Grant Vortex Pro Internal Combi Series, Combi 26, Combi 21, Combi XS, Combi XS 26 Installation And Servicing Instructions
...Page 1
Grant Vortex Pro Internal Combi
Combi XS, Combi 21, Combi 26 and Combi 36
Condensing Oil Boiler Range
Installation and Servicing Instructions
UK | DOC 0122 | Rev 1.1 | May 2018
Page 2
IMPORTANT NOTE FOR INSTALLERS
These instructions are intended to guide installers on the
installation, commissioning and servicing of the Grant Vortex oil
boiler. After installing the boiler, leave these instructions with the
user.
A user handbook is available to guide users in the operation of the
oil boiler.
SPECIAL TEXT FORMATS
The following special text formats are used in these instructions
for the purposes listed below:
! WARNING !
Warning of possible human injury as a consequence of not
following the instructions in the warning.
! CAUTION !
Caution concerning likely damage to equipment or tools
as a consequence of not following the instructions in the
caution.
! NOTE !
Used for emphasis or information not directly concerned
with the surrounding text but of importance to the reader.
PRODUCT CODES AND SERIAL
NUMBERS COVERED
The serial numbers used on Grant oil boilers consist of a fteen
digit numerical code with the nal three digits being the product
identier.
For example:
100000200218740
These instructions cover the following product codes and serial
numbers:
Product code Serial number identier
VTXCOMBI21 740
VTXCOMBI26 741
VTXCOMBI36 742
VTXXSCOMBI26 781
SERVICING
The boiler should be serviced at least every twelve months and
the details entered in the Service Log in the user handbook.
FUEL TYPE
All Grant Vortex boilers are suitable for use with Class C2
Kerosene.
To use Bio-Kerosene (B30K), refer to the information below:
OPERATION ON BIO-FUEL
All Grant Vortex condensing boilers manufactured since May
2011 are suitable for for operation on both standard Kerosene
(Class C2 to BS 2869) and also bio-kerosene - up to a 30% blend
(B30K).
All burner settings and nozzle sizes (as detailed in Section 2.2 of
these instructions) are correct for both standard kerosene and biokerosene (B30K).
In order to operate this boiler on bio-kerosene, it will be necessary
to take the following actions:
• Use a bio-kerosene (B30K) compatible exible oil line in
place of the oil line supplied with the boiler.
• Have the oil storage tank and oil supply line (including all
pipework, sight gauges, lters, isolating valves, re valves,
de-aeration devices, etc.) checked for their compatibility with
bio-kerosene (B30K).
Where necessary, some or all of these items may have to be
replaced with a bio-kerosene compatible alternative.
• Check the suitability of the ue system with Grant UK.
• Use only bio-kerosne (B30K) that conforms to OPS24.
IMPORTANT:
Under no circumstances, should the boiler be used with
bio-kerosene without the above actions being taken rst.
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU
Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991
Email: info@grantuk.com www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.
However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the
author or others involved in its publication.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited. No part of this manual may be reproduced by any means without prior written consent.
Page 2
Page 3
CONTENTS
1 INTRODUCTION 4
1.1 How a condensing boiler operates 4
1.2 Boiler description 4
1.3 Flue options 4
1.4 Boiler components 5
2 TECHNICAL DATA 6
2.1 Boiler technical data 6
2.2 Burner settings 7
2.3 Flue gas analysis 7
2.4 Boiler dimensions 8
3 OIL STORAGE AND SUPPLY SYSTEM 10
3.1 Fuel supply 10
3.2 Burner oil connection 12
4 INSTALLATION 14
4.1 Introduction 14
4.2 Boiler location 14
4.3 Regulations compliance 14
4.4 Heating system design 14
considerations
4.5 Pipework materials 14
4.6 Connections 15
4.7 Preparation for installation 15
4.8 Installing the boiler 15
4.9 Expansion vessel 15
4.10 Filling the heating system 15
4.11 Before you commission 15
4.12 Completion 15
5 PIPE CONNECTIONS 16
5.1 Water connections 16
5.2 Making the water connections 17
5.3 Domestic hot water system 17
5.4 To use the water hardness kit 17
6 CONDENSATE DISPOSAL 18
6.1 General requirements 18
6.2 Connections 18
6.3 Pipework 18
6.4 External pipework 18
6.5 Condensate soakaway 19
6.6 Condensate trap 19
6.7 Condensate disposal pipework 19
6.8 Inspection and cleaning of trap 19
6.9 External condensate trap 20
7 SEALED SYSTEMS 21
7.1 Sealed system requirements 21
7.2 Filling the sealed system 22
7.3 Pressure relief (safety) valve 22
operation
8 ELECTRICAL 23
8.1 Connecting the power supply 23
8.2 Connecting the controls - 25
heating only
8.3 Connecting an external frost 25
frost thermostat
9 FLUE SYSTEM AND AIR SUPPLY 27
9.1 Air supply 27
9.2 Conventional ue systems 27
9.3 Connecting a conventional ue 30
9.4 Balanced ue systems 30
9.5 Flue clearances 34
9.6 Prepare the wall 35
10 COMMISSIONING 36
10.1 Before switching on 37
10.2 Burner settings 37
10.3 Air adjuster disc - combi 21 only 39
10.4 Switching on 39
10.5 Running the boiler 40
10.6 Balancing the system 40
10.7 Completion 40
10.8 Information for the user 40
11 SERVICING 41
11.1 Checks before servicing 41
11.2 Dismantling prior to servicing 41
11.3 Cleaning the boiler 41
11.4 Cleaning the burner 43
11.5 Adjuster the diffuser 44
11.6 Air adjuster disc - Combi 21 only 44
11.7 Recommissioning 44
11.8 Burner components 45
12 FAULT FINDING 46
12.1 Initial checklist 46
12.2 Main fault nding procedures 47
12.3 Poor hot water checklist 49
12.4 Burner fault nding 50
13 SPARE PARTS 51
13.1 Riello RDB 2.2 BX burners 51
14 DECLARATION OF CONFORMITY 54
15 HEALTH AND SAFETY INFORMATION 55
15.1 Insulation materials 55
15.2 Sealant and adhesive 55
15.3 Kerosene and Gas Oil fuels 55
16 END OF LIFE INFORMATION 56
17 PRODUCT FICHE 57
17 GUARANTEE 58
Contents Page 3
Page 4
1 INTRODUCTION
1.1 HOW A CONDENSING BOILER
OPERATES
During the combustion process, hydrogen and oxygen combine
to produce heat and water vapour. The water vapour produced
is in the form of superheated steam in the heat exchanger. This
superheated steam contains sensible heat (available heat) and
latent heat (heat locked up in the ue gas). A conventional boiler
cannot recover any of the latent heat and this energy is lost to the
atmosphere through the ue.
The Grant Vortex condensing boiler contains an extra heat
exchanger which is designed to recover the latent heat normally
lost by a conventional boiler. It does this by cooling the ue gases
to below 90°C, thus extracting more sensible heat and some of
the latent heat. This is achieved by cooling the ue gases to their
dew point (approximately 55°C).
To ensure maximum efciency, the boiler return temperature
should be 55°C or less, this will enable the latent heat to be
condensed out of the ue gases.
• The boiler will achieve net thermal efciencies of 100%.
To achieve maximum performance from the Grant Vortex boiler,
it is recommended that the heating system is designed so that a
temperature differential of 20°C between the ow and return is
maintained.
The Grant Vortex boiler will however still operate at extremely
high efciencies even when it is not in condensing mode and
therefore is suitable for tting to an existing heating system
without alteration to the radiator sizes. The boiler is capable of a
maximum ow temperature of 78°C.
1.2 BOILER DESCRIPTION
The Grant Vortex Pro Combi range of automatic pressure jet oil
boilers have been designed for use with a sealed central heating
system and will provide domestic hot water at mains pressure.
All boilers are supplied with the control panel and burner factory
tted.
The boilers are suitable for use in a sealed central heating system
only.
All the models in the current Grant Vortex Pro Combi range of
boilers are designed to comply with the maximum NOx emissions*
under the Energy-related Products Directive (ErP).
* From the 26th September 2018, the maximum NOx emissions
for all new oil red boilers (up to and including 400kW for both
new build and replacement boiler installations) is 120mg/kWh.
1.3 FLUE OPTIONS
The boilers can be connected to either a conventional ue system
or a balanced ue system, as required.
1.3.1 FOR CONVENTIONAL FLUE APPLICATIONS
Where a chimney is to be lined - Grant recommends the use
of the Grant ‘Orange’ ue system, specically designed for the
Vortex range of condensing boilers. Refer to Section 9.2 for
further details.
Where a rigid conventional ue - either internal or external - is
required, Grant recommends the use of the Grant ‘Green’ and
‘Orange’ ue system components. As no ue adaptor is supplied
with the boiler it will be necessary to purchase the Grant CF
adaptor kit in order to correctly connect this system to the boiler.
Flue adaptor kit (Grant product code: CFA15/70) is used for all
models as they all use the 100 mm ‘Green’ and ‘Orange’ system
components to construct a ue of maximum vertical height 19
metres.
! NOTE !
The ue system materials and construction MUST be
suitable for use with oil-red condensing boilers. Failure
to t a suitable conventional ue may invalidate the
guarantee on the boiler.
1.3.2 FOR BALANCED FLUE APPLICATIONS
The following ue kits are available from Grant UK. Refer to
Section 9.4.
Yellow system
Standard low level concentric balanced ue - components
available:
• Low level concentric balanced ue short
• Extensions 225 mm, 450 mm and 675 mm
• 90° extension elbow
• 45° extension elbow
• 45° elbow
• Plume diverter kits
Green system
Standard external high level/vertical ue starter kit (room sealed) -
components available:
• External high level/vertical ue starter kit short (room sealed)
• Extensions 150 mm, 250 mm, 450 mm, 950 mm
• Adjustable extension 195 to 270 mm
• 45° elbow
• High level terminal
• Vertical terminal
White system
High level and vertical concentric balanced ue kit- components
available:
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable 275 to 450 mm
• Vertical concentric balanced ue kit
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable extension 275 to 450 mm
• 45° elbow
Red system (for Combi 21, Combi 26 and Combi XS 26 only)
A exible vertical balanced ue system designed to be tted inside
an existing masonry chimney.
Consisting of three sections:
• Concentric white painted ue pipe connected to the boiler
• Vertical concentric exible ue (exible stainless steel ue liner
inside a stainless steel air inlet liner)
• Terminal assembly for chimney top mounting
Flue extensions and 45° elbows from the White system may be
used.
Fitting instructions for the Low level, High level and Vertical
balanced ue systems are supplied with the kits.
Section 1: IntroductionPage 4
Page 5
1.4 BOILER COMPONENTS
All burners are pre-set for use with kerosene and are supplied
ready to connect to a single pipe fuel supply system with a loose
exible fuel line and 3/8ʺ to 1/4ʺ BSP male adaptor supplied with
the boiler.
If required, an additional exible fuel line (600 mm) and 3/8” to
1/4” BSP male adaptor are available to purchase from Grant UK,
for two-pipe oil supply systems (Grant product code: RBS104).
The temperature of the water leaving the boiler to heat the
radiators is user adjustable.
The setting of the boiler thermostat on the Vortex Pro Combi
boilers has no affect on the hot water performance.
The boiler is tted with an overheat thermostat (which allows
it to be used on a sealed central heating system) which will
automatically switch off the boiler if the heat exchanger exceeds a
pre-set temperature of 110°C ± 3°C.
Figure 1-1 shows the components in the Vortex Pro Combi boilers
and the position of the control panel.
Figure 1-2 shows the details of the control panel.
The control panel is tted with an ON/OFF switch, heating switch,
hot water switch, indicator lights, boiler (heating), pressure gauge
and manual reset for the overheat thermostat.
Expansion vessel
Condensate trap
Burner lock-out button
Figure 1-1: Boiler components (model shown: Vortex Pro Combi 26)
Plug-in
programmer
position
(if fitted)
Boiler
On / Off
switch
Indicator lights Pressure gauge
Hot water pump
Heating
switch
Hot water
switch
Boiler
thermostat
Over heat
reset
(under
black cap)
Figure 1-2: Vortex Pro Combi boiler control panel
Section 1: Introduction Page 5
Page 6
2 TECHNICAL DATA
2.1 BOILER TECHNICAL DATA
Table 2-1: Boiler technical data
Units Combi XS 26 Combi 21 Combi 26 Combi 36
Water content
(including 32 litre primary store)
Weight (dry) *
Maximum heat output (Kerosene)
Heating system ow and return connections mm 22 22 22 28
Cold water mains inlet mm 15 15 15 22
Domestic hot water outlet mm 15 15 15 22
Minimum ow rate (∆T=10°C) l/h 2,200 1,800 2,200 3,000
Minimum ow rate (∆T=20°C) l/h 1,100 900 1,100 1,500
Pressure relief valve discharge mm 15
Maximum heating system pressure (cold) bar 1.0
Minimum heating system pressure (cold) bar 0.5
Expansion vessel (pre-charged at 1 bar) litres 24
Maximum heating system volume ** litres 255
Minimum domestic hot water ow rate
Maximum domestic hot water temperature °C 65 (factory set)
Maximum mains water inlet pressure bar 8.0
Minimum recommended mains water inlet pressure bar 2.5
Condensate connection 22 mm (only connect plastic pipe)
Flue diameter (conventional) mm 100
Waterside resistance ∆T=10°C mbar 28.5 26.0
Waterside resistance ∆T=20°C mbar 10.0 9.5
Maximum static head m 28
Minimum circulating head m 1
Boiler thermostat range °C 65 to 78
Limit (safety) thermostat shut off temperature °C 111 ± 3
Maximum hearth temperature °C Less than 50
Electricity supply ~230 1ph 50Hz 5A fused
Burner motor power Watts 90
Absorbed motor power kW 0.15
Starting current Amps
Running current Amps 0.85
Oil connection ¼ʺ BSP male (on end of exible fuel hose)
Conventional ue draught
Maximum operating pressure - sealed/open system bar 2.0
Maximum operating pressure - pressure relief valve bar 2.5
Boiler type ON/OFF
* Weight includes burner but excludes ue
litre 42.5 43 48.5 53.5
gal 9.4 9.5 10.7 11.8
kg 181 160 177 200
lb 399 353 390 441
kW 26.0 21.0 26.0 36.0
Btu/h 88,700 71,650 88,700 123,000
2.5 litres/min
(0.55 gal/min)
mbar Minimum: 0.087 - Maximum: 0.37
in wg Minimum: 0.035 - Maximum: 0.15
3.0 litres/min (0.66 gal/min)
Section 2: Technical DataPage 6
Page 7
2.2 BURNER SETTINGS
! NOTE !
Burners are supplied factory set at the outputs shown.
When commissioning, the air damper must be adjusted to
obtain the correct CO
the data label.
Table 2-2: Burner settings
level and the installer must amend
2
Distance †
15
13
15
17.5
level.
2
Burner
head/
air disc
setting
Boiler
models
(burner
type)
Combi XS 26
(Riello
RDB2.2 BX
VC26)
Combi 21
(Riello
RDB2.2 BX
E15/21)
Combi 26
(Riello
RDB2.2 BX
VC26)
Combi 36
(Riello
RDB2.2 BX
VC36)
Notes:
† Refer to Section 10.2 (Burner Settings: RDB2.2 BX burners)
‡ Flue gas VFR: Flue gas volumetric ow rate
1. The data given above is approximate only and is based on the boiler being used with a low level balanced ue.
2. The above settings may have to be adjusted on site for the correct operation of the burner.
3. Gas Oil is NOT suitable for use with Grant Vortex boiler range
4. The ue gas temperatures given above are ± 10%.
5. When commissioning, the air damper must be adjusted to obtain the correct CO
6. The combustion door test point may be used for CO
Heat output
(kW) (Btu/h) A D
26.0 88,700 0.75/60°EH 8.5 0 - 1 BX 500 N/A -
21.0 71, 60 0 0.60/60°EH 8.0 0 - 1 BX 500 Disc: C -
26.0 88,700 0.75/60°EH 8.5 0 - 1 BX 500 N/A -
36.0 122,80 0 1.00/ 60°ES 9.0 0 - 1 BX 700 N/A -
Nozzle
Oil
pressure
(bar)
2
Smoke
and smoke readings only. Do not use this test point for temperature or efciency readings.
No.
Burner
head
type
Fuel
ow rate
(kg/h)
2.19 75 - 80 12.5 28.5
1.84 75 - 80 12.5 23.0
2.16 75 - 80 12.5 28.5
2.99 75 - 80 12.5 39.5
Flue gas
temp.
(°C)
CO
(%)
2
Flue
gas
VFR ‡
(m³/hr)
2.3 FLUE GAS ANALYSIS
To allow the boiler to be commissioned and serviced, the boiler is supplied with a combustion test point on the front cleaning door.
When this test point is used please note the following:
• The test point is for CO
• The boiler efciency and temperature must be taken from the ue test point on high level, vertical and conventional ue adaptors.
• Concentric low level ues do not contain a test point. The temperature and efciency readings must be taken from the ue terminal.
and smoke readings only.
2
Section 2: Technical Data Page 7
Page 8
2.4 BOILER DIMENSIONS
LEFT SIDE VIEW
PLAN VIEW
REAR VIEW
99
588
100
699
35
227
75
90
202 210
690 140
RIGHT SIDE VIEW
858
760
307
614
O
31
O
3
1
O
3
1
O
25
INTERNAL DRAIN
TRAP EXIT
(LEFTSIDE
PANEL ONLY)
90
606
O
1
1
0
O
15
5
105
440
106
5
15
0
O
1
1
O
514
257
187 140
90
74
764
690 144
REAR VIEW
90
74
O
2
5
699 135
Figure 2-3: Vortex Pro Combi XS 26 dimensions
PLAN VIEW
192
35
15
1
3
O
*
31
O
100
588
31
O
99
441
LEFT SIDE VIEW
606
859
RIGHT SIDE VIEW
Figure 2-4: Vortex Pro Combi Internal 21 and 26 dimensions
Section 2: Technical DataPage 8
Page 9
Figure 2-5: Vortex Pro Combi 36 dimensions
RIGHT SIDE VIEW
LEFT SIDE VIEW
PLAN VIEW
REAR VIEW
90
62
62
90
182 250
614
307
O
11
0
O
1
8
5
60
190
556
100
695
106
O
3
1
O
3
1
O
3
1
INTERNAL DRAIN
TRAP EXIT
(LEFTSIDE
PANEL ONLY)
900
783
O
25
177
606
Section 2: Technical Data Page 9
Page 10
3 OIL STORAGE AND SUPPLY SYSTEM
3.1 FUEL SUPPLY
3.1.1 FUEL STORAGE
The tank should be positioned in accordance with the
recommendations given in BS 5410-1 (Code of Practice for
Oil Firing - Installations up to 45kW output capacity for space
heating and hot water supply purposes). This gives details of the
requirements for suitable oil tank construction, tank installation,
tank bases, re protection and secondary containment.
For installations of greater than 45kW output capacity, the tank
should be installed accordance with BS 5410-2.
Oil storage tanks should comply with the following standards:
• Plastic tanks OFT T100
• Steel tanks OFT T200
! CAUTION !
A galvanised tank must not be used.
! NOTE !
Plastic tanks should be stood on a rm non-combustible
base that adequately and uniformly supports the weight of
the tank over its entire base area.
The tank capacity should be selected to suit the appliance rated
output. Refer to BS5410-1 for guidance.
3.1.2 FUEL PIPES
Fuel supply pipes should be either copper or steel. Galvanised
pipes or ttings should not be used.
Plastic oil supply pipe conforming to BS EN 14125 can be used
for underground pipe runs, but must not be used above ground.
All soft copper pipe connections should preferably be made using
ared ttings. If compression ttings are to be used, a suitable
pipe insert must be tted into the pipe end.
Soft soldered connections must NOT be used on oil supply
pipework.
Fuel supply pipework should be of a suitable diameter, depending
on the type of oil supply system being used. Refer to information
given in sections 3.1.3, 3.1.4 or 3.1.5.
Run pipes as level as possible to prevent air being trapped. Take
the most direct route possible from tank to burner whilst locating
the pipe where it will be protected from damage.
Pipes should be supported to prevent sagging and sleeved where
they pass through a wall.
A metal body fuel lter of no better than 70 μm (micron) must be
tted in the oil supply pipe close to the tank. This should be tted
with sufcient clearance around and below it to allow easy access
for maintenance.
An isolating valve should also be tted at the tank, before the lter,
to allow the oil supply to be shut off for the lter to be serviced.
A second lter (15 μm for Kerosene) must be located closer to the
burner to protect the burner pump and nozzle from contamination.
Refer to Figures 3-1 to 3-3.
A remote sensing re valve must be installed in the fuel supply
line in accordance with BS540-1.
A fusible wheelhead type combined isolating/re valve MUST
NOT be used in place of a remote sensing re valve.
The re valve must be located outside; just before the oil line
enters the building, with the re valve sensor located above the
burner.
A spring clip for mounting the sensor is provided with the boiler.
This should be xed with the screw provided, using the small hole
in the front panel of the boiler.
The re valve should be located after the second (15 micron) lter,
i.e. between the lter and the point at which the oil line enters the
building. Refer to Figures 3-1 to 3-3.
The re valve must have an operating temperature of between
90 and 95°C to avoid unnecessary nuisance shut-offs to the oil
supply.
A exible fuel hose and ¼ʺ isolating valve are supplied lose with
the boiler, to make the final connection to the burner.
If a two-pipe system or deaerator is to be used, the following
additional items will be required:
• Flexible fuel hose ⅜ʺ male x ¼ʺ female, 900 mm long
(product code: RBS36)
• ⅜ʺ x ¼ʺ BSP adaptor (product code: RBS35)
• ¼ʺ isolating valve (product code: ISOLATION1/4)
These are available to purchase from Grant UK.
Metal braided flexible fuel hoses should be replaced ANNUALLY
when the boiler is serviced.
Long life flexible fuel hoses should be inspected annually and
replaced, if necessary, or after a maximum five years service life.
3.1.3 SINGLE PIPE (GRAVITY) SYSTEM (REFER TO FIGURE 3-1)
Head A (m)
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
If the storage tank outlet is at least 300 mm above the level of the
level of the burner oil pump, a single pipe (gravity) system should
be used.
The maximum height of the oil level above the burner oil pump
when the tank is full, must not exceed four metres. If this height
is exceeded, a pressure reducing valve must be tted in the oil
supply pipe between the tank and the burner oil pump.
The maximum length of pipe run from the tank to the burner is
limited by the minimum head of oil (the height of the tank tank
outlet above the burner oil pump).
Maximum pipe run (m)
10 mm OD pipe 12 mm OD pipe
3.1.4 TWO PIPE SYSTEM (REFER TO FIGURE 3-2)
Head A (m)
0 35 100
0.5 30 100
1.0 25 100
1.5 20 90
2.0 15 70
3.0 8 30
3.5 6 20
If the storage tank outlet is below the level of the burner oil pump,
a two pipe (sub gravity) system can be used.
The return pipe should be at the same level as the tank outlet,
between 75 to 100 mm above the base of the tank. The return
pipe should be a sufcient distance from the tank outlet so as to
prevent any sediment disturbed by the return entering the supply
pipe from the tank.
A non-return valve should be tted in the supply pipe, along with
a re valve and lters (refer to section 3.1.2 - fuel pipes). A nonreturn valve should also be tted in the return pipe if the top of the
tank is above the burner oil pump.
The maximum suction height (from the tank outlet to the level of
the burner oil pump), must not exceed 3.5 metres.
The pump vacuum should not exceed 0.4 bar. Beyond this limit,
gas is released from the oil.
Maximum pipe run (m)
10 mm OD pipe 12 mm OD pipe
Section 3: Oil Storage and Supply SystemPage 10
Page 11
5
Min
7
9
12
8
Figure 3-1: Single pipe (gravity) system
7
9
12
8
3
2
4
2
1
4m Max
6
300mm
Min
5
10
4
2
6
150mm
Figure 3-2: Two pipe system
10
23
1
5
7
11
9
12
4
2
6
10
123
8
Figure 3-3: De-aeration device system
Key to oil supply diagrams
1 Oil tank 5 External wall 9 Burner
2 Isolating valve 6 Oil lter (15μm max. ltration size) 10 Non-return valve
3 Oil strainer 7 Fire valve sensor 11 De-aerator*
4 Fire valve to BS5410 8 Oil pump 12 Appliance isolation valves
* Position of de-aeration device must be level with or above the oil pump
3.5m Max
3.5m Max
Section 3: Oil Storage and Supply System Page 11
Page 12
For guidance on the installation of top outlet fuel tanks and
suction oil supply pipe sizing, refer to OFTEC Technical Book 3:
Storage and Supply, available for purchase from OFTEC.
If a two-pipe system is to be used, the following additional items
will be required:
• Flexible fuel hose ⅜ʺ male x ¼ʺ female, 900 mm long
(product code: RBS36)
• ⅜ʺ x ¼ʺ BSP adaptor (product code: RBS35)
• ¼ʺ isolating valve (product code: ISOLATION1/4)
These are available to purchase from Grant UK.
3.1.5 SINGLE PIPE (SUCTION) SYSTEM WITH
DEAERATOR - (REFER TO FIGURE 3-3)
If the storage tank outlet is below the level of the burner oil pump,
an alternative to the two pipe (sub gravity) system is the single
pipe (suction) system using a deaerator, e.g. a ‘Tiger Loop’
device.
The deaerator creates a loop with the burner oil pump, with the oil
being circulated through the pump out to the deaerator and back
to the pump. Any air in the single pipe lift from the tank is removed
from the oil, collected in the deaerator and then discharged to
outside.
! WARNING !
To prevent any fuel vapour being discharged within
the building, the deaerator must be tted outside, in
accordance with BS 5410-1, unless it is specically
designed to be installed inside.
The de-aerator must be mounted vertically at the same level as
(or above) the burner oil pump. Refer to Figure 3-3.
RETURN
FROM PUMP
Tiger Loop
3.2 BURNER OIL CONNECTION
! WARNING !
The blanking plug supplied in the inlet (suction) port is
plastic and will not provide an oil tight seal when the pump
is running.
Ensure that the supply from the tank is connected to this
port and that the plastic plug is discarded.
The burner fuel pump is supplied factory set for use with a single
pipe (gravity) oil supply system.
For ease of access to the burner oil pump connections, the burner
should be removed from the boiler as follows:
1. Remove the red plastic burner cover.
2. Unscrew and remove the single burner fixing nut from the
stud on the burner flange (at the top of the burner) using a 13
mm spanner. Retain the fixing nut for re-fitting the burner.
3. Carefully withdraw the burner from the boiler.
3.2.1 SINGLE PIPE (GRAVITY) CONNECTION -
REFER TO FIGURE 3-5
Connect the oil supply to the burner oil pump as follows:
1. Unscrew and remove the plastic blanking plug from the
suction port of the burner oil pump and discard it.
2. Fit the nut of the elbow connection on the exible fuel hose
(supplied with the boiler) into the suction port and tighten.
3. Fit the ¼ʺ isolating valve (supplied with the boiler) to the end
of the rigid oil supply pipe using a tting to suit the pipe size
and type (not supplied).
4. Connect the other end of the exible fuel hose to the isolating
valve using the ⅜ʺ x ¼ʺ BSP adaptor (supplied with the
boiler).
5. Re-t the burner to the boiler.
SUPPLY
TO PUMP
Figure 3-4: Tiger loop de-aeration device
An external deaerator must not be tted within 500 mm of a ue
terminal.
Always follow the manufacturers installation instructions supplied
with the deaerator.
To use a de-aertor, the following additional items will be required:
• Flexible fuel hose ⅜ʺ male x ¼ʺ female, 900 mm long
(product code: RBS36)
• ⅜ʺ x ¼ʺ BSP adaptor (product code: RBS35)
• ¼ʺ isolating valve (product code: ISOLATION1/4)
These are available to purchase from Grant UK.
1/4" BSP female
connections
SUPPLY
FROM TANK
Section 3: Oil Storage and Supply SystemPage 12
Page 13
8
6
1
Figure 3-5: Riello RDB pump
Figure 3-6: Key to Riello RDB pump
Item Description
1 Inlet (suction) port
2 Return port
3 By-pass screw
4 Pressure gauge port
5 Pressure adjustment
6 Vacuum gauge port
7 Solenoid
8 Auxiliary pressure test point
3.2.2 TWO PIPE CONNECTION
7
5
3
2
For either a two pipe (sub gravity) or a single pipe (suction)
system with a deaerator, the following additional items will be
required:
• Flexible fuel hose ⅜ʺ male x ¼ʺ female, 900 mm long
(product code: RBS36)
• ⅜ʺ x ¼ʺ BSP adaptor (product code: RBS35)
• ¼ʺ isolating valve (product code: ISOLATION1/4)
These are available to purchase from Grant UK.
Connect the oil supply to the burner oil pump as follows:
1. Fit the exible fuel hose (supplied with the boiler) to the
suction port of the burner oil pump, as detailed in Section
4
3.2.1.
With either a two pipe (sub gravity) system or a single pipe
(suction) system with a deaerator, the by-pass screw (supplied
with the boiler) must be tted to the burner oil pump as follows:
1. Unscrew and remove the blanking plug from the return port
on the burner oil pump and discard it.
2. Fit the by-pass screw into the threaded hole (inside the return
port) and fully screw it in using an allen key.
3. Fit the nut of the elbow connection on the exible fuel hose
into the return port and tighten.
4. Fit the ¼ʺ isolating valve (not supplied) to the end of the rigid
oil return pipe (to the deaerator or oil tank) using a tting to
suit the pipe size and type (not supplied).
5. Connect the other end of the exible fuel hose (not supplied)
to the isolating valve using a ⅜ʺ x ¼ʺ BSP adaptor (not
supplied).
6. Re-t the burner to the boiler.
Section 3: Oil Storage and Supply System Page 13
Page 14
4 INSTALLATION
4.1 INTRODUCTION
The boiler is supplied already fully assembled in a carton which
is carefully packed with packing materials. The installation
procedure therefore begins with unpacking of the packed boiler.
4.2 BOILER LOCATION
The boiler must stand on a rm, level and non-combustible
surface capable of supporting the boiler when full of water. Refer
to Section 2.1 for weights.
It does not require a special hearth as the temperature of the
boiler base is less than 50°C.
Sufcient clearance must be allowed at the front of the boiler to
remove the burner and bafes for servicing.
The Vortex Pro Combi XS 26, Combi 21 and 26 boilers can be
serviced from the front, but it is preferable for any worktop above
the boiler to be removable.
The Vortex Pro Combi 36 requires a removable section of worktop
above the boiler to provide access to components on top of the
boiler and for servicing.
Care should be taken when siting the condensate trap if it is to be
tted outside the boiler. Refer to Section 6.9.
4.3 REGULATIONS COMPLIANCE
! NOTE !
systems. Code of practice for domestic heating and hot water
supply)
• BS 2869 (Fuel oils for agricultural, domestic and industrial
engines and boilers. Specication)
4.4 HEATING SYSTEM DESIGN
CONSIDERATIONS
! WARNING !
Before starting any work on the boiler or fuel supply,
please read the Health and Safety information given in
Section 15.
To achieve the maximum efciency possible from the Grant Vortex
boiler, the heating system should be designed to the following
parameters:
RADIATORS:
• Flow temperature 70°C
• Return temperature 50°C
• Differential 20°C
Size radiators with a mean water temperature of 60°C.
Design system controls with programmable room thermostats
or use weather compensating controls to maintain return
temperatures below 55°C.
Failure to install and commission appliances correctly may
invalidate the boiler guarantee.
Installation of a Grant Vortex boiler must be in accordance with
the following recommendations:
• Building Regulations for England and Wales, and the Building
Standards for Scotland issued by the Department of the
Environment and any local Byelaws which you must check
with the local authority for the area.
• Model and local Water Undertaking Byelaws.
• Applicable Control of Pollution Regulations.
• National Building Regulations and any local Byelaws.
• Model Byelaws and the Water Supply Regulations.
• The following OFTEC requirements:
• OFS T100 Polythene oil storage tanks for distillate fuels.
• OFS T200 Fuel oil storage tanks and tank bunds for use
with distillate fuels, lubrication oils and waste oils.
Further information may be obtained from the
OFTEC Technical Book 3 (Installation requirements
for oil storage tanks) and OFTEC Technical Book 4
(Installation requirements for oil red boilers).
The installation should also be in accordance with the latest
edition of the following British Standard Codes of Practice (and
any relevant amendments):
• BS 5410-1 (Code of practice for oil ring. Installations up
to 45 kW output capacity for space heating and hot water
supply purposes)
• BS EN 12828 (Heating systems in buildings. Design for
water-based heating systems)
• BS EN 12831-1 (Energy performance of buildings. Method
for calculation of the design heat load)
• BS EN 14336 (Heating systems in buildings. Installation and
commissioning of water based heating systems)
• BS 7593 (Code of Practice for treatment of water in domestic
hot water central heating systems)
• BS 7671 (Requirements for Electrical installations, IET Wiring
Regulations)
• BS 7291 (Thermoplastics pipe and tting systems for hot and
cold water for domestic purposes and heating installations in
buildings. General requirements)
• BS 7074-1 (Application, selection and installation of
expansion vessels and ancillary equipment for sealed water
! NOTE !
The boiler should not be allowed to operate with return
temperatures of less than 40°C when the system is up to
temperature.
The use of a pipe thermostat is recommended to control the return
temperature when using weather compensating controls.
UNDERFLOOR:
• Flow temperature 50°C
• Return temperature 40°C
• Differential 10°C
In underoor systems, it is essential that the return temperature
must be maintained at or above 40°C to prevent internal corrosion
of the boiler water ‘primary’ jacket.
Refer to Section 2.2 for the size and type of the connections and
Section 5 for the position of the connections.
4.5 PIPEWORK MATERIALS
The Grant Vortex boiler is compatible with both copper and plastic
pipe. Where plastic pipe is used it must be of the oxygen barrier
type and be the correct class (to BS 7291-1) for the application
concerned.
On either sealed or open-vented systems; where plastic pipe is
used a minimum of ONE metre of copper pipe (or as per pipe
manufacturers instructions) MUST be connected between both
the boiler ow and return connections and the plastic pipe.
! NOTE !
Do not connect plastic pipe directly to the boiler.
Grant UK does not accept any responsibility for any damage,
however caused, to plastic piping or ttings.
SEALED SYSTEMS
If plastic pipe is to be used, the installer must check with the
Section 4: InstallationPage 14
Page 15
plastic pipe manufacturer that the pipe to be used is suitable for
the temperature and pressures concerned.
Plastic pipe must be Class S to BS 7291-1.
! WARNING !
When plastic pipe is used, the system MUST incorporate
a low level pressure switch to shut off power to the boiler
if the system pressure drops below 0.2 bar. A suitable low
pressure switch kit is available to purchase from Grant UK
(product code: MPCBS62).
UNDERFLOOR PIPEWORK
Plastic pipe may be used on underoor oor systems where the
plastic pipe is tted after the thermostatic mixing valve. Copper
tube must be used for at least the rst metre of ow and return
primary pipework between the boiler and the underoor mixing/
blending valves.
4.6 CONNECTIONS
4.6.1 FLOW AND RETURN CONNECTIONS
Refer to Section 5.
4.6.2 CONDENSATE CONNECTION
The condensate trap is supplied loose in the burner box and
needs to be tted as shown in Figure 6-2.
Refer to Section 6 for details of the condensate disposal pipework.
a 24 litre expansion vessel located in the front of the boiler.
The expansion vessel tted is supplied with a charge pressure of
1.0 bar (equivalent to a maximum static head of 10.2 metres). The
charge pressure must not be less than the actual static head at
the point of connection.
Do not pressurise the vessel above 1.5 bar.
! NOTE !
The air pressure in the vessel must be checked annually.
The central heating system volume, using the expansion
vessel as supplied, must not exceed the recommended
volumes. Refer to Section 2.1. If the system volume is
greater, an extra expansion vessel (complying with BS
4841) must be tted as close as possible to the central
heating return connection on the boiler. The charge
pressure of the extra vessel must be the same as the
vessel tted in the boiler.
Refer to BS 7074-1 for further guidance.
The air charge pressure may be checked using a tyre pressure
gauge on the expansion vessel Schraeder valve.
The vessel may be re-pressurised using a suitable pump. When
checking the air pressure the water in the heating system must be
cold and the system pressure reduced to zero.
4.10 FILLING THE HEATING SYSTEM
Refer to Section 7.2 (lling the heating system).
4.7 PREPARATION FOR
INSTALLATION
1. Carefully remove the packaging from the boiler and remove it
from the transit pallet.
2. Pull off the boiler front panel and remove the literature pack.
3. Lift off the two parts of the case top and remove the water
connecting ttings.
4.8 INSTALLING THE BOILER
1. Having decided upon the position of the boiler and type of
ue, prepare the wall as described in Section 9. Ensure
that the ue terminal position complies with the necessary
clearances.
2. Make the water connections as described in Section 5. If
access will be restricted, make any connections to the boiler
before placing it in its nal position. Refer to Section 7 if the
boiler is to be used on a sealed system.
! NOTE !
If using a balanced ue system - install the balanced ue
system before connecting the heating system pipework to
the boiler. Once the ue system is tted then complete the
water connections and ll the heating system.
3. Ensure the requirements are met for the disposal of
condensate as described in Section 6.
4. Connect the power supply as described in Section 8.
5. Connect the ue and ensure there is an adequate air supply
as described in Section 9.
4.11 BEFORE YOU COMMISSION
To avoid the danger of dirt and foreign matter entering the boiler
the complete heating system should be thoroughly ushed
out – both before the boiler is connected and then again after
the system has been heated and is still hot. This is especially
important where the boiler is to be installed on an older system.
For optimum performance after installation, the boiler and the
associated heating system must be ushed in accordance with
the guidelines given in BS 7593 (Treatment of water in domestic
hot water central heating systems). This must involve the use
of a proprietary cleaner, such as Sentinel X300 (new systems),
Sentinel X400 (existing systems), or Fernox Restorer.
After cleaning, it is vitally important that all traces of the cleaner
are thoroughly ushed from the system.
For long term protection against corrosion and scale, after
cleaning/ushing a suitable inhibitor should be added to the
system water, such as Sentinel X100 or Fernox MB-1, in
accordance with the manufacturers’ instructions.
Failure to follow the above will invalidate the guarantee.
If the boiler is installed in a garage or out house, in order to
provide further protection should there be a power failure in cold
weather, a combined anti-freeze and corrosion inhibitor can
be used such as Sentinel X500 or Fernox Alphi-11. Follow the
manufacturers’ instructions supplied to achieve the level of antifreeze protection required.
For details of the Sentinel Products visit www.sentinel-solutions.
net and for Fernox products visit www.fernox.com.
Grant UK strongly recommends that a Grant Mag One in-line
magnetic lter/s (or equivalent*) is tted in the heating system
pipework. This should be installed and regularly serviced in
accordance with the lter manufacturer’s instructions.
* As measured by gauss. The MagOne magnetic lter has a gauss
value of 12000.
4.9 EXPANSION VESSEL
The Combi XS 26 model is supplied with a separate 24 litre
expansion vessel (and mounting bracket), to be tted in a
convenient position externally to the boiler casing.
The vessel is supplied with an 800mm exible hose with a ½”
BSP male thread.
Using a suitable tting (not supplied), this vessel must be
connected to the heating system, via the exible hose, in a
convenient position where it can be readily accessed for servicing.
The Combi 21, Combi 26 and Combi 36 models are supplied with
4.12 COMPLETION
Following installation of the boiler, instruct the user in the
operation of the boiler, the boiler controls, the heating controls and
the safety devices.
Please ensure that the OFTEC CD/10 installation completion
report (provided with the boiler) is completed in full, leaving the
top copy with the user and retain the carbon copy for your own
records.
Ensure that the User Handbook (supplied with the boiler) is
handed over to the user.
Section 4: Installation Page 15
Page 16
5 PIPE CONNECTIONS
5.1 WATER CONNECTIONS
Water connections may be from the rear, left or right hand side. If
using low level side exit ue, connections must be on the opposite
side to the ue.
FLOW AND RETURN CONNECTIONS
All models are supplied with a push-t elbow connection for the
heating ow and return:
• Combi XS 26, Combi 21 and 26 - 22 mm
• Combi 36 - 28 mm
HOT WATER CONNECTIONS
All models are supplied with push-t elbow connections for the
cold water mains inlet pipe and hot water outlet pipe:
• Combi XS 26, Combi 21 and 26 - 15 mm
• Combi 36 - 22 mm
Boiler flow
sensor and
overheat
thermostat
bulb
! CAUTION !
All pipes to be tted into the push-t connectors provided
should be cut using a pipe slicer or pipe cutter - to leave
the pipe ends with a slight radius and free from any burrs
or sharp edges.
Pipes to be used with these ttings should not be cut
square using a hacksaw.
ALL MODELS
A 15 mm discharge pipe must be connected to the safety valve
outlet connection. The pipework between the safety valve and the
boiler must be unrestricted, that is, no valves. The discharge pipe
should be run to the outside of the building and terminate so that it
cannot cause injury to persons or property.
A drain tap is provided at the bottom on the front of the boiler (and
also on the hot water store on the Vortex Pro Combi).
Heating flow
connection
Heating circulating
pump
Safety valve
outlet
Manual
air vent
Heating
return
Safety valve
Automatic air vent
Cold water inlet
Cold water inlet
isolating valve
Flow switch
Primary return
isolating valve
Automatic
air vents
Non return
valve
Figure 5-1: Vortex Pro Combi pipe positions
Section 5: Pipe ConnectionsPage 16
Page 17
5.2 MAKING THE WATER
CONNECTIONS
Flow and return pipework can be routed to either side of the
boiler, dependant on the ue system used, from the push-t
elbows (supplied) on the ow and return connection. Refer to
Figure 5-1.
Holes are provided in the rear of the casing side panels to allow
the condensate pipe to be run through the back of the boiler. It will
be necessary to remove the back panel from the boiler casing to
t this pipework, and to ret the panel before placing the boiler in
its nal position. Refer to Figure 6-3.
If access will be restricted, make any connections to the boiler
before placing it in its nal position. If using a balanced ue
system - Install the balanced ue system before connecting the
heating system pipework to the boiler.
5.3 DOMESTIC HOT WATER SYSTEM
To maintain a longer and more consistent hot water temperature,
a ow restrictor is factory tted to all models except the Vortex Pro
Combi 36, to limit the ow rate to approximately 15 litres/minute.
The ow restrictor is located in the outlet side of the cold water
inlet isolating valve.
The incoming mains water pressure should be between 1 and 8
bar to ensure efcient operation.
! NOTE !
If the pressure is above 8 bar a pressure reducing valve
must be tted.
The boiler may still operate down to a pressure of 1.0 bar but with
a reduced ow rate. The minimum ow rate needed for the ow
switch to operate is 3 litres/minute.
To ensure economic use, the pipe runs between the boiler and
hot taps should be as short as possible and in 15 mm copper pipe
or 22 mm for the Vortex Pro Combi 36 only. Where possible the
pipework should be insulated to reduce heat loss.
All taps and mixing valves used in the domestic hot water system
must be suitable for operating at a mains pressure of up to 8 bar.
If required, a shower may be tted in the domestic hot water
system. It is recommended that thermostatically controlled
shower valves are used to protect against a ow of water at too
high a temperature. If a xed head type shower is used, no antisyphonage devices are required. If a loose or exible head type
shower is used, it must be arranged so that the head cannot fall
closer than 25 mm above the top of the bath, thereby preventing
immersion in the bath water. If this is not practicable, an anti-
syphonage device must be tted at the point of the exible hose
connection.
The supply of hot and cold mains water direct to a bidet is allowed
(subject to local Water Undertaking requirements) provided
that the bidet is of the overrim ushing type. The outlets should
be shrouded and unable to have a temporary hand held spray
attached.
Arrangements for antisyphonage are not necessary.
Before the mains water supply pipe is connected to the boiler, it
should be thoroughly ushed out to avoid the danger of dirt or
foreign matter entering the boiler.
The mains water connection to the boiler must be the rst
connection from the mains supply.
5.4 TO USE THE WATER HARDNESS
KIT
! NOTE !
A water hardness test kit is supplied with the boiler. Should
the total hardness of the water supply exceed 125 ppm,
an in-line scale inhibitor should be tted in the cold water
supply to the boiler.
Consult the local Water Undertaking if in doubt.
Do not immerse the test strip in running water and avoid
contact.
1. Fill a clean container with a sample of water from the mains
cold water supply to the boiler.
2. Immerse the test strip in the water for approximately one
second, ensuring that all the test zones are fully wetted.
3. Shake off the surplus water and wait for one minute.
4. Assess the colouration of the test zones using the following
chart.
Figure 5-2: Key to water hardness
Green
areas
Note: 1mg/l = 1 ppm (part per million)
If the hardness reading is found to be in the medium to very hard
range (the shaded area), it is essential that some form of water
conditioner or softener is tted to reduce scale formation within
the combination boiler. Failure to do so may invalidate both the
manufacturers guarantee and any extended guarantee covering
the appliance.
The water conditioner or softener should be tted to the cold
water supply serving the appliance and in accordance with the
manufacturer’s instructions. Grant UK cannot be held responsible
for any damage or misuse caused by the tting of any water
conditioning device.
Violet
areas
4 0 Very soft <50 mg/l calcium carbonate
3 1 Soft <70 mg/l calcium carbonate
2 2 Medium <125 mg/l calcium carbonate
1 3 Hard <250 mg/l calcium carbonate
0 4 Very hard <370 mg/l calcium carbonate
Hardness Total hardness mg/l (ppm)
! CAUTION !
Please protect the domestic hot water system from
harmful effects of scale. Problems caused by the buildup of limescale are not covered under the terms of the
guarantee.
Section 5: Pipe Connections Page 17
Page 18
32 mm waste pipe external to the building
and 50 mm from the bottom
away from the property.
6 CONDENSATE DISPOSAL
6.1 GENERAL REQUIREMENTS
When in condensing mode the Grant Vortex boilers produce
condensate from the water vapour in the ue gases.
This condensate is moderately acidic with a pH value of around
3.27 (similar to orange juice).
Provision must be made for the safe and effective disposal of this
condensate.
Condensate can be disposed of using one of the following
methods of connection:
Internal connection (preferred option)
• into an internal domestic waste system (from kitchen sink,
washing machine, etc.)
• directly into the soil stack
External connection
• into an external soil stack
• into an external drain or gulley
• into a rainwater hopper (that is part of a combined system
where sewer carries both rainwater and foul water)
• purpose made soakaway
All condensate disposal pipes must be tted with a trap - whether
they are connected internally or externally to a domestic waste
system/soil stack or run externally to a gully, hopper or soakaway.
6.2 CONNECTIONS
Connections into a rainwater hopper, external drain or gulley
should be terminated inside the hopper/drain/gulley below the grid
level but above the water level.
! CAUTION !
Condensate disposal pipes must not be connected
directly into rainwater downpipes or to waste/soil systems
connected to septic tanks.
Condensate should not be discharged into ‘grey water’ systems
that re-use water used in the home (not including water from
toilets).
It should be noted that connection of a condensate pipe to the
drain may be subject to local Building Control requirements.
6.3 PIPEWORK
Condensate disposal pipework must be plastic (plastic waste or
overow pipe is suitable).
! NOTE !
Copper or steel pipe is NOT suitable and MUST NOT be
used.
Condensate disposal pipes should have a minimum ‘nominal’
diameter of 22 mm (¾ʺ) - e.g. use 21.5 mm OD polypropylene
overow pipe.
Condensate disposal pipes must be tted with a fall (away from
the boiler) of at least 2.5° (~45 mm fall per metre run).
! NOTE !
Where it is not possible for the pipe to fall towards the
point of discharge - either internally into a waste system
or externally to a gulley (e.g. for boilers installed in a
basement), it will be necessary to use a condensate pump.
Condensate disposal pipes should be kept as short as possible
and the number of bends kept to a minimum.
Pipes should be adequately xed to prevent sagging, i.e. at no
more than 0.5 metre intervals.
6.4 EXTERNAL PIPEWORK
Ideally, external pipework, or pipework in unheated areas, should
be avoided. If unavoidable, external pipework should be kept as
short as possible (less than 3 metres) and 32 mm waste pipe
used to minimise the risk of ice blocking the pipe in freezing
conditions.
The number of bends, ttings and joints on external pipes should
be kept to a minimum to reduce the risk of trapping condensate.
! NOTE !
For boilers installed in an unheated area such as a loft,
basement, outhouse or garage, all condensate pipework
should be as ‘external’.
The pipework should be insulated using suitable
waterproof and weather resistant insulation.
100 mm plastic tube
Figure 6-1: Purpose made condensate soakaway
Cement seal
Minimum 2.5 fall
Sealed end Backfill with 10 mm
limestone chippings
O
Ground level
25 mm
300 mm
400 mm
min.
Two rows of 3 x 12 mm
holes at 25 mm centres
of the tube. Holes facing
Section 6: Condensate DisposalPage 18
Page 19
6.5 CONDENSATE SOAKAWAY
To keep external pipework to a minimum, locate the soakaway
as close as possible to the boiler but ensure it is at least 500 mm
from building foundations and away from other services, e.g. gas,
electricity, etc.
The condensate pipe may be run above or below ground level
and can enter either the top or side of the soakaway tube. Refer
to Figure 6-1.
Ensure that the drainage holes in the soakaway tube face away
from the building.
Backll both the soakaway tube, and the hole around it, with 10
mm limestone chippings.
Only use a soakaway where the soil is porous and drains easily.
Do not use in clay soils or where the soil is poorly drained.
! CAUTION !
Any damage due to condensate backing up into the boiler
due to a high water table, in the case of a soakaway, or
ooded drains when the condensate disposal is via a
gulley or soil stack, is not covered by the Grant product
guarantee.
6.6 CONDENSATE TRAP
Grant Vortex boilers are supplied with a condensate trap to
provide the required 75 mm water seal in the condensate
discharge pipe from the boiler.
The condensate trap is factory tted inside the boiler casing
- mounted on the inside of the left hand side panel - in an
accessible position to allow for routine maintenance.
The upper holes can only be used on the Vortex Pro Combi XS
26.
With the trap tted inside the boiler casing, the sealing cap must
be tted. If the trap is re-located outside the boiler then the
following applies:
• If connecting the condensate discharge - either internally or
externally - into a waste system or soil stack - the sealing cap
must be tted in the trap outlet.
• On external discharge systems to a hopper, gully or
soakaway, the sealing cap should be removed from the trap
outlet.
• If there is any discharge of condensate from the overow
outlet, this could indicate a blockage (possibly due to
freezing). Turn off the boiler and investigate the cause. If
necessary contact your service engineer for assistance.
! WARNING !
Care should be taken when siting the trap such that the
overow outlet is readily visible and that any condensate
overowing from the outlet cannot cause either a hazard to
persons or damage to surrounding property or equipment.
6.7 CONDENSATE DISPOSAL
PIPEWORK
The condense trap outlet is at an angle of 48° below the
horizontal. This is to automatically gives a 3° fall on any
‘horizontal’ runs of condense disposal pipe. Refer to Figure 6-1
and see trap outlet/pipe.
The outlet of the trap will accept 21.5 mm to 23 mm OD
Polypropylene overow pipe for the condensate discharge pipe.
This discharge pipe can exit through the left side of the boiler
through one of two pre-cut ‘knock-outs’ in the lower part of the
left casing panel. Push out the ‘knock-out’ from the required hole
taking care not to distort the side panel.
! NOTE !
If required, this condensate trap may be re-located outside
the boiler casing. Refer to the procedure given in Section
6.9. This procedure must be carried out before the boiler is
installed.
This trap incorporates a oat (which will create a seal when the
trap is empty) and an overow warning outlet (tted with a plastic
sealing cap), see Figure 6-2.
Condensate
Overflow
warning
outlet
(with cap)
Condensate
outlet to
drain
End cap
drain pipe
from boiler
Unscrew
this cap for
maintenance
access
Condensate
trap
! NOTE !
When connecting plastic discharge pipe, ensure that the
pipe is fully pushed into the outlet end on the exible hose
to prevent the possibility of leakage.
6.8 INSPECTION AND CLEANING OF
TRAP
The trap must be checked at regular intervals (e.g. on every
annual service) and cleaned as necessary to ensure that it is clear
and able to operate.
The bottom bowl can be unscrewed from the trap body for
inspection and cleaning.
To inspect and clean the trap:
1. Disconnect exible condensate hose from inlet connector.
2. Unscrew the inlet connection nut.
3. Remove the inlet connector and nut from trap.
4. Disconnect the condensate disposal pipe from the trap outlet.
5. Remove trap from bracket.
6. Remove oat from trap – clean if necessary.
7. Inspect inside of trap and clean as necessary.
8. Re-assemble trap, re-t to boiler and re-connect exible
hose. Ensure that hose is fully pushed onto the trap inlet
connector.
! CAUTION !
Figure 6-2: Condensate trap
A exible hose connects the outlet of the condensing heat
exchanger to the trap inlet. Ensure the elbow connector on the
hose is fully pushed onto the ‘top hat’ inlet connector of the trap.
Section 6: Condensate Disposal Page 19
Failure to regularly check and clean the condensate trap
may result in damage to the boiler and will not be covered
by the product guarantee.
Page 20
6.9 EXTERNAL CONDENSATE TRAP
FITTING
! NOTE !
This procedure must be carried out before the boiler is
installed.
To re-locate the factory-tted trap outside the boiler casing, use
the following procedure:
1. Remove both the top casing panel(s) from the boiler.
2. Unscrew and remove the screws securing the bottom of the
rear panel to the base tray of the boiler casing.
3. Grip the top of the rear panel and pull it upwards. Slide it all
the way up and out of the channels on the rear edge of the
two casing side panels to remove it from the boiler. Refer to
Figure 6-3.
4. Push out pre-cut ‘knock-out’ from condensate outlet hole in
rear of left side casing panel.
5. Disconnect condensate discharge hose from heat exchanger
and condensate trap and remove it from the boiler.
6. Replace with condensate trap hose (Grant product code:
VBS107).
7. Pass the straight connector end of the hose through the
new hole in the left hand casing panel. Push the straight
connector rmly onto the condensate outlet connection of the
condensing heat exchanger as far as possible.
8. Ret the rear casing panel. Ensure that both edges of the
rear panel are correctly located into the channels in the rear
edge of both side casing panels. Then carefully slide the
rear panel fully down until the top edges is level with the top
edges of the side panels.
9. Secure the bottom of the rear panel to the base tray with the
screws previously removed.
10. Remove the trap from the mounting bracket.
11. Unscrew and remove the trap mounting bracket from the left
side panel.
12. Fix the trap mounting bracket to the wall adjacent to the
boiler in the required position.
! NOTE !
The top of the trap must be below the condensate
connection on the boiler.
13. Re-t the trap to the mounting bracket. The mounting bracket
supplied with the trap must be used - the trap should not be
supported by the condensate pipework only.
14. Connect the exible condensate hose to the trap - pushing
the right angle hose connector onto the trap inlet connection.
! NOTE !
The exible hose must fall continuously from the outlet to
the top of the trap.
Rear panel
Left hand side panel
Figure 6-3: Gaining access to the condensate outlet
Section 6: Condensate DisposalPage 20
Page 21
7 SEALED SYSTEMS
7.1 SEALED SYSTEM
REQUIREMENTS
All Grant Vortex Pro Combi boilers must be used as part of a
sealed system complying with the requirements of BS EN 12828,
BS EN 12831 and BS EN 14336.
The maximum temperature of the central heating water is 78°C.
The boiler is supplied factory tted with the following items:
• 24 litre diaphragm expansion vessel complying with BS EN
13831*
• Pressure gauge
• Pressure relief (safety) valve
• Approved lling loop
* The Grant Combi XS 26 is supplied with a separate
24 litre expansion vessel (and mounting bracket) for
installation in a suitable position outside the boiler
casing. Refer to Section 4.9.
7.1.1 EXPANSION VESSEL
On all models except the Combi XS 26, the expansion vessel is
factory tted on the front of the boiler, inside the casing.
It is connected to the boiler via a exible hose to allow the vessel
to be removed from the boiler to access the boiler to access the
front cleaning door without disconnecting it. Take care to ensure
that the exible hose is not twisted or kinked.
The Grant Combi XS 26 is supplied with a separate 24 litre
expansion vessel (and mounting bracket). This vessel should be
installed in a suitable location where it can be easily accessed for
servicing. Refer to Section 4.9 for further installation details.
! NOTE !
7.1.2 PRESSURE GAUGE
The pressure gauge is factory tted in the boiler control panel. It
has an operating range of 0 to 4 bar. Refer to Section 1.4.
7.1.3 SAFETY VALVE
The safety valve is factory tted to the ow pipework on the top of
the boiler.
A discharge pipe should be connected to the outlet of the safety
valve. This discharge pipe must terminate in a position that will
allow the discharge to be seen, but cannot cause injury to persons
or damage to property. Refer to Section 5.1 for further details.
7.1.4 FILLING LOOP
In order to ll or top up the heating system, a factory tted
lling loop is located at the front of the boiler, to the right of the
expansion vessel.
Refer to Section 4.10 for details on how to ll and vent the system.
7.1.5 HEATING SYSTEM
The maximum ‘setpoint’ temperature for the central heating water
is 78°C. Refer to Section 1.1.
An automatic air vent should be tted in the ow and return pipes
of the highest point of the system.
If thermostatic radiator valves are tted to all radiators, a system
by-pass must be tted. The by-pass must be an automatic type.
All ttings used in the system must be able to withstand pressures
up to 3 bar. Radiator valves must comply with the requirements of
BS 2767.
One or more drain taps (to BS 2879) must be used to allow the
system to be completely drained.
Ensure that the expansion vessel is of sufcient size for
the system volume.
Refer to BS 7074-1 or the Domestic Heating Design Guide
to check the vessel size required.
If thermostatic radiator valves
are fitted, the system must
incorporate an adequate by-pass.
Boiler
Domestic
hot water
Expansion
vessel
Domestic
cold water
Stop valve
Water mains
Heating flow
Static head of system
350mm
Heating
return
By-pass if required
(automatic type)
Figure 7-1: Sealed system
Section 7: Sealed Systems Page 21
Page 22
7.2 FILLING THE HEATING SYSTEM
Filling of the system must be carried out in a manner approved by
the local Water Undertaking.
! WARNING !
Only ever ll or add water to the system when it is cold and
the boiler is off. Do not overll.
The procedure for lling the sealed system is as follows:
1. Check the air charge pressure in the expansion vessel
BEFORE lling the system.
! NOTE !
The air charge pressure can only be correctly checked
when the system water pressure is zero.
The expansion vessel air charge pressure should always be
slightly greater than the maximum static head of the system,
in bar, at the level of the vessel (1 bar = 10.2 metres of
water).
For example: If the height to the top of the highest radiator
from the centre of the expansion vessel is 5metres, then the
static head at the vessel would be 0.5 bar. Refer to Figure
7-2.
The air charge pressure must not be less than the actual
static head at the point of connection.
7.3 PRESSURE RELIEF (SAFETY)
VALVE OPERATION
Check the operation of the pressure relief (safety) valve as
follows:
1. Turning the head of the valve anticlockwise until it clicks. The
click is the safety valve head lifting off its seat allowing water
to escape from the system.
2. Check that the water is escaping from the system.
3. Top-up the system pressure, as necessary.
! NOTE !
The air charge pressure may be checked using a tyre
pressure gauge on the expansion vessel Schraeder valve.
The vessel may be re-pressurised, when necessary, using
a suitable pump. When checking the air charge pressure,
the water in the heating system must be cold and the
system pressure reduced to zero.
2. Check that the small black plug on the side of both automatic
air vents is unscrewed one turn. Also check that the cap on
the manual air vent is unscrewed one turn. Refer to Section
4.10.
3. Ensure that the exible lling loop is connected between the
double check valve (on the cold water pipe) and the lling
point on the drain cock connection in the lower right corner of
the boiler.
Also ensure that the shut off valves on both the double check
valve and the ll point are closed.
Note that these valves are open when the operating lever is
in line with the valve, and closed when it is at right angles to
it.
4. Open the shut off valve on the ll point valve.
5. Gradually open the shut off valve on the double check valve
until water is heard to ow into the system from the cold
water supply.
6. When the needle of the pressure gauge is between 0.5 and
1.0 bar, close the shut off valve on the double check valve.
7. Vent each radiator in turn, starting with the lowest one in the
system, to remove air.
8. Continue to ll the system until the pressure gauge indicates
between 0.5 and 1.0 bar. Close the ll point valve.
The system ll pressure (cold) should be 0.2 - 0.3 bar greater
than the vessel air charge pressure.
Refer to the Domestic Heating Design Guide for further
information if required.
9. Repeat steps 4 and 5 as required until system is full of water
at the correct pressure and vented.
10. Water may be released from the system by manually
operating the safety valve until the system design pressure is
obtained.
11. Close the shut off valves on the ll point and double check
valves and disconnect the lling loop.
12. Check the system for water soundness, rectifying where
necessary.
Section 7: Sealed SystemsPage 22
Page 23
8 ELECTRICAL
! WARNING !
Ensure that the electrical supply has been isolated before
making any connections to the boiler.
8.1 CONNECTING THE POWER
SUPPLY
A three core cable is required to connect the boiler terminal block
to the live supply. Refer to Figure 8-1 for boiler wiring terminal
details.
The procedure for connecting the boiler power supply is as
follows:
1. Loosen (do not remove) the four screws securing the control
panel to the side panels, hinge the panel forward and allow it
to drop down to gain access to the top of the panel.
2. Remove the two screws securing the terminal block cover
and lift off the cover.
3. Remove the screws securing the cable clamp and open
clamp.
4. Connect the power supply cable to the left hand terminal
block as follows:
• Brown to mains Live (terminal 3)
• Blue to mains Neutral (terminal 2)
• Green/Yellow to mains earth (terminal 1)
BURNER LEAD PLUG/SOCKET CONNECTOR
On all four models, the electrical cable between the boiler
control panel and burner is now tted with an in-line 3-way plug
and socket connector. This enables the burner to be easily
disconnected from the boiler control panel for ease of removal for
servicing.
! WARNING !
After completing electrical connections and before
reconnecting the electrical supply to the boiler, replace
the terminal block cover and secure it using the screws
provided.
Section 8: Electrical Page 23
Page 24
Central
Domestic
Heating
Hot Water
Switch
Switch
Const
4B
5B
6B
Off Off
Timed
4B5B1A
Const
Timed
2A
Printed Circuit Board
Limit
GR
BL
BR
BR
BL
Timer
GR
G/Y
Thermostat
2
C
G/Y
G/Y
Electrical Mains
Connection Plug
Colour code:
BR - Brown
BL - Blue
RD - Red
G/Y - Green/Yellow
BLK - Black
OR - Orange
Y - Yellow
GR - Grey
Mains CH Pump DHW Pump Burner
E N L
1 2 3
230V 5A Fused
Supply
E N L
4 5 6
Black
Cable
N L
E N L E N L
CH
Pump
E N L
7 8 9
DHW
Pump
White
Cable
E N L
10 11 12
N
E
Burner
L
Flow
Switch
1314 1516 2324 2526 27 28171819 20 21 22
No
Flow
Switch
BR
DHW
Timed on
RD ORBLK
CH
Timed on
Timer Neutral
Timer Live
Ext Frost Stat (from)
Ext Frost Stat (to)
Figure 8-1: Boiler wiring diagram
Mains
CH Timer On
Timer Neutral
CH Pump Earth
CH Pump Neutral
CH Pump Live
DHW Pump Earth
DHW Pump Neutral
DHW Pump Live
Burner Pump Earth
Burner Pump Neutral
E N L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26
Burner Pump Live
Flow Switch
Flow Switch
DHW Timer On
Thermistors
Store Flow
Room Stat (from)
Black shroud
indicates flow
thermistor
Store
Thermistor
Flow
Thermistor
Boiler Control Panel - PCB Connections
Room Stat
Ext. Frost Stat
Ext. Frost Stat
Room Stat
Timer Live
Earth connection
boiler top bracket
Store Thermistor
Flow Thermistor
NE L
230V 5A Fused
Supply
Figure 8-2: Vortex Pro Combi wiring terminals
Brown
Red
Black
Orange
Section 8: ElectricalPage 24
Page 25
8.2 CONNECTING THE CONTROLS -
HEATING ONLY
To control the central heating on/off periods only (and not
the domestic hot water), it is recommended to use one of the
following options:
• A remote single channel timer and room thermostat.
• A ‘plug-in’ Grant Mechanical 24-hour timer (product code:
MTKIT) and room thermostat.
• A programmable room thermostat.
With any of these options the timer, room thermostat or
programmable room thermostat should be sited at a suitable and
convenient location within the property.
CONNECTION OF AN EXTERNAL REMOTE TIMER
AND ROOM THERMOSTAT
! WARNING !
Any remote timer must be of a single channel 230V type
with voltage free output contacts.
1. Pass a 3-core cable (or 3-core and earth if the room
thermostat to be used has an earth connection) through the
cable clamp on the control panel.
2. Remove the Orange room thermostat link wire from terminals
25 & 26 on the connection block and connect the wires from
the room thermostat. Refer to Figure 8-3 for further details
3. Connect the room thermostat to the terminal block in
accordance with the room thermostat manufacturer’s
instructions.
4. Pass a 4-core cable (or 4-core and earth if the timer to be
used has an earth connection) through the cable clamp on
the control panel.
5. Remove the black link wire from terminals 19 & 20 on the
connection block. Connect the two switch wires from the
timer.
6. Connect the live, neutral (and earth if required) from the timer
to terminals 3, 2 & 1 respectively on the boiler terminal block.
Refer to Figure 8-3 for further details.
7. Re-t terminal block cover on control box and fasten with the
two screws previously removed.
8. Hinge the control panel back into position on the two
retaining screws.
9. Replace top casing panels.
10. Re-connect electrical supply and check operation of the timer
and room thermostat.
11. Refer to the Fitting and User Instructions supplied with the
timer for operating and setting.
Leave the Timer and Room Thermostat Fitting and User
instructions with the user after installation.
FITTING AND CONNECTION OF A GRANT ‘PLUG-IN’
24-HOUR TIMER (MTKIT) AND ROOM THERMOSTAT
1. Pass a 3-core cable (or 3-core and earth if the room
thermostat to be used has an earth connection) through the
cable clamp on the control panel.
2. Remove the Orange room thermostat link wire from terminals
25 & 26 on the connection block and connect the wires from
the room thermostat. Refer to Figure 8-4 for further details.
3. Connect the room thermostat to the terminal block in
accordance with the room thermostat manufacturer’s
instructions.
Fit and connect the ‘plug-in’ timer as follows:
1. Remove front and top boiler casing panels. Loosen (do not
remove) the four screws securing control panel to the side
panels. Hinge the panel forward to access top and rear of
control panel.
2. Remove the two screws and lift off the terminal block cover
from top of control panel.
3. Remove the four screws from the rear of the control panel
and remove the rear access cover.
4. Remove the Black wire links from terminals 19 & 20 on
control panel.
5. Carefully push through and remove square pre-cut ‘knockout’
section in the control panel front.
6. Feed the wires through hole in control panel front and then
up through rectangular opening in control panel top. Connect
wires to terminals on control panel as follows:
8.3 CONNECTING AN EXTERNAL
FROST THERMOSTAT
The boiler is tted with a pre-set internal frost protection
thermostat. Should either the air temperature around the boiler, or
the water temperature within the boiler, fall to below 5°C then this
thermostat will be activated to protect the boiler from freezing.
If necessary, to protect any exposed heating system and any
exposed pipework, an external frost thermostat can also be
connected to the boiler.
This frost thermostat should be sited within the house in such
a place that it can detect any rise and fall in the ambient air
temperature, such as, in a room with a radiator. It is connected to
the boiler as follows:
1. Connect the wires from the frost thermostat to terminals 23
& 24 on the connection block. Refer to Figure 8-3 for further
details.
2. Connect the frost thermostat in accordance with the frost
thermostat manufacturer’s instructions.
This external frost thermostat will operate in parallel
Section 8: Electrical Page 25
Page 26
Mains
Timer Neutral
DHW Timed On
Red
HTG
CH Timed On
ON
E N L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26
N
E L
230V 5A Fused
Supply
Remote mounted
Time Switch
e.g. Danfoss Randall
TS715
1 2N L 4
HTG
COM
OFF
Timer Live
Room Thermostat
e.g. Danfoss Randall
RMT230
Figure 8-3: Connections for a remote timer and room thermostat
Boiler Control Panel - PCB Connections
Room Stat
Room Stat
Ext. Frost Stat
Ext. Frost Stat
4 1 2
N COM ON
N L 3
N L ON
Frost Thermostat
(if required)
e.g. Danfoss Randall
RET230F
Mains
Timer Neutral
DHW Timed On
E N L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26
N
E L
230V 5A Fused
Supply
COM L N
Grant Plug-in (panel mounted)
Mechanical Timer
Grant Ref. MTKIT
HTG
OFF
3 25 4 1
HTG
ON
CH Timed On
Red
Timer Live
Figure 8-4: Connections for an MTKIT and room thermostat
Boiler Control Panel - PCB Connections
Room Stat
Room Stat
Ext. Frost Stat
Ext. Frost Stat
4 1 2
N COM ON
Room Thermostat
e.g. Danfoss Randall
RMT230
N L 3
N L ON
Frost Thermostat
(if required)
e.g. Danfoss Randall
RET230F
Section 8: ElectricalPage 26
Page 27
BOILER IN
ROOM
BOILER IN
COMP
compartment ventilated from room
compartment ventilated from outside
BOILER
ROOM
BOILER
COMP
compartment ventilated from room
compartment ventilated from outside
9 FLUE SYSTEM AND AIR SUPPLY
9.1 AIR SUPPLY
A sufcient permanent air supply to the boiler should be provided
for the following reasons:
• For proper combustion of fuel and effective discharge of
combustion products to the open air.
• For the ventilation of any conned space in which the boiler
is installed to prevent overheating of the boiler and any
equipment in and near the boiler.
It should be both the designer’s and installer’s concern that the air
required for these functions be introduced so as to cause as little
discomfort as possible to the building occupants and thus to offer
them the least temptation to obstruct the ventilators.
Further details may be obtained from BS 5410-1.
! NOTE !
IN
IN
AR TMENT
C
Conventional open flue
C
D
C
For a boiler tted in a compartment, which is ventilated as
shown, no additional allowance is necessary.
Open ue - Extract fans, where needed, should be in accordance
with Section 5.4.7 in BS 5410-1.
All ventilation areas given are for domestic applications and relate
to the full output rating of the boiler.
For installations in older dwellings (constructed prior to the
introduction of Approved Document L1A 2006) the rst 5 kW of
output can be ignored. For all other cases refer to BS 5410-2.
Room sealed balanced flue
no ventilation required to room
AR TMENT
B
B
Room sealed balanced flue
A
A
Room sealed balanced flue
Figure 9-1: Air supply for room sealed balanced ue boilers
E
Conventional open flue
D
Conventional open flue
Figure 9-2: Air supply for conventional ue boilers
9.2 CONVENTIONAL FLUE SYSTEMS
! NOTE !
Under no circumstances can Grant Vortex boilers be
installed with existing ue systems. Only ue systems and
components suitable for wet ues should be used.
Failure to install the correct type of ue system will
invalidate the guarantee.
Grant condensing boilers have high operating efciencies and
low ue gas temperatures. Care must be taken to ensure the
ue system is suitable for the very low ue gas temperatures and
condensate in the ue gases.
Suitable conventional ue systems are available from Grant UK.
The ue must terminate in a down draught free area, i.e. at least
600 mm above the point of exit through the roof or preferably
above the ridge level.
The condensate may be allowed to run back into the boiler. A
condensate drain at the base of the ue system is not required.
The high level ue terminal must be at least 600 mm from
any opening into the building, and 600 mm above any vertical
structure or wall less than a horizontal distance of 750 mm from
the terminal.
Table 9-3: Ventilation areas
Output Combi XS 26 Combi 21 Combi 26 Combi 36
Area cm² in² cm² in² cm² in² cm² in²
Vent A 143 22 116 18 143 22 198 31
Vent B 286 44 231 36 286 44 396 61
Vent C 143 22 11 6 18 143 22 198 31
Vent D 286 44 231 36 286 44 396 61
Vent E 429 67 347 54 429 67 594 92
Section 9: Flue System and Air Supply Page 27
Page 28
If an existing chimney is to be used, it must be lined with a smooth
bore stainless steel liner suitable for use with oil red condensing
boilers. The top and bottom of the annular space must be sealed.
Grant recommends the use of the Grant ‘Orange’ ue system,
specically designed for the Vortex range of condensing boilers.
The internal ue and liner diameter for all models up to 46 kW
output must be 100 mm (4 in).
The maximum vertical height (from the top of the boiler to the
terminal) for the ‘Orange’ system is 19 metres.
! NOTE !
The Grant Orange system exible stainless steel liner
is directional. The arrows marked on the liner MUST be
pointing vertically upwards, following the direction of the
ue gases. Failure to comply with this instruction could
lead to a leakage of condensate from the ue liner.
If a rigid ue is used externally, it must be of the twin-wall type
incorporating seals at all joints, constructed with a stainless steel
inner skin and be suitably insulated and weatherproofed. The
internal ue diameter for a rigid ue for all models - up to and
including the 58/70 - is 100 mm (4 in). Use the larger ‘200’ size of
‘Green’ system components as listed in Figure 9-14.
Grant recommends the use of the Grant ‘Green’ and ‘Orange’ ue
system components for this application. Refer to Section 1.3 for
details.
! NOTE !
As no ue adaptor is supplied with the boiler, in order to
correctly connect the hybrid system, it will be necessary
to purchase the Grant CF adaptor kit (product code:
CFA15/70).
If required, it is possible to use the white painted single-wall
straight ue extensions, adjustable extensions and elbows from
the Grant ‘Orange’ system for the internal section of the ue
system, see Figure 9-6. These components can be tted between
the boiler connector and ue adaptor. The ue adaptor, to which
the external twin-wall ‘Green’ ue components are connected, can
therefore be situated just before the ue system passes through
the wall.
! NOTE !
To comply with the requirements of the Building
Regulations Approved Document J - conventional ue
systems must have a ue data plate. A suitable data plate
is supplied with the Grant Orange ue system and should
be displayed next to the boiler or ue.
FLUE LINING KITS
Grant EZ-Fit Flexi Pack conventional ue system (Orange
System)
A range of Flexi pack conventional ue lining kits are available
from Grant UK. The packs have been specically produced for
Grant Vortex oil red condensing boilers.
The pack includes a terminal/top plate/exi ue adaptor, stainless
steel smooth bore exible ue liner, a rigid to exi adaptor and a
boiler ue connector.
Two diameters are available, a 100 mm for models up to 46 kW
and 125 mm for models above 46 kW.
Table 9-4: Conventional ue kits
Product code Flexi pack (Orange system)
GFKIT 6/100 100 mm diameter x 6 metre
GFKIT 6/125 125 mm diameter x 6 metre
GFKIT 8/100 100mm diameter x 8 metre
GFKIT 8/125 125mm diameter x 8 metre
GFKIT 10/100 100mm diameter x 10 metre
GFKIT 10/125 125mm diameter x 10 metre
GFKIT 11/100 100mm diameter x 11 metre
GFKIT 11/125 125mm diameter x 11 metre
GFKIT 12/100 100mm diameter x 12 metre
GFKIT 12/125 125mm diameter x 12 metre
GFKIT 14/100 100mm diameter x 14 metre
GFKIT 14/125 125mm diameter x 14 metre
GFKIT 16/100 100mm diameter x 16 metre
GFKIT 16/125 125mm diameter x 16 metre
! NOTE !
Grant ‘Orange’ system single-wall ue components must
not be used externally.
The maximum vertical height (from the top of the boiler to the
terminal) for the 100 mm diameter hybrid ‘Green/Yellow’ system is
8 metres.
Grant ‘Green’ twin-wall ue is recommended for externally run
ues to reduce the possibility of the condensate freezing in the
ue.
No part of any ue system should be made of an asbestos
material; aluminium must not be used in any part of the ue.
Only stainless steel ue components should be used.
If the draught conditions are satisfactory, the ue should terminate
with a standard cowl.
Refer to the locally applicable Building Regulations, BS 5410:1
and OFTEC Installation Requirements (OFTEC Technical Books 2
and 4) for further guidance on conventional ue systems.
! CAUTION !
Caution concerning likely damage to equipment or tools
as a consequence of not following the instructions in the
caution.
Only use ue systems suitable for oil red condensing boilers.
Do not use re cement. The use of high temperature silicone
sealants is recommended.
Extensions
A range of white powder coated single wall extensions are
available to connect the boiler to the exible liner.
The nominal diameter of the extensions is 100 mm or 125 mm.
Extensions are supplied with locking bands.
Table 9-5: Extensions
Product code Ex tensions (Orange system)
WX 150/100 100 mm diameter x 150 mm
WX 150/125 125 mm diameter x 150 mm
WX 250/100 100 mm diameter x 250 mm
WX 250/125 125 mm diameter x 250 mm
WX 450/100 100 mm diameter x 450 mm
WX 450/125 125 mm diameter x 450 mm
WX 950/100 100 mm diameter x 950 mm
WX 950/125 125 mm diameter x 950 mm
Flue extensions cannot be cut.
Also available are:
• An adjustable extension (235 to 300 mm)
• 45° elbow
! NOTE !
The rigid ue between the boiler and exible ue liner
should incorporate an adjustable section to allow
inspection and cleaning of the ue system.
Section 9: Flue System and Air SupplyPage 28
Page 29
Rigid to flexible flue
Terminal
(refer to Figure 9-9)
Flaunching
Brick
chimney
Locking band
Adjustable section 235/300mm
WXA250/100
WXA250/125
O
45 elbow
100mm dia.
125mm dia.
Clamp
Top plate
Flexible stainless
steel liner
The flue liner
Note:
is directional
(see Section 9.2)
Green System
components
connector (bottom)
This
C
Note:
component
must be installed
vertically
Adaptor
(from CFA 15/70 kit)
Extension
Locking band
Boiler flue
connector
Boiler
Orange System
components
(refer to Figure 9-3)
Boiler flue
connector
(from CFA 15/70 kit)
Boiler
Figure 9-6: Grant Orange ue system in a typical brick chimney
Figure 9-7: Hybrid ue system using Grant Orange and Green
systems components
Section 9: Flue System and Air Supply Page 29
Page 30
9.3 CONNECTING A CONVENTIONAL
FLUE
If the Grant ‘Orange’ ue system is being used – follow the
instructions supplied with the ue kit.
If the Grant ‘Green’ system (100 mm rigid twin-wall ue) is to be
tted to the boiler then the Grant CF adaptor kit (product code:
CFA15/70) must be used – refer to Section 1.3.
To t the adaptor kit, proceed as follows:
1. Fully screw the length of threaded studding (provided in the
kit) into the nut located in the centre of the boiler ue outlet.
2. Fit the boiler connector (from the CF adaptor kit) over the
threaded studding.
3. Position ange on to the neoprene gasket around the boiler
ue outlet, ensuring that small spigot on the base of the
connector is located in the hole in the centre of the neoprene
gasket and that end of studding passes through the hole in
the of the spacer bracket.
4. Fit washer and wing nut provided onto the end of threaded
studding and secure connector in position by tightening down
on wing nut – as shown in Figure 9-8.
5. Fit the ue adaptor (from the adaptor kit) into the boiler
connector.
9.4 BALANCED FLUE SYSTEMS
Apart from a conventional ue, several balanced ue options are
available for use with the Grant Vortex boilers.
All are suitable for use with Class C2 Kerosene.
! NOTE !
None of the flue sections in the following system can be cut.
LOW LEVEL HORIZONTAL BALANCED FLUE
(YELLOW SYSTEM)
Available in Short (for single thickness brick walls) and Standard
kits.
Extensions are available which extend the ue by 225 mm, 450
mm or 675 mm.
90° and 45° elbows are also available.
The maximum ue length - from the centre of the boiler ue outlet
to the outer face of the wall - is 4 metres (with or without elbows
included).
No more than 2 x 45 or 1 x 90 elbow should be tted per system.
The low level balanced ue (Yellow system) is supplied with a
stainless steel guard. This must be tted in all circumstances to
prevent objects from entering the ue outlet.
The guard must be tted centrally over the ue terminal and
securely xed to the wall.
Figure 9-8: Boiler ue connector
! NOTE !
Lubricate the seal on the adaptor using the lubricant
provided before attempting to t the ue adaptor.
6. Fit the rst section of ue into the ue adaptor and secure
using the clamp band provided.
7. Assemble the remainder of the ue system as required,
lubricating the seal on each component before tting.
Figure 9-9: Low level balanced ue
Section 9: Flue System and Air SupplyPage 30
Page 31
HIGH LEVEL (HORIZONTAL) BALANCED FLUE
(WHITE SYSTEM)
The High Level (horizontal) balanced ue (White system) allows
the ue to rise vertically within the building before exiting through
the wall horizontally.
The maximum ue length - from the top of the boiler ue outlet
to the outer face of the wall - is 10 metres for all Grant Vortex
boilers.
The following items are additionally available:
• Extensions to extend the ue by 225 mm, 450 mm or 950
mm.
• An adjustable extension of 275 to 450 mm.
• A 45° elbow - No more than 6 x 45° elbows should be tted
per system. Each elbow reduces the overall maximum length
of the system by 1 metre.
VERTICAL BALANCED FLUE (WHITE SYSTEM)
Allows the ue to rise vertically from the boiler to exit through the
roof.
The maximum ue length - from the top of the boiler ue outlet to
the terminal - is 12 metres for all Vortex boilers.
The following items are additionally available:
• Extensions to extend the ue by 225 mm, 450 mm or 950
mm.
• An adjustable extension of 275 to 450 mm.
• A 45° elbow - No more than 6 x 45° elbows should be tted
per system. Each elbow reduces the overall maximum length
of the system by 1 metre.
Figure 9-10: High level balanced ue
Table 9-11: White system components - product codes
Item Combi XS 26, 21 and 26 models Combi 36 models
1.2 metre high level adjustable ue kit c/w 90° elbow and terminal HLK015090 HLK0290200
Adjustable vertical 3 metre ue kit c/w terminal and storm collar VTK055090 VTK0690200
225 mm extension EXTK31225/90 EXTK32225/200
450 mm extension EXTK09450/90 EXTK10450/200
950 mm extension EXTK11950/90 EXTK12950/200
275 to 450 mm adjustable extension EXTK13ADJ/90 EXTK14ADJ/200
45° elbow ELBK2145/90 ELBK2245/200
Pitched roof ashing - aluminium (VTK055090 and VTK0690200) VTMF200
Pitched roof ashing - lead VTK25P90 (includes collar)
Flat roof ashing - aluminium VTK27F90 VTK28F200
Wall bracket BRK2990 BRK30200
VTK26P240 (no collar)
VTK26P200/X (includes collar)
Section 9: Flue System and Air Supply Page 31
Page 32
FLEXIBLE VERTICAL BALANCED FLUE (RED
SYSTEM)
! NOTE !
Terminal upstand
Outer stainless steel liner
Locking band
Locking band
Elbow, extension
and adjustable extension
from 'White' system
Boiler
Terminal
Support clamp
Top plate
Flexible inner
stainless steel liner
The flue liner
Note:
is directional
(see Section 9.4)
Connector
Rigid/flexible adaptor
Telescopic flue (upper)
Locking band for
adjustable joint section
Telescopic flue (lower)
Locking band
Starter section
One mete of straight ue length should be deducted for
every elbow used. If the exible liner has to pass around
an offset in the chimney, two metres of straight ue length
should be deducted to compensate for this, i.e. equivalent
to two 45° elbows.
The Grant Red system exible stainless steel liner is directional.
The arrows marked on the liner MUST be pointing vertically
upwards, following the direction of the ue gases. Failure to
comply with this instruction could lead to a leakage of condensate
from the ue liner.
Flue extensions cannot be cut, use adjustable extensions where
required.
Three types of locking band are supplied with the kit.
The rst type is for connecting ue sections that butt together (2 of
this type of locking band are supplied).
The second type is to cover the joint on the adjustable (telescopic)
section.
! NOTE !
The locking band for the adjustable section is labelled for
easy identication.
The third locking band is plastic and supplied in two halves. This
is to secure the plastic exible liner to the adapter.
The ue kit includes a Black coated terminal with upstand and is
designed to be xed (using the screws provided) to the top of a
masonry chimney.
The ue system may be offset using 45° elbows (product code:
ELBK2145/90 models up to 26 kW output or ELBK22145/200 for
models 26 to 70 kW output).
No more than a maximum of four elbows should be used per
system.
Figure 9-12: Red system balanced ue
This is a exible vertical balanced ue system (for the Combi XS
26, Combi 21 and Combi 26 models only) designed to be tted
inside an existing masonry chimney. See Figure 9-12.
It basically consists of three sections:
• Concentric white painted ue pipe connected to the boiler.
• Vertical concentric exible ue (exible stainless steel ue
liner inside a exible plastic air inlet liner).
• Terminal assembly for chimney top mounting.
The ue pipe seals are factory tted and must be lubricated with
the lubricant supplied before assembly.
The Red system is supplied as a separate kit. Flue extensions
and 45° elbows from the White system may be used to extend the
ue between the boiler and the exible section of the system.
The maximum vertical straight length of ue, from the top of the
boiler to the top of the terminal, is 20 metres – using no more than
four 45° elbows. Deduct 1 metre of straight ue length for every
elbow used.
EXTERNAL BALANCED FLUE
(GREEN SYSTEM)
Where it is not practical to use a low level (Yellow system) or
internal high level/vertical (White system) balanced ue, the
boiler can be tted with an external vertical/high level ue (Green
system).
See Figure 9-13.
The Starter kit ts to the boiler in the same way as a low level
balanced ue (Yellow system) and the external Tee allows the
connection of a twin wall insulated ue pipe and a combustion air
inlet - providing a room sealed ue system.
The external system can terminate at either high level or vertically
(above roof level) as required.
See Figure 9-13.
The minimum dimensions for locating the terminal from building
features (windows, doors, etc.) are shown in Figure 9-15.
The terminal must be positioned so as to avoid products of
combustion accumulating in stagnant pockets around the
buildings or entering into buildings. Care should be taken that the
plume from condensed ue gases does not cause a nuisance.
The components listed on the following page for the external ue
(Green system) components are available from Grant UK.
Section 9: Flue System and Air SupplyPage 32
Page 33
Typical
ue system
Vertical terminal kit
GTV90 (15 - 26 kW)
GTV200 (26 - 70 kW)
O
45 elbow kit
GE45/90 (15 - 26 kW)
GE45/200 (26 - 70 kW)
High level terminal kit
GTH90 (15 - 26 kW)
GTH200 (26 - 70 kW)
Extended wall bracket
Wall bracket
Locking band
Extension kits
Air
intake
DO NOT
OBSTRUCT
Starter kit
GK90 (15 - 26 kW)
GK200 (26 - 70 kW)
GK90S - short (15 - 26 kW)
GK200S - short (26 - 70 kW)
Components and Part Numbers
Figure 9-13: External balanced ue (green system)
Table 9-14: Green system components - product codes
Item Combi XS 26, 21 and 26 models Combi 36 models
Standard starter kit (stainless steel) GK90B GK200B
Short starter kit (stainless steel) GK90SB GK200SB
150 mm extension GX150/90B GX150/200B
250 mm extension GX250/90B GX250/200B
450 mm extension GX450/90B GX450/200B
950 mm extension GX950/90B GX950/200B
195 - 270 mm adjustable extension GXA250/90B GXA250/200B
45° elbow GE45/90B GE45/200B
Straight terminal GTL90B GTL200B
High level 90° terminal GTH90B GTH200B
Vertical terminal GTV90B GTV200B
Wall bracket - standard GWB90B GWB200B
Wall bracket - extended GEB90B GEB200B
Section 9: Flue System and Air Supply Page 33
Page 34
9.5 FLUE CLEARANCES
Figure 9-15: Flue clearances
Table 9-16: Flue clearances
Ref Location of outlet
A
Directly below an opening, air brick opening, opening window, etc.
B
Horizontally to an opening, air brick opening, opening window, etc.
C
Below a gutter, eaves or balcony with protection
D
Below a gutter, eaves or balcony without protection
E
From vertical sanitary pipework
F
From an internal or external corner
G
Above ground or balcony level
H
From a surface or boundary facing the terminal
J
From a terminal facing the terminal
K
Vertically from a terminal on the same wall
L
Horizontally from a terminal on the same wall
M
Above the highest point of an intersection with the roof
N
From a vertical structure to the side of the terminal
O
Above a vertical structure less than 750 mm from the side of the terminal
P
From a ridge terminal to a vertical structure on the roof
Q
Above or to the side of any opening on a at or sloping roof
R
Below any opening on a sloping roof
S
From oil storage tank (Class 1)
*
A heat shield at least 750 mm wide must be tted to provide protection of combustible material.
**
Clearances required by BS 5410-1:2014 to alleviate the effect of plume nuisance. If a risk assessment shows that there will be no impact from pluming,
then the ‘pressure jet’ gure could apply - seek conrmation from Local Authority Building Control.
Seek guidance from OFTEC Book 3 (Oil Storage and Supply).
***
Minimum distance (mm)
Pressure jet Condensing
600 1,000 **
600 1,000 **
75 * 1,000 **
600 1,000 **
300
300
300
600 2,500 **
1,200
1,500
750
600
750
600
1,500
300
1,000
1,800 ***
NOTES
1. Appliances burning class D fuel have additional restrictions. Refer to BS 5410-1:2014.
2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers, etc.
3. Terminating positions A to L are only permitted for appliances that have been approved for low level ue discharge when tested in accordance with BS EN 303-1, OFS A100 or OFS
A101.
4. Terminating positions should be at least 1.8 metres from an oil storage tank (Class 1) unless a wall with at least 30 minutes re resistance and extending 300 mm higher and wider than
the tank is provided between the tank and the terminating position.
5. Where a ue is terminated less than 600 mm away from a projection above it and the projection consists of plastics or has a combustible or painted surface, then a heat shield of at least
750 mm wide should be tted to protect these surfaces.
6. If the lowest part of the terminal is less than 2 metres above the ground, balcony, at roof or other place to which any person has access, the terminal should be protected by a guard.
7. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300 mm to combustible material. In the case of a thatched roof, double this separation distance
should be provided. It is also advisable to treat the thatch with a re retardant material and close wire in the immediate vicinity of the ue.
8. A ue or chimney should not pass through the roof within the shaded area delineated by dimensions Q and R.
9. Where protection is provided for plastics components, such as guttering, this should be to the standard specied by the manufacturer of the plastics components.
10. Terminals must not be sited under car ports.
11. Terminals at low levels (terminals under 2.1 metres) have more restrictive recommendations and should not be positioned near public footways, frequently used access routes, car
parking spaces less than 2.5 metres from the terminal or patio’s (hard surface area).
Further guidance can be obtained from BS 5410-1:2014, OFTEC Book 4 (Installation) and Approved Document J.
Grant UK ue products are fully compliant with the CE (Communauté Européenne/European Community) standards having undergone rigorous product testing.
Section 9: Flue System and Air SupplyPage 34
Page 35
9.6 PREPARE THE WALL
Hole to be
Rear exit
Side exit
9.6.1 LOW LEVEL BALANCED FLUE
If the boiler is to be used with a low level balanced ue (Yellow
system) make the hole in the wall for the ue as shown in Figure
9-17.
Note: This dimension is given with
the boiler pushed back against
Boiler
centre line
A
C
the rear wall. Any clearances
must be added to it.
Outline
of boiler
Rear wall
A
B
Side wall
Hole to be
cut in wall
C
9.6.2 HIGH LEVEL AND VERTICAL BALANCED
FLUE
If the boiler is to be used with the high level balanced ue (White
system) make the hole in the wall as shown in Figure 9-19.
cut in wall
D
C
Standard kit with no extensions
A
Note: This dimension is given with
the boiler pushed back against
the rear wall. Any clearances
must be added to it.
Boiler
centre line
Outline
of boiler
Rear wall
B
Side wall
A
Hole to be
cut in wall
Rear exit
Side exit
Figure 9-17: Flue hole dimensions and position for low level
system
Table 9-18: Low level balanced ue hole cutting dimensions
Model
A (dia.) B C
15/21, 15/26 127 11 5 768
26/36, 36/46 162 11 5 780
46/58, 58/70 162 11 2 1,102
Dimension (mm)
! NOTE !
Dimension A given in Figure 9-11 includes an extra 10 mm
over the size of the terminal to provide clearance for tting.
Figure 9-19: Flue hole dimensions and position for high level
system
Table 9-20: High level balanced ue hole cutting dimensions
Model
A (dia.) B C D
15/21, 15/26 175 115 1,215*
26/36, 36/46 200 115 1,280*
46/58, 58/70 200 112 1,595*
* Dimension C for starter section and elbow/terminal only
Dimension (mm)
1,715 -
2,115
1,700 -
2,020
2,015 -
2,335
! NOTE !
Dimension A given in Figure 9-12 includes an extra 10 mm
over the size of the terminal to provide clearance for tting.
Fitting instructions for the high level balanced ue and vertical
balanced ue are supplied with the ue kits.
Adjustable extensions
The adjustable extensions are telescopic.
The wall terminal section is adjustable and is suitable for a wall
thickness of 215 mm to 450 mm.
Simply adjust to the required length using a twisting motion. The
outer pipes must overlap by a minimum of 25 mm.
Section 9: Flue System and Air Supply Page 35
Page 36
10 COMMISSIONING
To ensure safe and efcient operation, it is essential that a
Grant Combi boiler is commissioned as detailed in the following
procedure.
To access the controls, remove the front panel from the boiler (pull
forward at the top and then lift off).
The controls are shown in Figure 10-1.
Plug-in
programmer
position
(if fitted)
Boiler
On / Off
switch
Indicator
lights
Pressure
gauge
Heating
switch
Hot water
switch
Figure 10-1: Vortex Pro Combi boiler control panel
Boiler
thermostat
Flow sensor (black sleeve)
Over heat
reset (under
black cap)
Store sensor (white sleeve)
Figure 10-2: Position of boiler components - Vortex Pro Combi boiler
Section 10: CommissioningPage 36
Page 37
10.1 BEFORE SWITCHING ON
1. Ensure the boiler is isolated from the electrical supply and
the boiler On/Off switch is set to OFF.
2. Check that the high limit thermostat bulb and both thermistor
sensors are correctly located in their respective pockets.
Refer to Figure 10-2. Check condition of both thermistor
cables and thermostat capillary. Ensure they are not
damaged, broken, kinked or crushed.
3. Remove the nuts and washers securing the front cleaning
door. Withdraw the door – take care as it is HEAVY!
4. Check that the turbulators are in position and that the ends
are vertical. Refer to Figure 11-4.
5. Check that the bafes are in position. Refer to Figures 11-1,
11-2, or 11-3 as required.
6. Re-t cleaning door and check it is tted correctly and that a
good seal is made.
7. Unscrew the burner xing nut (located at the top of the
mounting ange) and remove the burner from the boiler.
8. Check/adjust the burner settings as described in Section 10.2
(burner settings).
9. Re-t the burner to the boiler and tighten the xing nut. DO
NOT OVERTIGHTEN!
10. Check that the sealed system has been vented and
pressurised and there are no leaks.
11. Ensure both automatic air vents, and also the manual vent on
the ow pipe, are open.
12. Check that all fuel line valves are open.
13. Remove the plastic burner cover if it was not previously
removed.
14. Connect a combined vent manifold and pressure gauge to
the pressure gauge connection port on the oil pump. Refer to
Figure 3-5. Open the vent screw on the vent manifold to vent
the oil supply whilst the pump is running.
15. Check that all system controls are calling for heat and turn
the boiler thermostat to maximum.
10.2 BURNER SETTINGS
With the burner removed from the boiler:
1. Remove the burner head. Refer to Figure 10-3. Loosen the
three xing screws (1) and remove head (2) from burner.
1
2
3
7
4
Figure 10-3: Burner head, diffuser and nozzle holder
5
8
6
2. Check the nozzle is correct for the required boiler output.
Refer to Table 2-2 for the correct nozzle size and type for the
required boiler output.
3. If the nozzle needs to be replaced - remove the diffuser/
electrode assembly. Refer to Figure 10-3.
• Using a 4 mm Allen key, loosen the diffuser xing screw
(3) on the electrode assembly.
• Lift diffuser/electrode assembly (5) up and off the nozzle
holder.
• Disconnect both ignition leads (4) from the electrodes.
4. Use a 16 mm spanner to remove/re-t the nozzle, whilst
holding the nozzle holder using a 19 mm spanner.
! CAUTION !
The use of an ill-tting spanner will damage the nozzle
and could lead to an incorrect ame pattern and poor
combustion.
! NOTE !
Ensure that the nozzle is securely tightened so that it does
not leak but DO NOT OVER TIGHTEN!
5. Re-t the diffuser/electrode assembly. Refer to Figure 10-3.
• Reconnect ignition leads (4) to electrodes.
• Re-t the diffuser/electrode assembly (5) onto the nozzle
holder lining up the xing screws with the recess in the
nozzle holder.
• Ensure diffuser assembly is tted down hard onto the
shoulder on the nozzle holder.
• Tighten the xing screw (3) to secure the diffuser/
electrode assembly in place on the nozzle holder.
Section 10: Commissioning Page 37
Page 38
! NOTE !
A
1
D
! NOTE !
Do not overtighten the xing screw as this may damage
the electrode insulator.
±0.3
B
±0.5
A
Figure 10-4: Ignition electrode settings
Model A B C
Combi 21 and 26
Combi XS 26
Combi 36 4.5 3 2 - 2.5
6. Check/adjust electrode setting. Refer to Figure 10-4.
7. Re-t the burner head. Refer to Figure 10-4.
• Locate the head xing screws (5) in the countersunk
slots in the burner collar.
• Check that the small oil drip hole (on the head) is
pointing downwards.
• Tighten the two screws (1) to secure the head (2) in
position on the burner.
8. Adjust the diffuser position. Refer to Figure 10-5.
7 2.5 2.5 - 3
The distance between the end of the burner head and the
front face of the diffuser (D) MUST be correctly set for the
burner to operate correctly.
• Refer to Table 2-2 for the required distance (head
setting) for the boiler output required.
• Check the distance D using the gauge plate supplied
with the boiler.
• To use the gauge plate:
- Position the gauge plate on the burner head as
shown in Figure 10-5.
- Locate the gauge plate with the correct steps
C
• To adjust the diffuser position:
(i.e. the two marked with the required distance D)
resting on the edge of the burner head.
- Check the gauge plate is at 90° to the end of the
burner head and is positioned at the full diameter of
the head.
- If distance D is correct is correct, the tongue of
the gauge plate should just make contact with the
diffuser with BOTH steps still in contact with the
edge of the burner head.
- If the steps are not in contact with the edge of the
burner head when the tongue of the gauge plate is
touching the diffuser, the diffuser must be ‘opened’
(see below).
- If the tongue does not reach the diffuser when the
steps are in contact with the edge of the burner
head, the diffuser must be ‘closed’ (see below).
- If necessary, adjust distance D using the black
adjustment knob located around the oil supply pipe
on the front of the burner. Refer to item A (Figure
10-5). Re-check distance D using the gauge plate,
as described above.
- For easier access to the adjustment knob, pull the
photocell out from the burner housing.
- To increase distance D (to open the diffuser): rotate
the knob clockwise - indicated as ‘+’ on the knob.
- To decrease distance D (to close the diffuser):
rotate the knob anti-clockwise - indicated as ‘-’ on
the knob.
Figure 10-5: Diffuser position and gauge plate
! NOTE !
One full rotation of the adjustment knob is approximately
1mm of diffuser movement.
! NOTE !
It is essential that the nal position of the diffuser is
checked, using the gauge plate provided with the boiler
and the diffuser adjusted as necessary to achieve the
required distance D.
9. For Combi 21 models only:
Check the burner air adjuster disc is correctly set. Refer to
Section 10.3.
Section 10: CommissioningPage 38
Page 39
10.3 AIR ADJUSTER DISC – COMBI 21
ONLY
The Riello RDB 2.2 BX burner tted to this boiler incorporates a
secondary air adjustment.
This is an air adjuster disc located on the fan housing (inside the
air inlet housing).
It is essential, for correct operation of the burner, that this internal
air adjuster disc is correctly set.
Refer to Figure 10-6.
To access the air adjuster disc:
1. Ensure the boiler is isolated from the electrical supply.
2. Remove the burner xing nut (located at the top of the
mounting ange) and withdraw the burner from the boiler.
3. Undo the two screws and remove the air inlet cover from the
side of the burner.
4. The air adjuster disc is mounted on the fan housing. Refer to
Figure 10.6.
5. Check that this disc is correctly set for the factory set output
of the boiler, i.e. with the correct cut-out marked located
against the moulded boss on the fan housing. Refer to Table
2-2 for correct disc settings. If the disc is not correctly set it
MUST be re-positioned. Refer to step 6 below.
6. The air adjuster disc is re-positioned as follows:
• Remove the screw from the centre of the air shutter
disc.
• Re-position the disc so that the correct cut-out is located
against the moulded boss on the fan housing.
• Replace the screw in the centre of the air shutter disc
and tighten.
7. Re-t the air inlet cover to the side of the burner and secure
in place using the two screws.
10.4 SWITCHING ON
1. Switch on the electricity supply to the boiler.
2. Set the boiler On/Off switch to ON. A neon on the switch
lights when it is in the ON position. Note that the neon lights
when the boiler is switched on, but does not necessarily
indicate the burner is ring.
Set both the Hot Water and Heating switches to ON. The
burner should then re. Open the vent screw on the vent
manifold to vent the supply while the oil pump is running
3. Fully open a hot tap and allow it to run for a few moments
to vent the internal primary circuit. The Hot Water pump will
operate and the burner should light within about 12 seconds.
If the burner does not light and the ‘Lock-out’ reset button
lights, wait for about 45 seconds then press the reset button
to restart the ignition process. This procedure may have to be
repeated during rst lighting.
4. Close the hot tap. The burner will continue to re to heat the
primary water in the boiler or primary store until the required
temperature is reached.
! NOTE !
Grant Vortex Combi boilers incorporate a “pump overrun”
feature, within the control circuit board, that operates as
follows:
• When reheating the Primary Hot Water store: the burner
will cut out when the boiler reaches 83°C (as detected by
the boiler “ow” thermistor).
• If there is a demand for Central Heating: the hot water
“store” pump will run on for 90 seconds before it stops and
the “central heating” pump then comes in.
• If there is no demand for Central Heating: the hot water
“store” pump will continue to run until the temperatures in
the Primary Hot Water store and the boiler have equalised.
The adjustable Boiler thermostat on the control panel
regulates the boiler temperature when in Heating mode
only. The recommended ow temperature setting is 70°C.
The Primary Hot Water store temperature is controlled via
the “store” thermistor and control circuit board. The control
thermostat has NO inuence on either the store temperature or
the hot water temperature at the tap.
Figure 10-6: Air adjuster disc
! NOTE !
The hot water pump will continue to run for a short period
after the burner has stopped.
The boiler will now be operating in the central heating mode.
! NOTE !
The burner may not re immediately in the central heating
mode.
5. With the burner alight, check the fuel pressure. Refer to
Section 2.2 (burner settings).
6. Adjust the pressure if necessary.
! NOTE !
It is important that the oil pressure is correctly set.
7. Operate the boiler until it reaches normal operating
temperature. Check oil supply/return pipe for leaks, rectifying
where necessary.
8. Check the operation of the boiler thermostat. Ensure that by
turning it anticlockwise it switches the burner off.
9. With the burner alight, re-check the fuel pressure and readjust if necessary. Turn the boiler off, remove the pressure
gauge and replace the plug in the pump.
Section 10: Commissioning Page 39
Page 40
10. Ensure that there are no oil leaks, replace the burner cover.
11. On balanced ue installations - ensure the exible air inlet
tube is correctly connect to both the burner air inlet and the
ue system.
10.5 RUNNING THE BOILER
1. Relight the boiler and allow it to run for at least 20 minutes.
2. Check the smoke number, if it is 0-1 then it is satisfactory.
3. Using a calibrated electronic ue gas analyser, set to the
correct fuel, check the %CO2 in the ue gases.
4. Set the %CO2, as indicated on the ue gas analyser, to
the required value as given in Section 2.2 for the boiler
concerned.
5. Adjust the burner air damper, using the hexagonal key
supplied, to achieve the required %CO2. Refer to Figure 10-
3.
6. To increase the %CO2: Turn the screw anti-clockwise. This
will close down the burner air damper and decrease the
combustion air entering the burner.
To decrease the %CO2: Turn the screw clockwise. This will
open up the burner air damper and increase the combustion
air entering the burner.
7. When the %CO2 is set to the correct level, re-check the
smoke number if the burner air damper has been moved.
Under no circumstances must the smoke number be above
1.
! NOTE !
For safe and efcient operation of the boiler it is essential
that the air damper is correctly set to give the required
%CO2 in the ue gases.
10.6 BALANCING THE SYSTEM
1. When the boiler has been adjusted and is running
satisfactorily, balance the central heating system by adjusting
the radiator lock shield valves.
Start with the radiator nearest the boiler and adjust the
valves to achieve the required temperature drop across each
radiator.
If thermostatic radiator valves have been installed, check the
system bypass.
2. Switch off the boiler.
! CAUTION !
If there is any possibility of the boiler being left during
freezing conditions, then the boiler and system should be
drained. Alternatively, a suitable heating system antifreeze
should be used.
! NOTE !
To allow the boiler to be commissioned and serviced
correctly a combustion test point is provided on the front
cleaning door. Both the %CO2 and smoke test may all be
carried out using this test point.
This test point is NOT suitable for measuring boiler efciency or
conventional ue draught.
When using the test point on the cleaning cover note that the ue
gas temperature reading will be higher than that measured in the
ue thus resulting in an inaccurate efciency reading. To obtain an
accurate ue gas temperature and efciency, the reading can only
be measured outside through the low level ue terminal (or the
test point on the conventional ue starter section when used).
10.8 INFORMATION FOR THE USER
The User must be advised (and demonstrated if necessary) of the
following important points:-
• How to start and switch off the boiler and how to operate the
system controls.
• The precautions necessary to prevent damage to the central
heating system and to the building, in the event of the boiler
not being in operation during frost conditions.
• The importance of servicing the boiler to ensure safe and
efcient operation. This should normally be required only
once a year.
• The type of fuel used.
• That any servicing or replacement of parts must only be
carried out by a suitably qualied engineer.
• Ensure that the boiler controls and room thermostat (if tted)
are set to the User’s requirements.
• Tell the User the system pressure and show them the
position of the safety valve discharge pipe.
• Show the User how to reset the overheat thermostat and how
to restart the boiler if it goes to ‘Lockout’.
10.7 COMPLETION
1. With the system hot, check again for leaks, rectifying where
necessary. Drain the system while it is hot to complete the
ushing process. Rell and vent the sealed system.
2. A suitable central heating system inhibitor must be added to
protect the system against the effect of corrosion.
3. A suitable antifreeze should be used to prevent damage to
the boiler in areas where electrical power failure can occur in
winter months.
4. Replace the top, front and rear panels as necessary.
! NOTE !
After commissioning the boiler complete the OFTEC CD/11
commissioning report. Leave the top copy with the User
and retain the carbon copy.
If the boiler is to be left in service with the User, set the controls
and room thermostat (if tted) to the User’s requirements.
If the boiler is not to be handed over immediately, close the boiler
fuel supply valve and switch off the electricity supply.
Section 10: CommissioningPage 40
Page 41
11 SERVICING
To ensure safe and efcient operation it is essential that a Grant
Combi boiler is serviced at regular intervals of no longer than 12
months.
Servicing and replacement of parts must only be carried out by a
suitably qualied engineer.
! CAUTION !
Details of every service should be entered in the Service
Log, in the Boiler Handbook.
This information may be required to validate the Grant
extended guarantee.
! WARNING !
Before starting any work on the boiler or fuel supply,
please read the Health and Safety information given in
Section 15 of these Instructions.
11.1 CHECKS BEFORE SERVICING
The following sequence of checks should be made before starting
any servicing work:
1. Check the ue terminal and ensure it is not blocked or
damaged.
2. Run the boiler and check the operation of its controls.
3. Ensure that all water system connections and ttings are
sound. Remake any joints and check the tightness of any
ttings that may be leaking.
4. Allow the boiler and system to cool down.
5. If the boiler is part of a sealed central heating system, check
the system pressure, check the operation of the pressure
relief valve and check the expansion vessel air charge. Refer
to Section 7.
6. Rell, vent and re-pressurise the system as necessary. Refer
to Section 7.
7. Check that any ventilation openings are adequate of
adequate free area and are clear of obstructions. Refer to
Section 9.
8. Remove any sludge/water from the fuel tank by opening the
sludge valve at the lower end of the tank (if tted).
9. Ensure that all fuel system connections and ttings are
sound. Remake any joints and check the tightness of any
ttings that may be leaking.
10. With the fuel supply valve (at the oil tank) closed, clean/
replace the lter element and clean the lter bowl.
! WARNING !
Before servicing, set the boiler ON/OFF switch to OFF,
isolate the electricity supply and close the fuel supply
valve.
The data label on the inside of the case side panel will indicate
the fuel used and the nozzle tted.
11.2 DISMANTLING PRIOR TO
SERVICING
The procedure for dismantling the boiler is as follows:
1. Remove the front panel from the boiler (pull forward at the
top and lift off).
2. Carefully lift up the expansion vessel and remove it from
the boiler. Place it on the oor, taking care not to strain the
exible pipe.
3. Disconnect the exible air tube from the burner.
4. Unscrew and remove the two xing screws and remove the
red cover from the burner.
5. Remove the burner xing nut (located at the top of the
mounting ange) and withdraw the burner from the boiler. If
required, disconnect the exible oil line(s), using a suitable
container to prevent any oil spillage.
6. Check or replace the exible fuel supply hose, as follows:
• Braided exible fuel supply hoses (as supplied with the
boiler) should be replaced annually, i.e. when the boiler
is serviced.
• Long-life hoses should be inspected annually. If in doubt
replace the hose(s). In any event, these hoses must be
replaced every ve years.
! NOTE !
With a two-pipe oil supply there will be two exible hoses
connected to the burner. Identify (mark if necessary) which
is the inlet and return if they are to be disconnected.
11.3 CLEANING THE BOILER
The procedure for cleaning the boiler is as follows:
1. Remove the nuts and washers securing the front cleaning
door and withdraw the door. Take care - it is heavy.
2. Remove the bafes as shown in Figure 11-1, Figure 11-2 and
Figure 11-3.
3. Remove all deposits from the bafe plates and all the boiler
internal surfaces using a stiff brush and scraper if necessary.
4. Check the condition of the ue, clean as necessary.
5. Check the condition of the front cleaning door seal and
replace if necessary.
6. Replace the bafes, ensuring they are correctly tted. Refer
to Figures 11-1, 11-2 or 11-3, as appropriate. Pull out the
spiral turbulators from the heat exchanger tubes.
7. Clean the turbulators using a stiff brush.
8. Test the heat exchanger condensate drain by pouring water
into one of the lower tubes and observe whether the water
discharges from the 22 mm condensate outlet. Replace the
turbulators.
9. Replace the front cleaning door, ensuring the seal is in good
condition and secure it in position with the nuts and washers
previously removed. Tighten to form a seal.
10. Remove the condensate trap and check that it is not blocked
and is operating correctly, i.e. the oat is free to move. Clean
the trap and oat as required.
11. Check that the boiler condensate outlet is unobstructed.
Clean if necessary.
! NOTE !
The condensate trap and condensate outlet must be
checked on every service and cleaned as necessary.
The end cap is not sealed to the trap body and can be
removed for cleaning. Ensure that this cap is correctly re-
tted before re-starting the boiler.
Section 11: Servicing Page 41
Page 42
Figure 11-1: Bafes in Vortex Pro Combi 21
Position in vertical plane
Figure 11-3: Bafes in Vortex Pro Combi 36
IMPORTANT:
The ends of the
turbulators must
be vertical
Figure 11-2: Bafes in Vortex Pro Combi 26
Figure 11-4: Turbulators in Vortex Pro Combi boilers
Section 11: ServicingPage 42
Page 43
11.4 CLEANING THE BURNER
With the burner removed from the boiler:
Burner head, nozzle and diffuser/electrode assembly
1. Remove the burner head. Refer to Figure 10-3. Loosen both
xing screws (1) and remove head (2) from burner.
2. Clean the combustion head.
3. Remove diffuser/electrode assembly. Refer to Figure 10-3.
• Using a 4 mm Allen key, loosen the diffuser xing screw
(3) from electrode assembly.
• Lift diffuser/electrode assembly (5) up and off the nozzle
holder.
• Disconnect both ignition leads (4) from the electrodes.
4. Replace the nozzle (8). The nozzle should always be
replaced on an annual service. Refer to Table 2-2 for the
correct nozzle size and type for the required boiler output. Do
NOT attempt to clean the nozzle.
• Use a 16 mm spanner to remove/re-t the nozzle, whilst
holding the nozzle holder using a 19 mm spanner.
! CAUTION !
The use of an ill-tting spanner will damage the nozzle
and could lead to an incorrect ame pattern and poor
combustion.
! NOTE !
Ensure that the nozzle is securely tightened so that it does
not leak but do not overtighten.
5. Inspect the ignition electrodes - remove the diffuser xing
screw and withdraw the electrode assembly. Wipe clean and
check for any cracks in the ceramic insulation. Replace if
necessary.
6. Re-t the diffuser/electrode assembly. Refer to Figure 10-3.
• Reconnect ignition leads (4) to electrodes.
• Re-t the diffuser/electrode assembly (5) onto the nozzle
holder lining up the xing screw with the recess in the
nozzle holder.
• Ensure diffuser assembly is tted down hard onto the
shoulder on the nozzle holder.
• Tighten the xing screw (3) to secure the diffuser/
electrode assembly in place on the nozzle holder.
Burner air inlet cover
This is located on the right hand side of the burner. Refer to
Section 11.8 (burner components).
1. Unscrew and remove the two screws and remove the air inlet
cover from the burner.
2. Check inside and remove any debris, leaves, hair, uff, etc.
from the air inlet cover and air damper..
3. Check the condition of the rubber seal around the air inlet
cover. Replace if damaged or missing.
Burner fan housing
This is located over the fan impeller. Refer to Section 11.8 (burner
components).
With the Burner air inlet cover already removed:
1. Unscrew and remove the four screws and remove the fan
housing from the burner.
2. Check and clean the fan impeller and remove any debris,
leaves, hair, uff etc.
3. Check/clean the fan housing is clean.
4. Check the rubber seal around the fan housing. Replace if
damaged or missing.
5. Re-t the fan housing to the burner and secure with the four
screws.
6. Check the air adjuster disc (Combi 21 only). Refer to Section
11.6 for details.
7. Re-t the air inlet cover to the burner and secure with the two
screws.
Oil pump lter
This is located under the end cover on the oil pump. Refer to
Section 11.8 (burner components).
1. Unscrew and remove the four cap screws securing the pump
end cover.
2. Remove the lter and wash in kerosene.
3. Check the O-ring seal around the end cover. Replace if
damaged.
4. Replace the lter and end cover.
5. Re-t the four cap screws, tightening evenly, to secure the
end cap.
! NOTE !
Do not overtighten the xing screw as this may damage
the electrode insulator.
7. Check/adjust the electrode settings. Refer to Figure 10-4.
Always check the electrode settings after replacing the
nozzle.
8. Re-t the burner head. Refer to Figure 10-3.
• Locate the head xing screws (5) in the countersunk
slots in the burner collar.
• Check that the small oil drip hole (on the head) is
pointing downwards.
• Tighten the two screws (1) to secure the head (2) in
position on the burner.
Photocell
The photocell is a push-t in the front of burner body. Refer to
Section 11.8 (burner components).
1. Holding the body of the photocell (4) and NOT the cable,
carefully pull the photocell out of the burner.
2. Clean the sensor end of the photocell.
3. Replace photocell back in the burner and check that it is fully
pushed in.
.
Section 11: Servicing Page 43
Page 44
11.5 ADJUSTING THE DIFFUSER
Adjust the diffuser position. Refer to Figure 10-5.
! NOTE !
The distance between the end of the burner head and the
front face of the diffuser (D) MUST be correctly set for the
burner to operate correctly.
• Refer to Table 2-2 for the required distance (head setting) for
the boiler output required.
• Check the distance D using the gauge plate supplied with the
boiler.
• To use the gauge plate:
- Position the gauge plate on the burner head as shown in
Figure 10-5.
- Locate the gauge plate with the correct steps (i.e. the
two marked with the required distance D) resting on the
edge of the burner head.
- Check the gauge plate is at 90° to the end of the burner
head and is positioned at the full diameter of the head.
- If distance D is correct is correct, the tongue of the
gauge plate should just make contact with the diffuser
with BOTH steps still in contact with the edge of the
burner head.
- If the steps are not in contact with the edge of the burner
head when the tongue of the gauge plate is touching the
diffuser, the diffuser must be ‘opened’ (see below).
- If the tongue does not reach the diffuser when the steps
are in contact with the edge of the burner head, the
diffuser must be ‘closed’ (see below).
• To adjust the diffuser position:
- If necessary, adjust distance D using the black
adjustment knob located around the oil supply pipe on
the front of the burner. Refer to item A (Figure 10-5). Recheck distance D using the gauge plate, as described
above.
- For easier access to the adjustment knob, pull the
photocell out from the burner housing.
- To increase distance D (to open the diffuser): rotate the
knob clockwise - indicated as ‘+’ on the knob.
- To decrease distance D (to close the diffuser): rotate the
knob anti-clockwise - indicated as ‘-’ on the knob.
11.6 AIR ADJUSTER DISC – COMBI
21 ONLY
The Riello RDB 2.2 BX burner tted to this boiler incorporates a
secondary air adjustment.
This is an air adjuster disc located on the fan housing (inside the
air inlet housing).
It is essential, for correct operation of the burner, that this internal
air adjuster disc is correctly set.
Refer to Figure 10-6.
To access the air adjuster disc:
1. Ensure the boiler is isolated from the electrical supply.
2. Remove the burner xing nut (located at the top of the
mounting ange) and withdraw the burner from the boiler.
3. Undo the two screws and remove the air inlet cover from the
side of the burner.
4. The air adjuster disc is mounted on the fan housing. It should
be xed in position ‘C’ – i.e. with the cut-out marked ‘C’
located against the moulded boss on the fan housing. Refer
to Figure 10-6.
5. If the disc is not set to position ‘C’ it must be re-positioned as
follows:
• Remove the screw from the centre of the air shutter disc.
• Re-position the disc so that the cut-out ‘C’ is located
against the moulded boss on the fan housing.
6. Replace the screw in the centre of the air shutter disc and
tighten.
7. Re-t the air inlet cover to the side of the burner and secure
in place using the two screws.
11.7 RECOMMISSIONING
! WARNING !
To ensure safe and efcient operation of the boiler it is
important that recommissioning is carried out, especially
combustion checks (%CO2 level, ue gas temperature and
smoke number) after the boiler has been serviced. Refer to
the Commissioning instructions in Section 10.
! NOTE !
One full rotation of the adjustment knob is approximately 1
mm of diffuser movement.
! NOTE !
It is essential that the nal position of the diffuser is
checked, using the gauge plate provided with the boiler
and the diffuser adjusted as necessary to achieve the
required distance D.
Section 11: ServicingPage 44
Page 45
11.8 BURNER COMPONENTS
11.8.1 COMBI XS 26, COMBI 21, COMBI 26 AND COMBI 36
(RIELLO RDB 2.2 BX)
101743
8
5
16
6
2
9
1
13
11 15 12
Item Description Item Description
1 Oil pump 10 Air inlet
2 Air damper adjustment screw 11 Motor
3 Reset button with lockout lamp 12 Motor ignition capacitor
4 Photocell 13 Fuel suction line
5 Control box 14 Return line
6 Pump pressure adjustment screw 15 Combustion head adjustment handle
7 Extension for gauge connection 16 Coil
8 Combustion head 17 Air pressure test point
9 Flange with insulating gasket
14
7
Section 11: Servicing Page 45
Page 46
12 FAULT FINDING
12.1 INITIAL CHECKLIST - FOR INSTALLERS OR SERVICE ENGINEERS
12.1.1 IF THE BOILER FAILS TO LIGHT
First follow the procedure below
Check that the fused spur for the heating system is switched on.
Power supply
Heating system controls
Boiler controls
Burner
If burner still fails to light Follow the ‘burner not operating’ procedure in Section 12.2 (C).
12.1.2 FOR HOT WATER - ALL THE FOLLOWING INDICATOR LIGHTS MUST BE LIT
POWER
DHW PUMP
FLOW
DEMAND
BURNER
NOTE: There may be a delay before the ‘burner’ indicator is lit when the store is up to temperature
Check that the fuse has not blown.
Check that the electricity supply has not failed; check circuit breaker in consumer unit.
Check that the timer or programmer is working and set to an ‘ON’ period.
Check that all thermostats are set to the required temperature and are ‘calling’ for heat.
Check that the boiler ‘ON/OFF’ switch is set to ‘ON’.
Check that the ‘POWER’ deman indicator on the control panel is lit.
Check that the ‘DEMAND’ indicator is lit.
Check if the burner lockout reset button (on front face of burner) is lit.
If YES: press in the reset button to start the burner.
If burner fails to light and goes to lockout again, refer to Section 12.4.
If not lit, this indicates a problem with the power supply to the boiler - switched off or
possibly blown a fuse.
If ashing, this indicates either a ‘store’ thermistor or PCB fault.
Refer to the ‘is the DHW PUMP idicator ashing’ procedure in Section 12.2 (B).
If not lit when a hot tap is opened, this indicates either a lack of water ow or possible
ow switch problem.
If not lit, this indicates either timer/programmer is not ‘calling’ for hot water or ‘hot water’
switch is not set to ‘constant’.
If ashing, this indicates a PCB fault.
Refer to the ‘is the burner indicator lit’ procedure in Section 12.2 (B).
12.1.3 FOR NIGHT TIME HOT WATER FUNCTION - ALL THE FOLLOWING INDICATOR LIGHTS MUST BE
LIT
POWER
DHW PUMP
FLOW
DEMAND
BURNER
NOTE: The ‘DHW PUMP’ indicator may be lit if the boiler is operating to heat the store which has priority over the central heating operation.
There may be a delay before the ‘BURNER’ indicator is lit when the store is up to temperature.
For further guidance, refer to Section 12.2 (main fault nding procedures).
If not lit, this indicates a problem with the power supply to the boiler - switched off or
possibly blown a fuse.
If ashing, this indicates either a ‘store’ thermistor or PCB fault.
Refer to the ‘is the DHW PUMP indicator ashing’ procedure in Section 12.2 (B).
If not lit when a hot tap is opened, this indicates either a lack of water ow or possible
ow switch problem.
If not lit, this indicates either timer/programmer is not ‘calling’ for hot water or ‘hot water’
switch is not set to ‘constant’.
If ashing, this indicates a PCB fault.
Refer to the ‘is the burner indicator lit’ procedure in Section 12.2 (B).
Section 12: Fault FindingPage 46
Page 47
12.2 MAIN FAULT FINDING PROCEDURES
A NO CENTRAL HEATING - BUT HOT WATER OK
First, set the hot water switch to OFF
Is the ‘DEMAND’ indicator
lit?
Is the ‘CH PUMP’ indicator
lit?
Is the ‘CH PUMP’ indicator
lit?
Is the ‘CH PUMP’ indicator
ashing?
If the ‘CH PUMP’ indicator
continues ashing?
Is the ‘BURNER’ indicator
lit?
NO Check programmer/timer and room thermostat are calling for heating.
NO Checking ‘heating’ switch is set to ‘TIMED’.
YES
PCB is supplying voltage to
the CH pump but the pump
is not working.
YES
CH pump is not but there is
no circulation.
NO
YES
Fast or slow ash
Fast ash
(twice per second):
Indicates a possible fault
with the ‘ow’ thermistor.
Slow ash
(once every 2 seconds):
Indicates a possible fault
with the PCB relay.
YES
Check electrical connections at the pump.
Check for 230V at the pump terminals.
Check if CH pump is stuck:
• Check for rotation of shaft/impellar.
• If still not operating, replace the CH pump.
Check both pump valves are open.
Check non-return valve on CH pump is operational (not sticking).
Check there are no air locks in the system (if removal of air is difcult - see additional
check list).
Check the non-return valve on the CH pump - is it stuck blocked open - check/rectify.
NOTE: CH return will be botter than ow if CH non-return valve is jammed open.
Check by closing one heating pump valve to stop circulation - does the store then come
up to temperature?
If the problem is not due to CH non-return valve - continue to the next check.
First, set boiler ‘ON/OFF’ switch to ‘OFF’.
Wait 5 seconds
Then set ‘ON/OFF’ switch back to ‘ON’.
Check CH ‘ow’ thermistor connection to the PCB.
Replace ‘ow’ thermistor.
Replace PCB
Is the burner ring?
If no: refer to ‘burner not operating’ procedure in Section 12.2 (C).
Section 12: Fault Finding Page 47
Page 48
B NO CENTRAL HEATING - BUT CENTRAL HEATING OK
First, set the heating switch to OFF
Is the ‘DEMAND’ indicator
lit?
Is the ‘FLOW SWITCH’
indicator lit?
Is the ‘FLOW SWITCH’
indicator lit?
Is the ‘DHW PUMP’
indicator lit?
Is the ‘DHW PUMP’
indicator ashing?
If the ‘DHW PUMP’ indicator
continues ashing.
Is the ‘DHW PUMP’
indicator lit?
Is the ‘BURNER’ indicator
lit?
NO
NO Check ‘heating’ switch is set to ‘TIMED’.
NO
Cannot achieve 3 litres/
minute
Is the water pressure OK?
Low water pressure = low
water ow rate.
If water pressure is OK.
Is plate heat exchanger is
OK.
YES
NO Continue to next check.
YES
Fast or slow ash
Fast ash
(twice per second):
Indicates a possible fault
with the ‘store’ thermistor.
Slow ash
(once every 2 seconds):
Indicates a possible fault
with the PCB (relay).
YES
PCB is supplying voltage to
the DHW pump - but pump
is not working.
YES
DHW pump is working but
no circulation.
YES
DHW pumpis working and
water is circulating.
YES
Check programmer is calling for hot water.
If no programmer is tted: check ‘hot water’ switch is set to ‘CONSTANT’.
Check hot water tap is open.
Check water ow rate is at least 3 litres/minute.
Check the mains stop tap is open fully.
Check the cold water isolation valve in the boiler is open.
Check if the ow restrictor (located in the cold water isolation valve) is clear.
If not, clean restrictor or remove from valve.
NOTE: No ow restrictor is tted to the Combi 36 model.
Check standing water pressure.
2 bar minimum standing pressure required.
Check running (dynamic) pressure.
1 bar minimum dynamic pressure required.
Check for blockage in plate heat exchanger unit.
NOTE: In hard water areas, scale will be produced that can block the plate heat
exchanger if no anti-scale protection has been installed.
Refer to Section 5 for further details.
Check ow switch is correctly positioned: the arrow (on ow switch body) must point in
the direction of ow, i.e. toward the front of boiler.
Check switch is free to operate: close cold water isolation valve, remove ow switch from
pipework - manually operate switch paddle to check.
Remove any debris/blockage from the pipework body or switch paddle.
Check for electrical continuity between ow switch terminals when switch is closed.
No continuity - replace ow switch.
No 230V - check connections at PCB.
If still no 230V - replace PCB.
Flow switch is activated.
Continue to the next check.
First, set boiler ‘ON/OFF’ switch to ‘OFF’.
Wait 5 seconds.
Then set ‘ON/OFF’ switch back to ‘ON’.
Check DHW ‘store’ thermistor connection to PCB.
Replace ‘store’ thermistor.
Replace PCB.
Check for electrical connections at the pump.
Check for 230V at the pump terminals.
Check if CH pump is stuck:
• Check for rotation of shaft/impeller.
• If still not operating, replace the DHW pump.
Check both pump valves are open.
Check non-return valve on DHW pump is operational (not sticking).
Check there are no air locks in the system (if removal of air is difcult - see additional
check list).
Hot or warm water should be present at hot tap.
If not: refer to ‘poor hot water’ procedure in Section 12.3.
Is burner ring?
If no: refer to ‘burner not operating’ procedure in Section 12.2 (C).
Section 12: Fault FindingPage 48
Page 49
C BURNER NOT OPERATING
First, set either hot water or heating to ON
Is the ‘BURNER’ indicator
lit?
Is the ‘BURNER’ indicator
ashing?
If the ‘BURNER’ indicator
continues ashing.
Is the ‘BURNER’ indicator
lit?
NO Refer to ‘initial checklist’ for guidance.
NO Continue to next check.
YES
Fast or slow ash.
Slow ash
(once every 2 seconds):
Indicates a possible fault
with the PCB (relay).
YES
PCB is supplying voltage to
the burner - but the burner
is not working.
First, set boiler ‘ON/OFF’ switch to ‘OFF’.
Wait 5 seconds
Then set ‘ON/OFF’ switch back to ‘ON’.
Replace PCB
Check all electrical connections to burner control box.
Check for 230V at L and N terminals in control box.
Is ‘lockout’ button (on control box) lit?
If yes: press ‘lockout’ button to reset burner.
If burner does not re, refer to Section 12.4 (burner fault nding).
12.3 POOR HOT WATER CHECKLIST
Always check the basics before changing parts.
Burner
DHW pump
Thermistors
Water ow rate at hot tap
Water pressure
Water condition
Thermostatic blending valve
If heat energy input is
incorrect: heat energy
output will be incorrect.
Poor heat input = poor hot
water.
Plate heat exchanger
requires water circulation
from primary store to
operate.
DHW ‘store’ and CH ‘ow’
thermistors must detect
temperatures correctly.
Excessive ow rate
exceeds heat input from
burner.
Excessive ow rate = poor
hot water.
Excessive pressure has a
major inuence on ow rate.
Scale forming in the plate
heat exchanger = poor heat
transfer in plate = poor hot
water temperature.
Must be correctly set to
provide optimum hot water.
Check nozzle is correct size.
Check oil pump pressure is correct.
Check combustion is correctly set.
Check pump speed setting: it must be maximum.
Check pump valves are fully open.
Check both are fully inserted in their pockets.
Check ow rate at tap.
Combi XS 26 = 15 litres/minute maximum.
Combi 21 = 12 litres/minute maximum.
Combi 26 = 15 litres/minute maximum.
Combi 36 = 18 litres/minute maximum.
Check standing and operating water pressure.
2 bar minimum standing pressure required.
8 bar maximum standing pressure.
If greater than 8 bar; t a pressure reducing valve on the cold supply to the boiler.
1 bar minimum dynamic pressure required.
Check for scale in the plate heat exchanger.
Replace plate heat exchanger if necessary.
In hard water areas some form of anti-scale device or water softener must be tted.
NOTE: Faults due to hard water scaling are not covered by the product guarantee.
Check if blending valve is scaled up (refer to ‘water condition’ above).
Clean or replace as necessary.
Section 12: Fault Finding Page 49
Page 50
12.4 BURNER FAULT FINDING - RIELLO RDB BURNERS
noitsubmoC
head set
SEY
noitsubmoC
tes ria
SEY
gnisimota
elzzoN
SEY
pmuP
produces
SEY
fuel
ON
ON
pressure
fo emalF f
and
SEY
ecalpeR
ON
dioneloS
evlav
SEY
W gnihsa
pressure
sthgiler
ON
elzzon
ON
gnitarepo
SEY
ON
1 to 2 bar
ro relioB
eulf
detanimatnoC
ro leuf
lio kcehC
pressure
gnilpuoc
evirD
dekcolb
retlif
rotaluger
ON
broken
lioc ecalpeR
ro riapeR
evlav mets
and/or
pmup lio
ecalper
,eulf decnalab fI
ecalpeR
SEY
llecotohP
ebut ria evomer
and retest
box
control
sound ***
eulf noitisoper ro
laeseR
ecnalab eulf d
OK
llecotohp
ecalpeR
ON
SEY
noitingI
spark
proved
SEY
purge
Lockout
after 12 sec
nihtiw
Lockout
1 second
SEY ON
SEY
dna kcehC
sedortcele
ON
riapeR
ON
SEY
Motor/pump
SEY
ON
set the
ecalper ro
motor/pump
thgit ro
dezies
ON
ecalpeR
ecalpeR
xob lortnoc
the
roticapac
motor
V CA
35 - 05 snruter eriw etihw rotoM
dionelos
fo lioC
ON
sound **
SEY
eriw etihw ot
sevig rotoM
*
ON
50 V stlo
ecalpeR
ecalpeR
dionelos
lioc
motor
burner
si ti fi llecotohp eht ecalper ot tseb si tI
neht dna serif renrub fI .xob lortnoc
suac stcudorp eulf etalucricer gni
dn
a noitisop eulf kcehc .gnilaes
.xob lortnoc ot
uokcol ot seog eb dluohs llecotohp ,t
alab no srenruB nac smetsys eulf decn
ilcycer renrub ,sneppah siht fI .gn
renruB
motor runs
slortnoc
kcehC
reliob
kcehC &L N
ON SEY
box
ON
to control
setoN
T ioc dionelos tse 001 ro ytiunitnoc rof l
T ocsid yb llecotohp tse ni ti gnitcenn
ohms.
***
**
*
suspect.
Section 12: Fault FindingPage 50
.decalper
Page 51
13 SPARE PARTS
13.1 RIELLO RDB 2.2 BX BURNERS
This section gives exploded views of the Riello burners in the Grant Vortex boilers, and parts lists associated with them.
30
41
8
14
28
28
31
9
28
10
35
47
44
33
20
38
A
39
11
24
18
22
6
45
7
3
5
25
2
32
1
4
28
26
29
34
27
23
12
43
40
42
40
46
13
34
A
15
42
21
37
19
36
17
16
42
48
Section 13: Spare Parts Page 51
Figure 13-1: Riello RDB 2.2 BX burner exploded diagram
Page 52
Description Riello product code Grant product code
• Electrode 20018693 Z20018693
36
Combi
26
Combi
21
Combi
XS 26
Combi
Key No.
2 • • • • Combustion head 20147320 Z20147320
1 • • • • Flange gasket 3005787 RBS27
• • • Electrode 20018545 Z20018545
3
• Diffuser disc 20133586 Z20133586
• • • Diffuser disc 20139837 Z20139837
4
5 • • • • Nozzle holder 20133588 Z20133588
Table 13-2: Riello RDB 2.2 BX burner parts list
8 • • • • Air damper assembly 20089768 Z20089768
7 • • • • High voltage lead 20119415 Z20119415
6 • • • • Collar 20141540 Z20141540
9 • • • • Fan 3005788 RBS151
10 • • • • Flame sensor 20132526 Z20132526
11 • • • • Capacitor 20071576 RBS149A
12 • • • • Needle valve 3007871 RBS109
14 • Air damper 20094349 Z20094349
13 • • • • Regulator 3008651 Z3008651
16 • • • • O-ring 3007175 RBS08
15 • • • • Circulating pump 20030953 RBS101
18 • • • • Connector 3003602 RBS35
17 • • • • O-ring and lter 3020436 RBS122
20 • • • • Tube 20018549 Z20018549
19 • • • • Hose 3005720 Z3005720
22 • • • • Coupling 3000443 RBS16
21 • • • • Extension 3008876 RBS138
23 • • • • Coil 3008648 RBS117
25 • • • • Protection 3008649 Z3008649
24 • • • • Motor and capacitor 20071577 RBS102A
Section 13: Spare PartsPage 52
27 • • • • Connection 3008851 RBS139
26 • • • • Control box 3008652 RBS103
30 • • • • Air intake 3020281 Z3020281
29 • • • • Front shield 3020306 Z3020306
28 • • • • Seals kit 20040600 Z20040600
32 • • • • Front piece 3006384 RBS119
31 • • • • Bulkhead 20081612 Z20081612
Page 53
Description Riello product code Grant product code
36
Combi
26
Combi
21
Combi
XS 26
Combi
48 • • • • Gauge plate - Contact Grant UK
47 • • • • Index 20147023 Z20147023
46 • • • • Coil 3007565 Z3007565
45 • • • • O-ring 3007178 RBS31
44 • • • • O-ring 3007167 Z3007167
43 • • • • O-ring seal 3007028 Z3007028
42 • • • • O-ring 3007177 Z3007177
41 • • • • Seal 3020086 Z3020086
40 • • • • Seal 3007087 Z3007087
39 • • • • Connection 20140287 Z20140287
38 • • • • Knob 20134372 Z20134372
37 • • • • Connector 3020076 Z3020076
36 • • • • Bypass screw 20029299 RBS56P
35 • • • • Screw 20119098 Z20119098
34 • • • • Shell and knob 3007566 Z3007566
33 • • • • Cover 3008879 RBS141
32 • • • • Front piece 3006384 RBS119
Key No.
Table 13-2: Riello RDB 2.2 BX burner parts list (continued)
Section 13: Spare Parts Page 53
Page 54
14 DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY
In accordance with BS EN ISO/IEC 17050-1:2004
We: Grant Engineering (UK) Limited
Of: Hopton House
Hopton Industrial Estate
Devizes
SN10 2EU
Telephone: +44 (0)1380 736920
Fax: +44 (0)1380 736991
Email: info@grantuk.com
Website: www.grantuk.com
Declare that:
Equipment: Domestic oil boilers
Model Name/Number: Grant Vortex Pro Combi XS 26, 21, 26 and 36
Indoor
Note: All Grant Combi variants are supplied with glandless high efciency integrated circulators
In accordance with the following Directives:
2006/95/EEC Conforms with the safety objectives of the Low Voltage Directive and its amending directives.
2004/108/EC Conforms with the essential protection requirements of the Electromagnetic Compatibility
Directive and its amending directives.
92/42/EC Conforms with the requirements of the Boiler Efciency Directive.
2010/30/EU Conforms with the Labeling of Energy related products to EU (no) 811/2013
2009/125/EC Conforms with the Ecodesign of Energy related products to EU (no) 813/2013
I hereby declare that the equipment named above has been tested and found to comply with the relevant sections of the above
referenced specications. The unit complies with all essential requirements of the Directives.
Responsible Person: Neil Sawers
Position: Technical Manager
Signature:
Date: 23rd September 2016
Section 14: Declaration of ConformityPage 54
Page 55
15 HEALTH AND SAFETY INFORMATION
Under the Consumer Protection Act 1987 and Section 6 of the
Health & Safety at Work Act 1974, we are required to provide
information on substances hazardous to health (COSHH
Regulations 1988).
Adhesives, sealants and paints used in the manufacture of the
product are cured and present no known hazards when used in
the manner for which they are intended.
The following other materials are present in the product:
15.1 INSULATION MATERIALS
Material Types:
Ceramic bre board, mineral wool.
Description:
Rigid board, slabs, sleeves, gaskets, ropes.
Known Hazards:
May cause temporary irritation or rash to skin. High dust levels
may irritate eyes and upper respiratory system.
Precautions:
Avoid unnecessary or rough handling, or harsh abrasion of
boards. Normal handling and use of material should not produce
high dust levels.
Avoid inhalation, and contact with skin and eyes.
After handling always follow normal good hygiene practices.
Protection:
Use disposable gloves, face mask and eye protection.
First Aid:
Eyes - If irritation occurs, wash eyes with copious amounts of
water.
If symptoms persist, seek immediate medical advice.
Skin
If irritation occurs, wash under running water before washing with
soap and water.
Inhalation
Remove to fresh air, drink water to clear throat and blow nose to
remove dust/bres.
Ingestion
Drink plenty of water.
15.3 KEROSENE AND GAS OIL FUELS
(MINERAL OILS)
Known Hazards:
The effect of mineral oils on the skin vary according to the
duration of exposure and the type of oil.
The lighter fractions remove the protective grease naturally
present on the skin, leaving it dry, liable to crack and more prone
to damage by cuts, abrasions and irritant chemicals.
Skin rashes (Oil acne) most often on arms, but also on any part of
the body in contact with oil or oily clothing.
Contact with fuel oils can cause dermatitis.
Precautions:
Avoid as far as possible any skin contact with mineral oil or with
clothing contaminated with mineral oil.
The use of a lanolin-based barrier cream is recommended, in
conjunction with regular washing with soap and rinsing with water
to ensure all oil is removed from the skin.
Take care to prevent clothing, especially underwear, from
becoming contaminated with oil.
Do not put oily rags or tools in pockets, especially trouser pockets.
Have rst-aid treatment at once for an injury, however slight.
Do not inhale any vapours from mineral oils.
15.2 SEALANT AND ADHESIVE
Material Types:
Silicone elastomer.
Description:
Sealant and adhesive.
Known Hazards:
Irritation to eyes.
Precautions:
Avoid inhalation of vapour, contact with eyes and prolonged or
repeated contact with skin.
After handling always follow normal good hygiene practices.
Protection:
Use eye protection. Rubber or plastic gloves should be worn
where repeated contact occurs and a face mask worn when
working in conned spaces.
First Aid:
Eyes
Flush eyes with water for 15 minutes. Seek immediate medical
attention.
Skin
Wipe off and wash with soap and water.
Inhalation
Remove to fresh air.
Section 15: Health and Safety Information Page 55
Page 56
16 END OF LIFE INFORMATION
GENERAL
Grant oil boilers incorporate components manufactured from a variety of different materials. The majority of these materials can be
recycled whilst the smaller remainder cannot.
Materials that cannot be recycled must be disposed of according to local regulations using appropriate waste collection and/or disposal
services.
DISASSEMBLY
There is little risk to those involved in the disassembly of this product. Please refer to and follow the
Health and Safety Information given in the Installation & Servicing Instructions provided with the boiler.
For guidance on the disassembly of the boiler refer to the information given in the Servicing section of the Installation & Servicing
Instructions provided with the boiler.
RECYCLING
Many of the materials used in Grant oil boilers can be recycled, these are listed in the table below:
COMPONENT MATERIAL
Outer casing panels Mild steel (polyester powder coated)
Primary heat exchanger and bafes Mild steel
Secondary heat exchanger Stainless steel
Secondary heat exchanger spirals Aluminium alloy
Pipework Copper
Burner body/ange Aluminium alloy
Burner oil pump Aluminium alloy/steel
Riello oil burner cover Plastic
Electrical wiring Copper/plastic
Thermostats Copper/plastic
Printed Circuit boards Copper/plastic
DISPOSAL
All materials other than those listed above must be disposed of responsibly as general waste.
Neil Sawers
Technical Manager
Grant Oil Boiler Fiche V1.9 21/02/2017
Section 16: End of Life InformationPage 56
Page 57
17 PRODUCT FICHE
Product che concerning the
COMMISSION DELEGATED REGULATIONS
(EU) No 811/2013 of 18 February 2013
(EU) No 813/2013 of 2 August 2013
Vortex Pro Combi Symbols Unit
Combi XS 26
Combi 21
Condensing boiler Yes Ye s Yes Yes
Low temperature boiler No No No No
B1 boiler No No No No
Combination heater Yes Ye s Yes Yes
Rated heat output Prated kW 26 21 26 36
Useful heat output
At rated heat output and high temperature regime P
At 30% of rated heat output and low temperature regime P
4
1
kW 26 21 26 36
kW 8.3 6.3 7.8 10.8
Auxiliary electricity consumption
At full load elmax kW 0.167 0.158 0.13 0.15
At part load elmin kW 0.049 0.052 0.052 0.039
In standby mode P
SB
kW 0.001 0.009 0.009 0.009
Declared load prole XL XL XL XL
Daily electricity consumption Q
elec
0.269 0.293 0.23 0.205
Annual electricity consumption AEC 59.2 65.4 50.5 45.2
Useful efciency
Seasonal space heating energy efciency ƞs % 92.00 90.81 91.71 94.56
At rated heat output and high temperature regime ƞ
At 30% of rated heat output and low temperature regime ƞ
4
1
% 91.92 88.9 93.6 95.1
% 97.64 97.1 96.4 99.3
Other items
Standby heat loss P
Ignition burner power consumption P
Annual energy consumption Q
Sound power level indoors L
Emissions of nitrogen oxides NO
stby
ign
HE
WA
X
kW 0.135 0.23 0.264 0.522
kW 0 0 0 0
kWh - - - -
dB 49.6 50.6 50.6 53.7
mg / kWh <120 <120 <120 <120
Emission class 2 2 2 2
Water heating efciency ƞ
Daily fuel consumption Q
wh
fuel
% 68.11 68.23 62.6 60.38
kWh 27.3 27.2 30 31.1
Annual fuel consumption AFC GJ 21.6 21.556 26.673 24.67
Combi 26
Combi 36
Section 17: Product Fiche Page 57
Page 58
18 GUARANTEE
You are now the proud owner of a Grant Vortex condensing boiler
from Grant Engineering (UK) Limited which has been designed to
give years of reliable, trouble free operation.
Grant Engineering (UK) Limited guarantees the manufacture of
the boiler including all electrical and mechanical components for a
period of twelve months from the date of installation
4
, provided
that the boiler has been installed in full accordance with the
installation and servicing instructions issued.
This will be extended to a total period of two years if the boiler is
registered with Grant Engineering (UK) Limited within thirty days
of installation and it is serviced at twelve month intervals
3
. See
main Terms and Conditions below.
If the boiler is installed as part of a VortexAir (hybrid) installation,
the guarantee for the boiler will start from its original date of
installation and NOT from the date of installation of the heat pump
(if installed on different dates).
Registering the product with Grant Engineering (UK) Limited
Please register your Grant Vortex condensing boiler with Grant
Engineering UK Limited within thirty days of installation. To do
so visit:
www.grantuk.com/support/product-registration
You can register your boiler for a further twelve months
guarantee (giving two years from the date of installation
4
). This
does not affect your statutory rights1.
If a fault or defect occurs within the manufacturer’s
guarantee period
If your boiler should fail within the guarantee period, you must
contact Grant Engineering (UK) Limited who will arrange for the
repair under the terms of the guarantee, providing that the boiler
has been correctly installed, commissioned and serviced (if the
appliance has been installed for more than twelve months) by a
competent person and the fault is not due to tampering, running
out of oil, oil contamination, debris, system water contamination,
misuse, trapped air or the failure of any external components
not supplied by Grant Engineering (UK) Limited, e.g. re valve,
motorised valve, etc.
This two year guarantee only applies if the boiler is
registered with Grant Engineering (UK) Limited within thirty
days of installation
4
and is serviced after twelve months3.
In the rst instance
Contact your installer or commissioning engineer to ensure
that the fault does not lie with the system components or any
incorrect setting of the system controls that falls outside of the
manufacturer’s guarantee otherwise a service charge could result.
Grant Engineering (UK) Limited will not be liable for any charges
arising from this process.
If a fault covered by the manufacturer’s guarantee is found
Ask your installer to contact Grant Engineering (UK) Limited
Service Department on +44 (0)1380 736920 who will arrange for
a competent service engineer to rectify the fault.
Remember - before you contact Grant Engineering (UK)
Limited
• Ensure the boiler has been installed, commissioned and
serviced by a competent person in accordance with the
installation and servicing instructions.
• Ensure there is oil to supply the burner.
• Ensure the problem is not being caused by the heating
system or its controls. Consult the boiler handbook for
guidance.
Free of charge repairs
During the two year guarantee period no charge for parts or
labour will be made provided that the boiler has been installed and
commissioned correctly in accordance with the manufacturer’s
installation and servicing instructions, it was registered with Grant
Engineering (UK) Limited within thirty days of installation
4
and,
for boilers over twelve months old, details of annual service is
available3.
The following documents must be made available to Grant
Engineering (UK) Limited on request:
• Proof of purchase
• CD10 Installation Completion Form (or equivalent document)
• CD11 Commissioning Report Form (or equivalent document)
• Service documents (CD11 or equivalent document)
Chargeable repairs
A charge may be made (if necessary following testing of parts)
if the breakdown is due to any fault(s) caused by the plumbing
or heating system, e.g. contamination of parts due to system
contamination, sludge, scale, debris or trapped air. Refer to
‘Extent of manufacturer’s guarantee’.
Extent of manufacturer’s guarantee
The manufacturer’s guarantee does NOT cover the following:
• If the boiler has been installed for over two years.
• If the boiler has not been installed, commissioned, or
serviced by a competent person in accordance with the
installation and servicing instructions.
• Instances where the serial number has been removed or
made illegible.
• Fault(s) due to accidental damage, tampering, unauthorised
adjustment, neglect, misuse or operating the boiler contrary
to the manufacturer’s installation and servicing instructions.
• Damage due to external causes such as bad weather
conditions (ood, storms, lightning, frost, snow, or ice), re,
explosion, accident or theft.
• Fault(s) due to incorrectly sized expansion vessel(s),
incorrect vessel charge pressure or inadequate expansion on
the system.
• Fault(s) caused by external electrics and external
components not supplied by Grant Engineering (UK) Limited.
• Problems caused by lack of oil or faults with the oil storage
and supply system.
• Fault(s) due to contamination of the oil storage and supply
system, e.g. water or debris.
• Bleeding or removing oil storage tank contamination or
blockages from oil lines.
• Problems due to the ue system being incorrectly tted or not
installed to meet installation requirements.
• Boiler servicing, de-scaling or ushing.
• Cleaning out condensate traps/discharge pipes or thawing
out frozen condensate pipework.
• Checking and replenishing system pressure.
• Oil supply pipelines, electrical cables and plugs, external
controls not supplied by Grant Engineering (UK) Limited.
• Heating system components, such as radiators, pipes,
ttings, pumps and valves not supplied by Grant Engineering
(UK) Limited.
• Instances where the oil boiler has been un-installed and re-
installed in another location.
• Use of spare parts not authorised by Grant Engineering (UK)
Limited.
• Consumable items including, but not limited to, oil nozzles, oil
hoses, gaskets and seals.
Section 18: GuaranteePage 58
Page 59
IMPORTANT
The nozzle and braided oil hose supplied with the boiler are only
covered for the period up to the time of the rst service (twelve
months). Both must be changed on the rst service and on every
annual service thereafter.
IMPORTANT
A suitable oil lter with a minimum 15µ ltration must be installed
in the oil supply line.
Do not wait until the fuel supply runs out before you re-order.
Sludge in the bottom of the tank may be drawn into the fuel lines.
It is recommended that the boiler is switched off when the new oil
supply is delivered and that the fuel is allowed to settle for an hour
before restarting the boiler.
Terms of manufacturer’s guarantee
• The Company shall mean Grant Engineering (UK) Limited.
• The boiler must be installed by a competent person and
in full accordance with the relevant Codes of Practice,
Regulations and Legislation in force at the time of installation.
• The boiler is guaranteed for two years from the date of
installation
4
, providing that every twelve months the annual
service has been completed3 and the boiler registered with
the Company within thirty days of installation. Any work
undertaken must be authorised by the Company and carried
out by a competent service engineer.
• This guarantee will be invalid if the boiler does not have an
annual (every twelve month) service and will then be limited
to twelve months from the date of installation
• The shell (heat exchanger) of the oil boiler is covered by a
ve year parts only guarantee from the date of installation
4
.
4
.
This is subject to the following:
• The boiler is operated correctly, in accordance with the
Installation and servicing instructions.
• Grant Engineering (UK) Limited strongly recommends
that a Grant Mag-One in-line magnetic lter/s (or
equivalent
5
) is tted in the heating system pipework. This
should be installed and regularly serviced in accordance
with the lter manufacturer’s instructions. We reserve
the right to ask for proof of installation – failure to
provide this may result in the guarantee becoming
invalid.
• Proof is provided that the system has been ushed or
chemically cleaned where appropriate (refer to BS 7593)
and that the required quantity of a suitable corrosion
inhibitor added.
• Proof of annual servicing (including the checking of any
expansion vessels and pressure relief valves) must be
provided if and when requested by the Company.
• This guarantee does not cover breakdowns caused by
incorrect installation, neglect, misuse, accident or failure to
operate the boiler in accordance with the manufacturer’s
installation and servicing instructions.
• The boiler is registered with the Company within thirty days
of installation. Failure to do so does not affect your statutory
1
rights
.
• The balance of the guarantee is transferable providing the
installation is serviced prior to the dwelling’s new owners
taking up residence. Grant Engineering (UK) Limited must be
informed of the new owner’s details.
• The Company will endeavour to provide prompt service in
the unlikely event of a problem occurring, but cannot be held
responsible for any consequences of delay however caused.
• This guarantee applies to Grant Engineering (UK) Limited
boilers purchased and installed on the UK mainland, Isle of
Wight, Channel Islands and Scottish Isles only
2
. Provision
of in-guarantee cover elsewhere in the UK is subject to
agreement with the Company.
• All claims under this guarantee must be made to the
Company prior to any work being undertaken. Invoices for
call out/repair work by any third party will not be accepted
unless previously authorised by the Company.
• Proof of purchase and date of installation, commissioning
and service documents must be provided on request.
• If a replacement boiler is supplied under the guarantee (due
to a manufacturing fault) the product guarantee continues
from the installation date of the original boiler and not from
the installation date of the replacement4.
• The oil boiler must be connected to a mains water supply
(installations utilising a private water supply are not covered
by this guarantee).
• Breakdown/failure due to lime scale will not be covered by
this guarantee.
• The replacement of a boiler under this guarantee does not
include any consequential costs, such as the removal or
replacement of worktops, kitchen units, etc.
• The boiler (excluding external modules) must not be sited in
a location where it may be subjected to frost.
Hard water advice (for Combi boilers only)
If you live in a hard water area, protection against scaling must
be given to the domestic hot water heat exchanger of your
combination boiler.
You should t an appropriate scale inhibitor or water softener as
any breakdown caused by water scaling is not covered by the
manufacturer’s guarantee. Ask your installer for advice.
Foot notes
1. Your statutory rights entitle you to a one year guarantee
period only.
2. The UK mainland consists of England, Scotland and
Wales only. Please note that for the purposes of this
denition, Northern Ireland, Isle of Man and Scilly Isles
are not considered part of the UK mainland.
3. We recommend that your oil boiler is serviced every twelve
months (even when the guarantee has expired) to prolong
the lifespan and ensure it is operating safely and efciently.
4. The guarantee period will commence from the date of
installation, unless the installation date is more than six
months from the date of purchase, in which case the
guarantee period will commence six months from the date of
purchase.
5. As measured by gauss. The MagOne magnetic lter has a
gauss measurement of 12,000.
Version 1.2 – February 2017
Section 18: Guarantee Page 59
Page 60
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU
Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991
Email: info@grantuk.com www.grantuk.com
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