge the lower front panel down into
the service position.
3. Removethetwoupperfrontpanelxingscrews,liftthe
panel and remove.
REPLACEMENT
4. Hook the upper panel onto the top retaining clips.
5. Retaintheupperpanelwiththetwoxingscrews
previously removed ensuring a good seal is made.
6. Swing the lower front panel up and retain with the two
screws.
7. Close the lower front panel access panel.
1. Disconnect the electrical leads from the fan.
2. Remove the clip from the gas control valve
outlet and ease the pipe upwards rotate and
then ease down to remove.
3. Remove the extended nut on the fan
mounting bracket.
4. Lift off fan and venturi assembly.
5. Inspect the injector for blockage or damage.
6. Inspect fan outlet sealing gasket and
replace if necessary.
1
3
5
Injector
2
3&5
1&72&6

19
SECTION 3 - SERVICING
3.4 BURNER REMOVAL & CLEANING
1. Ensure the sump is fully drained
2. Undo the two screws and remove the sump cover retaining the lower
uemanifold.
3. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
4. Removethe2burnerfrontxingscrewsandloosenthe2rear
extended nuts by at least ten turns.
5. Lift off the burner from the combustion chamber. To facilitate the
removal angle the burner as shown.
IMPORTANT
The burner head is a ceramic plaque construction. Care must be taken
to ensure thattheburnerisnotplaceddownuponitsfaceas this
may cause damage to the ceramic.
6. Brush off any deposits that may be on the ceramic with a SOFT brush.
7. Inspect the sealing gasket around the burner for any signs of damage.
Replace as necessary.
Note: Ensure condensate trap is fully drained before removal.
1. Pull off the rubber pipe at the siphon.
2. Turn the siphon clockwise to disengage and lift to remove.
3. Flush out all deposits with clean water.
4. Reassemble in reverse order
Note. When reassembling ensure the trap is full of water
3.5 CLEANINGTHECONDENSATETRAP/SIPHON
3
22
5
1

4
4

20
SECTION 3 - SERVICING
3
3.6 CLEANING THE HEAT EXCHANGER
Note:Ensurethecondensatetrap/siphon
is fully drained before cleaning. Refer to
Section 3.17.
1. Remove ignition electrode. Refer to
Section 3.12.
2. It is advisable to replace the sump cover
priortothewaterushprocess.
3. Thoroughlyushtheheatexchanger
by pouring water into the top of the
combustion chamber ensuring the full top
area is covered.
4. Remove the sump cover and clean loose
deposits from the sump.
5. Inspect the ignition electrode. Ensure that
it is clean and in good condition - replace
if necessary.
6. Re-ttheignitionelectrode.Ensurethat
earth wire is connected to the electrode.
7. Check that the ignition gap is correct.
Refer to Sections 3.12 & 3.13.
1
Ignition Electrode
Earth Wire
Reassemble the boiler in the following order:
1. Ensure that the condensate trap/siphon is full of water.
2. Rettheburnerensuringthesealinggasketiscorrectly
positionedandfreefromdamage(tightenthe4xingscrews
in the sequence A,B,C,D, shown below).
3. Retthefan/venturiassemblyensuringtheretainingtabs
are correctly positioned and the sealing gasket is correctly
positioned and free from damage.
4. Reconnect the fan electrical leads.
3.7 REASSEMBLY
5
A
5. Removethesumpcoverandrettheloweruemanifold
as shown.
6. Retthesumpcover.
7. Rettheboilerupperandlowerfrontpanels.
IMPORTANT. Ensure that the boiler upper front panel is
correctlyttedandthatagoodsealismade.
8. Turn on the gas supply at the gas service cock.
9. Reconnect the electrical supply.
C
B
D