UK | DOC 0089 | Rev 1.0 | November 2016
Grant UK Pro External Combi
Combi 21e, Combi 26e and Combi 36e
Condensing Oil Boiler Range
Installation and Servicing Instr
uctions
Commissioning Report
2
For use with Kerosene* only.
After installing the boiler leave these
instructions with the User.
This appliance is deemed a controlled
service and specific regional statutory
requirements may be applicable.
*Operation on Bio-fuel
All Grant Vortex Pro condensing boilers,
manufactured since May 2011, are
suitable for operation on both standard
kerosene (Class C2 to BS2869) and
also bio-kerosene – up to a 30% blend
(B30K).
All burner settings and nozzle sizes (as
detailed in Section 2.3 of this manual)
are correct for both standard kerosene
and bio-kerosene (B30K).
In order to operate this boiler on
bio-kerosene it will be necessary to
take the following actions:
a) Use a bio-kerosene (B30K)
compatible flexible oil line in place of
the oil line supplied with this boiler.
b) Have your oil storage tank and oil
supply line (including all pipework,
sight gauges, filters, isolating valves,
fire 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.
c) Check the suitability of the flue
system with Grant UK.
d) Use only bio-kerosene (B30K) that
conforms to OPS24.
IMPORTANT
Under no circumstances should the
boiler be used with bio-kerosene
without the above actions being taken
first.
Date:
Commissioning engineer:
Tel. No:
Boiler model: Boiler output:
kW
Fuel type: Kerosene
Nozzle size: Pump pressure:
Air setting: Flue gas % CO
2
:
Net ue gas temp: Smoke No:
System ushed: Yes / No
Corrosion inhibitor added: Yes / No
Antifreeze added: Yes / No
(where there is a Yes / No - please circle appropriate answer)
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU
Tel: 01380 736920 Fax: 01380 736991
Email: sales@grantuk.com www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specications and/or
appearances are changed in the interests of continued product improvement.
All good sold are subject to our ofcial Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited 2016. No part of this manual may be reproduced by any means without prior written consent.
For sealed systems only:
Expansion vessel size : litres
Expansion vessel change pressure : bar
Sealed system ll pressure (cold) : bar
Service Log
It is recommended that the boiler should be regularly serviced, at least once a year,
and the details entered in the Boiler Handbook by the service engineer.
Contents
3
1 Introduction 4
1.1 How a Condensing Boiler Works 4
1.2 Boiler Description 4
2 Technical Data 6
2.1 Boiler Technical Data 6
2.2 Approximate Air Damper Setting 7
2.3 Vortex Pro Combi e Oil Boilers using
Class C2 Kerosene 7
2.4 Flue Gas Analysis 7
2.5 Boiler Dimensions 7
3 Oil Storage & Supply System 8
3.1 Fuel Supply 8
3.2 Burner Oil Connection 11
4 Boiler Installation Information 12
4.1 Introduction 12
4.2 Boiler Location 12
4.3 Preparation for Installation 12
4.4 Installing the Boiler 12
4.5 Expansion Vessel 13
4.6 Filling and Venting the System 13
4.7 Regulations Compliance Requirements 13
4.8 Completion 14
4.9 Before you Commission 14
4.10 Underfloor Heating Systems 14
4.11 Pipework Materials 14
4.12 Sealed Systems 14
4.13 Underfloor Pipework 14
5 Pipe Connections 15
5.1 Water Connections 15
5.2 Making the Water Connections 15
5.3 Domestic Hot Water System 16
5.4 To use the Water Hardness Kit 16
6 Condensate Disposal 17
6.1 General Requirements 17
6.2 Connections 17
6.3 Pipework 17
6.4 External Pipework 17
6.5 Condensate Soakaway 17
6.6 Condensate Trap 18
6.7 Condensate Disposal Pipework 18
6.8 Inspection and Cleaning of Trap 18
7 Sealed Systems 19
7.1 System Models 19
8 Electrical 20
8.1 Connecting the Power Supply 20
8.2 Connecting the Controls - Heating Only 22
8.3 Connecting the Controls - Heating
and Hot Water 23
8.4 Connecting a Remote Frost Thermostat 25
9 Flue System & Air Supply 26
9.1 Low Level Discharge Flue 26
9.2 Grant Green System 27
9.3 Grant Hybrid System 27
9.4 Grant Horizontal System 28
9.5 General Guidance 28
9.6 Air Supply 28
10 Commissioning 30
10.1 Before Switching On 30
10.2 Switching On 30
10.3 Running the Boiler 31
10.4 Balancing the System 31
10.5 Completion 31
10.6 Air Adjuster Disc - Combi 21 only 32
10.7 Information for the User 32
11 Boiler Servicing 33
11.1 Checking before Servicing 33
11.2 Dismantling Prior to Servicing 33
11.3 Cleaning the Boiler 33
11.4 Cleaning the Burner 35
12 Fault Finding 36
12.1 Initial Checklist - for Installer or
Service Engineers 36
12.2 Main Fault Finding Procedure 37
12.3 Poor Hot Water Checklist 40
12.4 Riello RDB Burner Fault Finding 41
13 Spare Parts 42
14 Health & Safety Information 44
14.1 Insulation Materials 44
14.2 Insulation Materials 44
14.3 Kerosene and Gas Oil Fuels (mineral oils) 44
15 EC Declaration of Conformity 45
16 Guarantee 46
16.1 The Vortex Oil Boiler Gurantee 46
Appendixes 48
A High Efficiency Circulating Pump 48
B Product Fiche 50
1 Introduction
4
Warning of possible human injury as
a consequence of not following the
instructions in the warning.
The Grant VORTEX Pro Combi e
condensing boilers contain an extra
heat exchanger which is designed to
recover the latent heat normally lost
by a conventional boiler. It does this
by cooling the flue gases to below 90°
C, thus extracting more sensible heat
and some of the latent heat. This is
achieved by cooling the flue gases to
their dew point (approximately 55° C).
To ensure maximum efficiency, the
boiler return temperature should be 55°
C or less, this will enable the latent heat
to be condensed out of the flue gases.
The boiler will achieve net thermal
efficiencies of 100%.
To achieve maximum performance
from the Grant VORTEX Pro Combi
e boilers, it is recommended that
the heating system is designed so
that a temperature differential of
20°C between the flow and return is
maintained.
The Grant Vortex Pro Combi e boilers
will however still operate at extremely
high efficiencies even when it is not
in condensing mode and therefore
is suitable for fitting to an existing
heating system without alteration to the
radiator sizes. The boiler is capable of a
maximum flow temperature of 78° C.
1.2 Boiler Description
The Vortex Pro Combi e boilers are
automatic pressure jet oil boilers
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 the burner factory fitted, and
a factory fitted low level discharge fuel
system.
Caution concerning likely damage
to equipment or tools as a
consequence of not following the
instructions in the caution.
Note text. Used for emphasis or
information not directly concerned
with the surrounding text but of
importance to the reader.
1.1 How a Condensing
Boiler Works
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
flue gas). A conventional boiler cannot
recover any of the latent heat and
this energy is lost to the atmosphere
through the flue.
!
WARNING
!
CAUTION
!
NOTE
For conventional flue applications,
where required, Grant recommends
the use of the Grant ‘Green’ flue
system, to provide an insulated twin
- wall flue system. Refer to Section 9
for further details.
Only Kerosene must be used with a
low level discharge flue appliance.
The Vortex Pro Combi e boilers are
only suitable for use with Kerosene.
All burners are ready to connect to a
single pipe system with a loose flexible
fuel line (900mm) and
3
/8” to 1/4” BSP
male adaptor supplied with the boiler.
If required, an additional flexible fuel
line (900mm) and
3
/8” to 1/4” BSP male
adaptor are available to purchase from
Grant Engineering (UK) Limited, for
two-pipe oil supply system, Part No.
RBS36.
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 e boilers has no
effect on the hot water performance.
Figure 1-1 shows the components in
the Vortex Pro Combi e boilers and the
position of the control panel. Figure 1-2
shows the details of the control panel.
!
NOTE
This manual is intended to guide
engineers in the installation and
maintenance of Grant VORTEX Pro
External Combi e boilers. A separate
manual is available to guide users in
the operation of these boilers, and
is printed inverted at the end of this
manual.
The following special text formats
are used in this manual for the
purposes listed below:
5
Figure 1-1: Vortex Pro Combi 21e boiler with front panel removed showing position of control panel
Figure 1-2: Vortex Pro Combi e boiler control panel
Electrical
connection socket
Service
switch
Boiler
thermostat
Pressure
gauge
Boiler On / Off switch
Burner lock-out
button
Indicator lights
Overheat reset button
(under black cap)
Expansion
vessel
Heating (CH)
pump
Hot water
(DHW) pump
I
M
PO
RT
A
N
T
CAB
L
E
T
O
PLUG
M
UST
BE S
E
C
U
R
ED
I
N
C
A
BLE CLAMP BEL
OW
PA
N
EL
M
A
X
I
M
UM C
A
BLE
L
ENG
T
H
BET
W
E
EN P
LUG A
N
D
C
L
A
M
P
3
5
0
m
m
W
A
R
N
IN
G
230
V ISOLATE M
A
IN
S
P
O
W
E
R
SUP
P
L
Y
B
E
FOR
E
REM
O
V
IN
G
CO
V
ER
1
2
N
3
N
L
IMPORTANT
CABLE TO PLUG MUST BE SECURED IN CABLE CLAMP BELOW PANEL
MAXIMUM CABLE LENGTH BETWEEN PLUG AND CLAMP 350mm
WARNING 230V ISOLATE MAINS POWER SUPPLY BEFORE REMOVING COVER
1
2
N3N
L
2 Technical Data
6
2.1 Boiler Technical Data
Table 2-1: Technical Data
Combi 21e Combi 26e Combi 36e
Boiler water content
(including 32 litre primary store)
litres 48.0 48.5 53.5
gall 10.6 10.7 11.8
Weight (dry)*
kg 147 188 218
lbs 325 415 481
Maximum heat output (Kerosene)
kW 21.0 26.0 36.0
Btu/h 71,650 88,700 123,000
Flow connection mm 22 22 28
Return connection mm 22 22 28
Cold water mains inlet mm 15 15 22
Domestic hot water outlet mm 15 15 22
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 flow rate 3.0 litres/min (0.66 gal/min)
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 mm 22mm plastic pipe
Flue diameter (conventional)*** 100mm (4in) diameter
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) shut of f temperature °C 111±3
Maximum hearth temperature °C Less than 50
Electricity supply 230/240V 1ph 50Hz fused at 5A
Burner motor power W 212
Absorbed motor power W 0.15
Starting current A 4.2 2.60
Running current A 0.85
Oil connection ¼ BSP male (on end of flexible hose)
Conventional flue draught
N/m² Minimum: 8.7 - Ma ximum: 37
in wg Minimum: 0.035 - Ma ximum: 0.15
Maximum operating pressure - sealed/open system bar 2.0
Maximum operating pressure - pressure relief valve bar 2.5
* Weight includes burner (and expansion vessel) but excludes flue.
** Based on expansion vessel charge and initial cold system pressure of 0.5 bar.
*** If used as alternative to low-level terminal supplied with boiler (refer to Section 9).
2.2 Approximate Air Damper
Setting
Burners are supplied factory set at
the outputs shown.
When commissioning, the air damper
must be adjusted to obtain the
correct CO
2
level and the Installer
must amend the data label.
2.3 Vortex Pro Combi Oil
Boilers using Class C2
Kerosene
.
Vortex Combi e boilers are only for
use with kerosene.
!
NOTE
!
NOTE
The data given above is approximate
only and is based on the boiler being
used with a low level discharge flue.
The above settings may have to
be adjusted on site for the correct
operation of the burner.
Gas Oil is not suitable for use with a
Grant Vortex Pro Combi e boiler.
The net flue gas temperatures given
above are ± 10%.
When commissioning the air damper
must be adjusted to obtain the correct
CO
2
level.
2.4 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:
• ThetestpointisforCO
2
and smoke
readings only.
• Theboilerefciencyand
temperature must be taken from
the flue.
• Finalcombustionreadingsmustbe
taken from the flue terminal (or test
point on flue elbow if Green system
is used) with all panels fitted.
Figure 2-1: Vortex Pro External Combi e dimensions
All dimensions in the diagram above are in millimetres.
2.5 Boiler Dimensions
Heat
SEDBUK
Nozzle Oil Smoke Burner Fuel Flue gas CO2
output
SAP 2009
pressure
number head flow temp
Model Burner type kW Btu/h
%
bar kg/h °C %
21e Riello RDB 2.2 21.0 71,650 89.5 0.60/80ºEH 9.0 0-1 T1 1.83
80 (flue)
12
235 (door)
26e Riello RDB 1 26.0 88,700 90.2 0.75/80ºEH 8.0 0-1 T2 2.16 75 - 80 12
36e Riello RDB 2.2 36.0 123,000 91.6 1.00/80ºEH 9.1 0-1 T5 3.01 78 12
7
PLAN VIEW
LEFT SIDE VIEW
REAR VIEW
RIGHT SIDE VIEW
657
720
755
755
944
R
5
6
516
108
27
75
72
150
516
108
R
5
6
329
108
223
150
75
72
27
8
3 Oil Storage & Supply System
Single Pipe System
Where the storage tank outlet is above
the burner the single pipe system
should be used. The height of the tank
above the burner limits the length of
pipe run from the tank to the burner.
As supplied the burner is suitable for a
single pipe system.
Head A Max Pipe Run (m)
(m) 10mm 12mm
OD Pipe OD Pipe
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
Head A Max Pipe Run (m)
(m) 10mm 12mm
OD Pipe OD Pipe
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
Two Pipe System
With the storage tank outlet below
the burner, a two pipe system should
be used. The pipe runs should be as
shown in Figure 3-2. The return pipe
should be at the same level in the tank
as the supply pipe, both being 75 to
100mm above the base of the tank.
The pipe ends should be a sufficient
distance apart so as to prevent any
sediment disturbed by the return
entering the supply pipe.
Avoid the bottom of the tank being
more than 3.5m below the burner.
A non-return valve should be fitted in
the supply pipe together with the filter
and fire valve. A non-return valve should
be fitted in the return pipe if the top of
the tank is above the burner.
The pump vacuum should not exceed
0.4 bar. Beyond this limit gas is
released from the oil.
For guidance on installation of top
outlet fuel tanks and suction oil
supply sizing, see OFTEC technical
book 3.
Available at www.oftec.org.uk
3.1 Fuel Supply
Fuel Storage
The tank should be positioned in
accordance with the recommendations
given in BS 5410:1:1997, which gives
details of filling, maintenance and
protection from fire.
A steel tank may be used and must be
constructed to BS 799:5:1987 and
OFS T200.
A galvanised tank must NOT be
used.
A plastic tank may be used and must
comply with OFS T100.
Plastic tanks should be adequately
and uniformly supported on a
smooth level surface, across their
entire load bearing base area, that is,
the area in contact with the ground.
Fuel Pipes
Fuel supply pipes should be of copper
tubing with an external diameter of at
least 10mm.
Galvanised pipe must not be used.
All pipe connections should preferably
use flared fittings. Soldered connections
must not be used on oil pipes.
Flexible pipes must not be used
outside the boiler case.
A remote sensing fire valve must be
installed in the fuel supply line at least
one metre before it enters the boiler
casing, with the sensing head located
above the burner.
Recommendations are given in
BS 5410-1:2014.
It is recommended that a good quality
metal bowl type fuel filter is fitted at the
tank and a secondary filter in the fuel
supply line closer to the boiler (15 µ for
Kerosene) to protect the burner pump
and nozzle from contamination.
If the boiler operates on bio kerosene, a
compatible filter should be used.
A shut-off valve should be fitted
before the filter, to allow the filter to be
serviced.
A flexible fuel line, adaptor and 1/4”
BSP isolation valve are supplied loose
with the boiler for the final connection
to the burner. If a two pipe system
or Tiger Loop system is used, an
additional flexible fuel line (900mm) and
3
/8” to 1/4” BSP male adaptor are
available from Grant Engineering (UK)
Limited (Part No. RBS36).
Metal braided flexible pipes should be
replaced annually when the boiler is
serviced. Long life flexible pipes should
be inspected annually and replaced at
least every 60 months.
!
NOTE
!
CAUTION
!
CAUTION
Grant UK recommend that a fire
valve with a temperature rating
of 95°C be installed on any Grant
Vortex Pro Combi.
!
NOTE
9
Figure 3-1: Single pipe system
Figure 3-2: Two pipe system
Fire
valve
1m
1m
A
Fire valve sensor
Vent pipe
Fill pipe
Sludge
valve
Shut-off
valve
Shut-off
valve
Level
gauge
Filter
Fuel
storage
tank
Pump (see section 3.2)
Pump (see section 3.2)
Fire
valve
Fire
valve
sensor
Vent
pipe
Fill
pipe
Sludge
valve
Non return
valve
Shut-off
valve
Shut-off valve
Level gauge
Non
return
valve
Filter
Fuel
storage
tank
A
Supply
Return
10
3 Oil Storage & Supply System
Tiger Loop System
When The storage tank is below the
burner, an alternative to a two pipe
system can be achieved using a
‘Tiger Loop’ type oil de-aerator. This
effectively removes the air from the oil
supply on a single pipe lift.
The de-aerator is connected close
to the boiler as a two pipe system
(omitting the non-return valve) as shown
in Fig.
3-3. Refer to the manufacturer’s
instructions supplied with the
de-aerator. The de-aerator must be
mounted vertically, as shown in Figures
3-3 and 3-4.
To be used with a Tiger Loop system,
the burner must be fitted with an
additional flexible fuel line (a flexible fuel
line (900mm) and
3
/8” to 1/4” BSP male
adaptor are available to purchase from
Grant Engineering (UK) Limited - Part
No. RBS36).
To prevent any possibility of fuel
fumes entering the boiler, the
de-aerator must be fitted outside the
casing.
!
WARNING
Figure 3-4: Tiger loop de-aeration device
To burner
From burner
From tank
Figure 3-3: De-aeration device system
Fire valve
Supply
Return
Fire valve sensor
Vent pipe
Fill pipe
Sludge
valve
Tankmaster
Fuel
storage
tank
De-aeration device e.g
Tiger Loop see Figure 3-4
Pump (see section 3.2)
Figure 3-5: Burner pump connections
Oil inlet
connection
Return connection
By-pass screw
Pressure gauge connection
Pressure adjuster
Vacuum gauge connection
Solenoid
Supply to
nozzle
11
3.2 Burner Oil Connection
The fuel pump is supplied for use with a
single pipe fuel supply system. For use
on a two pipe system, it is necessary to
fit the By-pass screw into the tapping in
the return port. See Figure 3-5.
The By-pass screw is supplied in the
boiler accessory pack.
The procedure is as follows:
1. Remove the plastic burner cover
(two screws).
2. Remove and discard the blanking
plug from the return connection of
the pump and fit the By-pass screw
using a hexagonal key.
3. Connect the return oil flexible fuel
line to the pump.
4. Connect the
3
/8” to 1/4” BSP
adaptor to the flexible fuel line.
Flexible fuel lines and adaptors are
available to purchase from Grant
Engineering (UK) Ltd.
The burner cover may be left off until
the boiler is commissioned.
The blanking plug supplied in the
inlet (suction) port may now be
plastic and will not provide an oil
tight seal when the pump is running.
Ensure the supply from the tank
is connected to this port and the
plastic plug is discarded.
!
WARNING
4 Boiler Installation Information
12
4.1 Introduction
The boiler is supplied already fully
assembled with the flue terminal guard
supplied loose inside the boiler.
4.2 Boiler Location
1. The External Combi boiler must
stand on a solid, level surface
capable of supporting the weight of
the boiler when full of water, e.g. a
prepared concrete standing, paving
slabs bedded down on sand /
cement, or similar.
2. The Module can be installed either
against the building or ‘free standing’
some distance away from the
building.
3. The Module must be positioned
such that the required clearances
from the low level flue outlet, as
shown in Figure 9-1, are achieved.
4. Adequate clearance must be left
around the boiler for servicing. In
particular, a minimum clearance of
600mm above the boiler for removal
of the top panel and 600mm at
each end allow for access to the
burner and condensate trap.
4.3 Preparation for Installation
1. Carefully remove the packaging
from the boiler and remove it from
the transit pallet.
2. Remove the case top panel and
also the front and rear panels, as
required.
3. The flue may exit the boiler from
the left, right or rear of the casing.
Carefully press out the pre-cut
section on the side or end casing
panel to provide the opening in the
required position for the flue to pass
through the casing.
Fit the cover panel (with the round
flue exit hole) over the square flue
opening in the casing. Fit the circular
rubber sealing grommet provided
into the hole in the cover panel
before fitting the flue terminal section.
4. Slacken the wing nuts holding the
flue elbow and rotate the elbow to
the required direction for the flue to
exit the casing.
5. Push the end of the flue terminal
section with the red seal through
the seal in the casing. The terminal
has been factory lubricated. Take
care not to dislodge or damage the
red seals.
6. Carefully insert the terminal into
the flue elbow until the bend of the
terminal contacts the outer casing,
then, pull the terminal forward
approximately 25mm and rotate the
bend so that the outlet is horizontal.
Rear Exit - The flue must discharge
away from the building.
Side Exit - The flue should
discharge towards the rear of
the casing to prevent flue gases
reentering the boiler casing through
the air inlet vents on the casing
front door.
The flue terminal must be fitted
horizontally to prevent dripping from
the end of the terminal.
7. Tighten the wing nuts holding the flue
elbow and fit the stainless steel flue
guard using the two screws provided.
8. The top panel of the casing has
been designed so that it may be
fitted to create a slight slope away
from the side positioned against the
wall. To tilt the top panel, loosen
the four top panel casing screws,
one at each corner and push down
on the side furthest from the wall.
Tighten the screws. See Figure 4-1.
4.4 Installing the Boiler
1. If the boiler is to be fitted against
the wall, prepare the wall to accept
the heating system pipework. To
mark the wall for drilling, refer to
Figure
2-1 for the positions of the
pipework openings in the enclosure
sides.
Pipework should be insulated where
it passes through the wall into the
boiler enclosure.
2. A painted steel wall flashing strip
is supplied with the boiler to cover
the gap between the wall and the
boiler casing. It should be secured
to the wall leaving a gap of 30mm
between the bottom edge and
the top of the casing top panel, to
allow removal of the top panel for
servicing.
3. If the boiler is to be installed ‘free
standing’ (that is, away from a wall)
and the pipework run underground,
push out the ‘knock-outs’ to open
the required pipe openings in the
base of the boiler enclosure.
Using a sharp knife, cut through
the polystyrene in the base, around
the edge of the holes, to allow the
flow and return pipes to enter the
enclosure.
A spare blanking plate with a 112mm
diameter hole is supplied with the
Outdoor Vortex Combi boilers. This
is intended to provide an opening
into the boiler if a 110mm soil pipe is
used as a pipe duct through the wall.
!
NOTE
!
NOTE
Figure 4-1: Standard supplied flue
Top panel
fixing screw
Top panel
fixing screw
Top panel
fixing screw
Angle top panel to
slope away from wall
using slots provided
Terminal guard
fixing screw
(one each side)
End of terminal
with red seal
Flue elbow
Rear Exit Right ExitLeft Exit
13
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.
4.6 Filling and Venting
the System
Automatic and manual air vents
The boiler is fitted with two Automatic
air vents at the top of the boiler, located
as follows:
• oneonthetopoftheprimarystore
• oneontheheatingowpipe
Refer to Figure 5-1.
Check that the small black plug on
the side of each air vent is screwed
in fully. Then unscrew it one complete
turn - the cap remains in this position
thereafter.
A single manual air vent is also fitted
at the top of the boiler - on the return
pipe. Unscrew the cap one turn vent air
from the pipe during filling and then fully
close the cap.
Filling loop
If the flexible filling loop is used to fill
the system, ensure it is connected and
that the valve connecting it to the boiler
is open and the valve at the front is
closed.
A valve is open when the operating
lever is in line with the valve, and closed
when it is at right angles to it.
Ensure that the mains cold water
supply valve is open (operating lever
in line with the valve), then turn on the
mains cold water supply and gradually
open the front valve on the filling loop
until water is heard to flow.
Vent each radiator in turn, starting
with the lowest one in the system, to
remove air.
Check the operation of the safety valve
by turning the head anticlockwise until
it clicks. The click is the safety valve
head lifting off its seat allowing water
to escape from the system. Check that
this is actually happening.
Continue to fill the system until the
pressure gauge indicates between
0.5 and 1.0 bar. Close the fill point
valve and check the system for water
soundness, rectifying where necessary.
Water may be released from the system
by manually operating the safety valve
until the system design pressure is
obtained.
The system design pressure (cold)
should be between 0.5 bar and 1.0
bar. The pressure is equivalent to the
maximum static head in bar + 0.3 (1
bar = 10.2 metres of water), where the
static head is the vertical height from
the centre of the expansion vessel to
the highest point of the system.
Close the valves either side of the filling
loop and disconnect the loop.
4.7 Regulatory Compliance
Requirements
Installation of a Grant VORTEX
Pro External Combi e must be
in accordance with the following
recommendations:-
• BuildingRegulationsforEngland
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.
• ModelandlocalWaterUndertaking
Byelaws.
• ApplicableControlofPollution
Regulations.
• ThefollowingOFTECrequirements:
• OFST100Polytheneoilstorage
tanks for distillate fuels.
• OFST200Fueloilstoragetanks
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 Technical Book 4
(Installation requirements for oil fired
boilers).
The installation should also be in
accordance with the latest edition of
the following British Standard Codes of
Practice:
4. The electrical supply to the boiler
should be routed through the wall
in a suitable conduit, such that it
enters the boiler enclosure via one
of the unused pipework openings.
The cable can be routed to the
front of the boiler, for connection
to the boiler control panel, either
over the top or beneath the boiler
heat exchanger. Heat resistant PVC
cable, of at least 1.0mm² cross
section should be used within the
boiler enclosure. See section 8.1 for
details.
5. The oil supply line should be
installed up to the position of the
boiler. Refer to Section 3 for details.
The final connection into the boiler
enclosure can be made with 10mm
soft copper, routed along the base
of the enclosure (either between
the enclosure and wall or in front
of the enclosure) to enter through
one of the holes located in the
bottom edge side panel, at the
front (burner) end. See Section 3 for
details.
4.5 Expansion Vessel
The 21e, 26e and 36e models are
supplied with a 24 litre expansion
vessel located in the front of the boiler.
The expansion vessel fitted is supplied
with a charge pressure of 1.0 bar
(equivalent to a max. 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.
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. If the system volume is
greater, an extra expansion vessel
(complying with BS4841) must be fitted
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 fitted in
the boiler. Refer to BS7074:1 for further
guidance.
!
NOTE
14
• BS715Metaluepipes,ttings,
terminals and accessories.
• BS799:5Oilstoragetanks.
• BS1181Clayueliningsandue
terminals.
• BS4543:3Factorymadeinsulated
chimneys for oil fired appliances.
• BS4876Performancerequirements
for oil burning appliances.
• BS5410:1CodeofPracticeforoil
firing appliances.
• BS5449Forcedcirculationhot
water systems.
• BS7593CodeofPracticefor
treatment of water in heating
systems.
• BS7671Requirementsforelectrical
installations, IEE Wiring Regulations.
Failure to install and commission
appliances correctly may invalidate
the boiler guarantee.
Before starting any work on the
boiler, or fuel supply please read the
health and safety information given
in Section 14.
4.8 Completion
Please ensure that the OFTEC CD/10
installation completion report (provided
with the boiler) is completed in full.
Leave the top copy with the User.
Retain the carbon copy.
Ensure that the User Information pack
(supplied with the boiler) is handed over
to the Householder.
4.9 Before you Commission
To avoid the danger of dirt and foreign
matter entering the boiler the complete
heating system should be thoroughly
flushed out - 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 used on an old system.
For optimum performance after
installation, this boiler and its associated
central heating system must be flushed
in accordance with the guidelines given
in BS 7593:1992 ‘Treatment of water
in domestic hot water central heating
systems’.
This must involve the use of a
proprietary cleaner, such as Betz
Dearborn’s Sentinel X300 or X400,
or Fernox Restorer. Full instructions
are supplied with the products, but
for more details of Betz Dearborn’s
products, view the website www.
sentinel-solutions.net and for more
details of Fernox products view the
website www.fernox.com.
For Long term protection against
corrosion and scale, after flushing, it is
recommended that an inhibitor such
as Betz Dearborn’s Sentinel X100 or
Fernox MB-1 is dosed in accordance
with the guidelines given in BS
7593:1992.
Failure to implement the guidelines will
invalidate the guarantee.
4.10 Underfloor Heating
Systems
In underfloor systems it is essential
that the return temperature must be
maintained above 40°C to prevent
internal corrosion of the boiler water
jacket.
!
NOTE
!
WARNING
4 Boiler Installation Information
4.11 Pipework Materials
Grant boilers are compatible with both
copper and plastic pipe. Where plastic
pipe is used it must be of the oxygen
barrier type and be of the correct
class (to BS 7291:Part 1:2001) for the
application concerned.
The first metre of pipework
connected to both the heating flow
and return connections of the boiler
must be made in copper on all types
of system - sealed or open-vented.
4.12 Sealed Systems
If plastic pipe is used, the installer
must check with the 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: Part 1:2001.
4.13 Underfloor Pipework
Plastic pipe may be used on Underfloor
systems where the plastic pipe is fitted
after the thermostatic mixing valve.
Copper tube must be used for at
least the first metre of flow and return
primary pipework between the boiler
and the underfloor mixing/blending
valves.
!
NOTE
15
5 Pipe Connections
5.1 Water Connections
The pipework can exit the boiler
enclosure through the pre-cut openings
provided in either side panel to pass
through the wall when installed against
the building. The side flue exit openings
may also be used to route the pipework
and cables through the casing sides
and into the building. See Section 2.5.
A spare blanking plate with a 112mm
diameter hole is supplied with the
Vortex Pro Combi e boilers.
This is intended to provide an opening
into the boiler if a 110mm soil pipe is
used as a pipe duct through the wall.
Alternatively for free standing
installations, pipework can be routed
down and through the pre-cut openings
provided in the base of the enclosure,
to be run underground to the building.
See Section 2.5.
Flow and return connections -
All models are supplied with a push-fit
elbow connection for the heating flow
and return - 22mm (Vortex Pro Combi
21e and 26e) or 28mm (Vortex Pro
Combi 36e).
Hot water connections - All models
are supplied with push-fit elbow
connections for the cold water mains
inlet pipe and hot water outlet pipe.
These are 15mm for the Vortex Pro
Combi 21e and 26e, and 22mm for the
Vortex Pro Combi 36e.
All pipes to be fitted into the push-fit
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 fittings
should not be cut square using a
hacksaw.
!
CAUTION
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).
5.2. Making the Water
Connections
Flow and return pipework can be
routed to either side of the boiler,
whichever is adjacent to the building,
from the push-fit elbows (supplied) on
the flow and return connection. Refer to
Figure 5-1.
Holes are provided at the base of
the casing side panels to allow the
condensate pipe to be run through
at the rear of the boiler. It will be
necessary to remove the back panel
from the boiler casing to fit this
pipework.
All Models
A 15mm 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 boiler casing, through
one of the openings provided at the
base of each side panel, and terminate
so that it cannot cause injury to
persons or property.
Figure 5-1: Vortex Pro Combi e pipe positions
Heating flow
connection
Heating circulating
pump
Heating
return
Flow switch
Cold water inlet
isolating valve
Cold water inlet
Automatic air vent
Safety valve
Manual
air vent
Primary return
isolating valve
Non return
valve
Automatic
air vents
Boiler flow
sensor and
overheat
thermostat
bulb
Safety valve
outlet
5 Pipe Connections
16
5.3 Domestic Hot Water
System
To maintain a longer and more
consistent hot water temperature,
a flow restrictor is factory fitted to
all models except the Vortex Pro
Combi 36e, to limit the flow rate to
approximately 15 litres / minute.
The flow 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 efficient operation.
If the pressure is above 8 bar a
pressure reducing valve must be fitted.
The boiler may still operate down to a
pressure of 1.0 bar but with a reduced
flow rate. The minimum flow rate
needed for the flow 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 15mm
copper pipe or 22mm for the Vortex
Pro Combi 36e 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 fitted in
the domestic hot water system. It is
recommended that thermostatically
controlled shower valves are used to
protect against a flow of water at too
high a temperature. If a fixed head type
shower is used, no anti-syphonage
devices are required. If a loose or
flexible head type shower is used, it
must be arranged so that the head
cannot fall closer than 25mm above
the top of the bath, thereby preventing
immersion in the bath water. If this is
not practicable, an anti-syphonage
device must be fitted at the point of the
flexible 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 flushing type. The outlets should
be shrouded and unable to have a
temporary hand held spray attached.
Arrangements for antisyphonage are
not necessary.
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
fitted 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 fitted to the cold water
supply serving the appliance and in
accordance with the manufacturers
instructions. Grant Engineering (UK)
Ltd. cannot be held responsible for any
damage or misuse caused by the fitting
of any water conditioning device.
Please protect the domestic hot
water system from harmful effects
of scale. Problems caused by the
build-up of limescale are not covered
under the terms of the guarantee.
Before the mains water supply pipe is
connected to the boiler, it should be
thoroughly flushed out to avoid the
danger of dirt or foreign matter entering
the boiler.
The mains water connection to the
boiler must be the first connection from
the mains supply.
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 fitted 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.
5.4 To use the Water
Hardness Kit
Fill a clean container with a sample of
water from the mains cold water supply
to the boiler.
Immerse the test strip in the water for
approximately one second, ensuring
that all the test zones are fully wetted.
Shake off the surplus water and wait for
one minute.
Assess the colouration of the test zones
using the following chart.
!
CAUTION
!
NOTE
Green Areas Violet Areas Hardness Total Hardness mg/l (ppm)
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
Note: (1 mg/l = 1 ppm (part per million)
17
6 Condensate Disposal
6.1 General Requirements
When in condensing mode the Grant
Vortex PRO boilers produce condensate
from the water vapour in the flue gases.
This condensate is slightly acidic with a
ph value of around 3 (similar to vinegar).
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):
• Intoaninternaldomesticwaste
system (from kitchen sink, washing
machine, etc.).
• Directlyintothesoilstack.
External Connection:
• Intoanexternalsoilstack
• Intoanexternaldrainorgully
• intoarainwaterhopper(thatispart
of a combined system where sewer
caries both rainwater and foul water)
• purposemadesoakaway.
All condensate disposal pipes must
be fitted 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 gully should be
terminated inside the hopper / drain /
gully below the grid level but above the
water level.
Condensate disposal pipes should 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 overflow pipe is
suitable).
Copper or steel pipe is NOT suitable
and MUST NOT be used.
Condensate disposal pipes should
have a minimum ‘nominal’ diameter
of 22mm (
3
/4”) - e.g. use 21.5mm OD
polypropylene overflow pipe.
Condensate disposal pipes must be
fitted with a fall (away from the boiler) of
at least 2.5° (~45mm fall per metre run).
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
gully (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 fixed 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 32mm waste pipe used
to minimise the risk of ice blocking the
pipe in freezing conditions.
The number of bends, fittings and joints
on external pipes should be kept to a
minimum to reduce the risk of trapping
condensate.
For a boiler installed in an unheated
area such as an outhouse or garage,
all condensate pipework should be
considered as an ‘external’.
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 500mm 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 Fig.6-1.
Ensure that the drainage holes in the
soakaway tube face away from the
building. Backfill both the soakaway
tube, and the hole around it, with
10mm 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.
Any damage due to condensate
backing up into the boiler due to a
high water table, in the case of a
soakaway, or flooded drains when
the condensate disposal is via a
gully or soil stack, is not covered by
the Grant product guarantee.
!
NOTE
!
NOTE
!
NOTE
!
CAUTION
Figure 6-1: Purpose made condensate soakaway
32mm waste pipe
external to the building
Two rows of 3 x 12mm
holes at 25mm centres and
50mm from the bottom
of the tube. Holes facing
away from the property.
Backfill with
10mm limestone
chippings
Sealed
end
100mm
plastic tube
Cement seal
Ground level
2.5° fall
25mm
300mm
400mm min.
18
6.6 Condensate Trap
Grant Vortex PRO boilers are supplied
with a factory-fitted condensate trap to
provide the required 75mm water seal
in the condensate discharge pipe from
the boiler.
This trap incorporates a float (which
will create a seal when the trap is
empty) and an overflow warning outlet
(fitted with a plastic sealing cap),
See Figure 6-2.
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 is sealed to the
trap body and cannot be removed.
To inspect and clean the trap, perform
the following procedure:
1. Disconnect flexible condensate
hose from inlet connector.
2. Unscrew the inlet connection nut.
3. Remove the ‘top hat’ inlet
connector and nut from trap.
4. Remove trap from bracket.
5. Remove float from trap - clean if
necessary.
6. Inspect inside of trap and clean as
necessary.
7. Re-assemble trap, re-fit to boiler
and re-connect flexible hose.
Ensure that hose is fully pushed
onto the ‘top hat’ inlet connector.
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.
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 Fig.6-2 and see trap
outlet/pipe.
The outlet of the trap will accept
21.5mm OD to 23mm OD
Polypropylene overflow pipe for the
condensate discharge pipe.
Possible routes for disposal
pipework
The casing of the Vortex Pro External
boiler has several openings in both the
sides and base of the casing. These
are designed to allow pipework to pass
through the casing, as required, to suit
the installation. These openings can be
used to allow the condensate disposal
pipe to exit the casing in one of the
following ways:
Side outlet - The lower opening on
either side of the boiler casing can allow
the condensate disposal pipe to be
installed as follows:
• Connectiontoaninternalstack-
passing back through the wall of
the house.
• Connectiontoanexternalsoilstack
adjacent to the boiler.
• Dischargeintoanadjacent(external)
drain or gully.
• Dischargeintoasoakaway-with
pipe either above or below ground
level.
Bottom outlet - There are three
openings in the base of the boiler
casing that can allow the condensate
disposal pipe to be installed as follows:
• Dischargeintoadrainorgully
beneath the boiler (e.g. drain built in
to the concrete base for the boiler).
• Dischargeintoasoakaway-with
pipe below ground level.
The trap is factory-fitted inside the
boiler casing at the rear of the boiler mounted on the inside of the side panel
- in an accessible position to allow for
routine maintenance.
A flexible hose connects the outlet of
the condensing heat exchanger to the
trap inlet. Ensure the straight connector
on the hose is fully pushed onto the
‘top hat’ inlet connector of the trap.
With the trap fitted inside the boiler
casing, the sealing cap must be fitted in
the trap outlet.
Care should be taken when siting
the trap such that the overflow
outlet is readily visible and that any
condensate overflowing from the
outlet cannot cause either a hazard
to persons or damage to surrounding
property or equipment.
6 Condensate Disposal
Figure 6-2: Condensate trap
!
NOTE
!
NOTE
!
WARNING
Sealing
cap must
be fitted
Flexible
hose from
outlet of
condensing
heat
exchanger
Condensate
trap
Condensate
outlet to
drain
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