Grant Combi 90 V3, Combi 26, Combi Max, Combi 36 User, Installation & Servicing Instructions

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Page 1

Part No. IRL 005 Rev: 0 Jan 07

USER, INSTALLATION

and

SERVICING INSTRUCTIONS

Outdoor Combi 90 V3

Combi Max

Outdoor Condensing Combi 26 and 36

For use with Kerosene or Gas Oil (Condensing Combi 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

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Outdoor Combi 90 V3, Combi Max and Condensing Combi

LIST OF CONTENTS

SERVICE LOG

COMMISSIONING REPORT

Section Subject Page

1 Outdoor Combi V3 and Combi Max user instructions 3 2 Outdoor Condensing Combi user instructions 4 3 Outdoor Combi 90 V3, Combi Max and Condensing Combi User instructions 5 4 Technical information 8 5 General boiler information 14 6 Boiler installation 26 7 Fill and vent the system 35 8 Commissioning 36 9 Boiler Handover 37 10 Boiler servicing 37 11 Boiler components 41 12 Wiring diagrams 43 13 Fault finding 49 14 Burner spares 54 15 Health and safety information 55 16 EC declaration of conformity 57

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.

Date: ................................................................................

Commissioning engineer: ................................................................................ Tel. No: ..................................................

Boiler model/output: ........................................................Btu/h Fuel type: Kerosene or Gas oil

Nozzle size: ................................................................ Pump pressure: .................................... Air setting: ..........................

Flue gas % CO2: .......................................................... Net flue gas temp: ................................ Smoke No: ..........................

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Your Grant Combi boiler is fully automatic when the b

oiler On/Off switch is set to ON, and will provide domestic hot water at mains pressure on demand and central heating when the boiler and heating system controls call for it.

Your installer may have fitted either:

A simple timer - either 7-day or 24-hour timer, to control the central heating operation of the boiler only, or a programmable version.

Whichever type of time control is used, it will allow you to set the operating times of the central heating. Domestic hot water will be available continuously, irrespective of the central heating settings, UNLESS the hot water is set to OFF on the programmer (if fitted).

To access the Outdoor Combi controls, remove the front panel by turning the handle at the bottom and pull it forward at the bottom.

1 Boiler On/Off switch - This switches the boiler on and

off.

Note: The boiler will not supply central heating OR domestic hot water if this switch is set to OFF, but the built in frost thermostat will still operate - provided that the electrical supply to the boiler is still switched on.

2 Burner and Pump switches - These switches isolate

the burner and pump respectively and are intended for the service engineer to use.

They should NOT be switched off during normal use of the boiler.

3 Test switch - This is also for the Service engineer to

use and should be left set to OFF.

4 Boiler thermostat - This control allows adjustment of

the temperature of the water leaving the boiler to heat either the radiators or the hot water, via the hot water heat exchanger.

The boiler thermostat has an operating range of 75˚C to 85˚C. For optimum hot water operation, ensure

this is set to maximum.

If a timer/programmer has been fitted, it is useful to remember when setting the times for the 'on' periods that it might take up to an hour for the house to become warm, especially in colder weather. Also the effect of the central heating will remain for a time when the central heating is turned off.

The boiler will operate on either Class C2 Kerosene or Class D Gas Oil to BS 2869:1998. Your Installer will have informed you of the type of fuel your boiler has been set to use and he will have marked this on the boiler data label. You should always quote the type of fuel you require when ordering from your supplier.

Do not wait until the fuel runs out before you order some more. Sludge in the bottom of the tank may be drawn into the fuel lines. If it is possible, switch off the boiler when the new supply is delivered and leave the fuel to settle for an hour before restarting the boiler.

1 - OUTDOOR COMBI 90 V3 and COMBI MAX USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

1.1

bout your Combi V3 or Combi Max Boiler

1.2

Boiler controls (see Fig. A)

1.4

About your fuel

1.3

Useful tips

To ensure that the hot water performance is not reduced first thing in the morning, or in the evening if the heating is off through the day, set the heating timer/programmer to switch the heating on at least 30 minutes before hot water will normally be required in the morning (or evening).

Note: Low level flue installations ( flue terminal directly from the Outdoor module case) must only be used with Kerosene.

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our Grant Condensing Combi boiler is fully automatic once switched on, and will provide domestic hot water at mains pressure on demand and central heating when the boiler and heating system controls call for it. The boiler On/Off switch i

ncorporates a 'mains on' neon, see Fig. B, which lights when the boiler is switched on, but does not necessarily indicate the burner is firing.

Your installer may have fitted either:-

a) A simple timer - either 7-day or 24-hour timer, to control

the central heating operation of the boiler only, or

b) A programmable room thermostat, to control the central

heating operation of the boiler only, or

c) A 2-channel programmer to control the central heating

On/Off times AND allow the hot water to be switched off when required.

To access the Outdoor module controls, remove the front panel by turning the handle at the bottom and pull it forward at the bottom.

1 On/Off switch - This switches the boiler on and off.

Note: The boiler will not supply central heating OR

domestic hot water if this switch is set to OFF, but the built in frost thermostat will still operate - provided that the electrical supply to the boiler is still switched on.

2 Test switch - This is for the Service engineer to use and

should be left set to OFF.

3 Boiler heating thermostat - Controls the temperature of

the water leaving the boiler to the central heating system. Operation of this control does not affect the temperature of the hot water flowing to the taps.

You should always quote the type of fuel you require when ordering from your supplier.

2.3

About your fuel

2.2

Boiler controls (see Fig. B)

Grant Condensing Combi boilers only operate on Class C2 Kerosene to BS 2869:1998.

About your Outdoor Condensing Combi

2.1

Outdoor Combi 90 V3, Combi Max and Condensing Combi

2 - OUTDOOR CONDENSING COMBI USER INSTRUCTIONS

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Fig. A - Boiler controls (Outdoor Combi 90 V3 and Combi MAX)

Fig. B - Boiler controls (Outdoor Condensing Combi)

Outdoor Combi 90 V3, Combi Max and Condensing Combi

3 - OUTDOOR COMBI 90 V3, COMBI MAX & CONDENSING COMBI USER INSTRUCTIONS

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Ensure that - There is sufficient fuel in the supply tank and all fuel supply valves are open, the water supply is on, the electricity supply to the boiler is off, the Boiler On/Off switch is set to OFF, the white pointer on the pressure gauge i

s not below the red pointer, the room thermostat (if fitted) is at the desired setting and the timer/programmer (if fitted) is correctly set.

2 Switch on the electricity supply to the boiler.

3 Set the On/Off switch to ON.

4 The boiler will light automatically to heat the water stored

in the boiler.

If the timer/programmer is set to an 'on' period the boiler will continue to run to provide central heating. If a hot tap is opened the boiler will supply hot water.

For short periods - Set the On/Off switch to OFF. To restart, simply set the switch to ON.

For long periods: Set the On/Off switch to OFF and switch off the electricity supply to the boiler. If required, the fuel supply valve may be closed and the water and electricity supplies turned off at the mains.

To restart, refer to the full lighting instructions above.

Note: The built in frost thermostat will not operate the boiler if the electricity supply to the boiler is switched off.

1 Check that the boiler On/Off switch is set to ON.

2 Check that the timer/programmer (if fitted) is working and

is in an 'on' period.

3 Check that all thermostats are set to the desired setting and

are calling for heat.

4 Check if the burner 'Lock-out' reset button on the burner is

lit. If it is, press it to start the burner. If the burner fails to light and goes to 'Lock-out' again, check that you have sufficient fuel in the storage tank and that the fuel supply valve is open.

5 Ensure that a fuse has not blown or that the electricity

supply has not failed.

6 Check to see if the overheat thermostat has operated (see

note 4 in Section 3.6).

7 Check that the white pointer on the pressure gauge is not

below the red pointer.

If the heating system water pressure falls below 0.2 bar the boiler low pressure cut-out switch will activate and an a

mber neon on the control panel (see Fig. A or B) will light. The system must be recharged to between 0.5 and 1 bar. If the heating system loses pressure on a regular basis then contact your Installer to investigate the cause.

If the burner still fails to light after carrying out these checks t

hen a fault exists. Switch off the electricity supply to the boiler

and contact your Service engineer.

The boiler will supply domestic hot water whenever a hot tap is opened, providing the Boiler On/Off switch is set to ON, and the hot water switch of the programmer (if fitted) is also set to ON.

The flow of water from the taps (hot or cold) depends upon the mains water pressure, and in some homes it may not be possible to use more than one tap at the same time.

The boiler operates on a sealed central heating system which will have been pressurised by your Installer. He will have set the red pointer on the pressure gauge (see Fig. A or B), to indicate the system pressure (when cold) usually between 0.5 and 1.0 bar. Do not adjust this pointer. The white pointer indicates the actual system pressure which will increase slightly when the boiler is operating. If the white pointer falls below the red pointer (when the boiler is switched off and cold), you should contact your Service Engineer to re-pressurise the system. If the system requires frequent re-pressurising, ask your Service Engineer to check the heating system for leaks. If the heating system water pressure falls below 0.2 bar the boiler low pressure cut-out switch will activate and an amber neon on the control panel (see Fig. A or B) will light. The system must be recharged to between 0.5 and 1 bar. If the heating system loses pressure on a regular basis then contact your Installer to investigate the cause.

The boiler is fitted with an automatic air vent which removes air trapped in the boiler. Any air trapped in the radiators needs removing by venting the radiators using the vent screw at the top of the radiators. Only vent a radiator if the top is cool and the bottom is hot. Excessive venting will reduce the system pressure, so only vent when necessary and check the system pressure as mentioned above.

3 - OUTDOOR COMBI 90 V3, COMBI MAX & CONDENSING COMBI USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

3.1

ighting your boiler (see Fig. A or B)

3.2

Turning off your boiler (see Fig. A or B

3.4

Domestic hot water system

3.5

Sealed central heating system

3.3

Points to check if burner fails to light

Note: Your sealed system may incorporate a 'Top up' vessel, advice on how to use it should be obtained from your Installer.

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he boiler is fitted with a safety valve to release excess pressure from the system. If water or steam is emitted from the end of the s

afety valve discharge pipe, switch off the boiler and contact

your Installer or Service engineer.

To re-pressurise the system by adding water:

1 Only add water to the system when it is cold and the boiler

is off. Do not overfill.

2 Ensure the flexible filling loop is connected and that the shut

off valve connecting it to the boiler is open and the double check 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.

3 Gradually open the double check valve on the front of the

filling loop until water is heard to flow.

4 Vent each radiator in turn, starting with the lowest one in

the system, to remove air.

5 Continue to fill the system until the pressure gauge indicates

the required pressure between 0.5 and 1.0 bar. Close the fill point valve.

6 Close the valves either side of the filling loop and

disconnect the loop.

The temperature of the water leaving the boiler to the radiators can be increased by turning the boiler thermostat (see Fig. A or B) clockwise.

The boiler will provide central heating whenever the timer/ programmer (if fitted) is in an 'on' period and the room thermostat (if fitted) is calling for heat.

1 Boiler controls - Refer to Section 1.2 or 2.2.

2 Pressure switch - If the heating system water pressure falls

below 0.2 bar the boiler low pressure cut-out switch will activate and an amber neon on the control panel (see Fig. A or B), will light. The system must be recharged to between

0.5 and 1 bar. If the heating system loses pressure on a regular basis then contact your Installer to investigate the cause.

3 Burner Lock-out reset button - If there is a burner

malfunction, a built-in safety circuit switches the burner off and the Lock-out reset button on the burner (see Fig. A or B), will light. Usually such malfunctions are short lived and pressing the reset button will restore normal operation.

If the burner continually goes to 'Lock-out' a fault exists or the fuel supply is low. If you have sufficient fuel, you will need to call your Service engineer.

Overheat thermostat - Your boiler is fitted with a safety overheat thermostat which will automatically switch off` the b

oiler in the case of a control malfunction causing overheating. A red neon on the control panel (see Fig. A or B), will light indicating the thermostat has operated.

If your boiler goes off and you try to light it but nothing happens and the 'Lock-out' reset button on the burner is not l

it, the overheat thermostat has probably operated. The boiler will not light until the thermostat is reset. To reset, unscrew the small plastic cap (see Fig. A or B), press the button then replace the cap.

Note: You may have to wait for the boiler to cool down before the button will reset. If this condition continually repeats, contact your Service engineer.

5 Flue terminal - The boiler flue terminal must not be

obstructed or damaged.

In severe conditions check that the terminal does not become blocked by snow.

6 Failure of electricity supply - If the electricity supply fails,

the boiler will not operate. It should relight automatically when the supply is restored.

Note: The timer/programmer may need to be reset after a power failure.

The boiler requires a 230/240 V - 50 Hz supply. It must be protected by a 5 Amp fuse.

3 - OUTDOOR COMBI 90 V3, COMBI MAX & CONDENSING COMBI USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

3.6

General notes and care of your system

3.7

Electricity Supply

The expansion vessel air charge must be checked annually. Failure to maintain an adequate air charge in t

he vessel may invalidate the warranty.

Warning: This appliance must be earthed.

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oiler technical data - Outdoor Combi 90 V3 and Outdoor Combi Max boilers

4.1

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Model Combi 90 V3 Combi Max

Boiler water content litre 40 40

gal 8.8 8.8

* Weight (dry) kg 158 159

lb 348 350

Max. heat input (Kerosene) kW 27.6 36.8

Btu/h 94 200 125 500

Connections: Heating flow and return 22 mm copper pipe

Cold water mains inlet 15 mm copper pipe

Domestic hot water outlet 15 mm copper pipe **

Pressure relief valve discharge 15 mm copper pipe

Waterside resistance Flow/Return temp. diff. of 10˚C 26.5 mbar

Waterside resistance Flow/Return temp. diff. of 20˚C 9.5 mbar

Boiler thermostat range 75˚ to 85˚C

Limit (safety) thermostat switch off temp. 111˚C ± 3˚C

Maximum heating system pressure (cold) 1.0 bar

Minimum heating system pressure (cold) 0.5 bar

Pressure relief valve 2.5 bar

Expansion vessel 12 litres (pre-charged at 1.0 bar)

Maximum heating system volume *** 128 litres

Maximum operating pressure 2.5 bar

Minimum domestic hot water flow rate 3.0 litres/min (0.66 gal/min)

Maximum domestic hot water temperature 65˚C (factory set)

Maximum mains water inlet pressure 8.0 bar

Minimum recommended mains water inlet pressure 2.5 bar

Max. hearth temperature Less than 50˚C

Electricity supply 230/240 V ~ 50 Hz Fused at 5 Amp

Motor power 90 W max.

Starting current 2.60 Amp

Running current 0.85 Amp

Oil connection 1/4" BSP Male (on end of flexible fuel line)

* Weight includes burner but excludes flue ** 22 mm hot water pipe can be connected to the Combi Max if required. *** Based on expansion vessel charge and initial cold system pressure of 0.5 bar.

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oiler technical data - Outdoor Condensing Combi boilers

4.2

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Model Condensing Combi 26 Condensing Combi 36

Boiler water content litre 48.5 53.5

(including 32.5 litre primary store) gal 10.7 11.8

Weight (dry) kg 188 218

lb 415 481

Max. heat input (Kerosene) kW 26 36

Btu/h 88 700 123 000

Connections: Heating flow and return - copper 22 mm 28 mm

Cold water mains inlet - copper 15 mm 22 mm

Domestic hot water outlet - copper 15 mm 22 mm

Pressure relief valve discharge 15 mm copper pipe

Condensate connection 22 mm plastic pipe

Waterside resistance Flow/Return temp. diff. of 10˚C 28.5 mbar 26.0 mbar

Waterside resistance Flow/Return temp. diff. of 20˚C 10.0 mbar 9.5 mbar

Boiler thermostat range 65 to 80˚C

Limit (safety) thermostat switch off temp. 111˚C +0 -3˚C

Maximum heating system pressure (cold) 1.0 bar

Minimum heating system pressure (cold) 0.5 bar

Pressure relief valve 2.5 bar

Expansion vessel (pre-charged at 1 bar) 12 litres 14 litres

Maximum heating system volume** 128 litres 148 litres

Maximum operating pressure 2.5 bar

Minimum domestic hot water flow rate 3.0 litres/min (0.66 gal/min)

Maximum domestic hot water temperature 65˚C (factory set)

Maximum mains water inlet pressure 8.0 bar

Minimum recommended mains water inlet pressure 2.5 bar

Max. hearth temperature Less than 50˚C

Electricity supply 230/240 V - 50 Hz Fused at 5 Amp

Motor power 90 W max.

Starting current 2.60 Amp

Running current 0.85 Amp

Oil connection 1/4" BSP Male (on end of flexible fuel line)

* Weight includes burner but excludes flue

** Based on expansion vessel charge and initial cold system pressure of 0.5 bar

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4.4

Outdoor Combi 90 V3 & Outdoor Combi MAX Boilers using Class D gas oil - High level flue only

4.5

Approximate air damper settings

utdoor Combi 90 V3 & Outdoor Combi MAX Boilers using Class C2 kerosene

4.3

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Note: Boilers are despatched for use with kerosene. Combi 90 V3 (Riello RDB1 burner)

Heat Output Net Heat Input Net eff. * Head Nozzle Oil press. Smoke Fuel Flow Net flue gas Flue gas mass CO

(kW) (Btu/h) (kW) (Btu/h) % type size (bar) No. rate (kg/h) temp. (˚C) flow rate (kg/h) (%)

26.4 90 000 28.5 97 402 92.4 LD3 0.75/60˚EH 9.5 0 - 1 2.4 180 38.7 12.0

Combi MAX (Riello RDB2.2 burner)

Heat Output Net Heat Input Net eff. * Head Nozzle Oil press. Smoke Fuel Flow Net flue gas Flue gas mass CO

(kW) (Btu/h) (kW) (Btu/h) % type size (bar) No. rate (kg/h) temp. (˚C) flow rate (kg/h) (%)

33.3 113 600 36.8 125 500 90.5 T5 1.00/80˚EH 9.0 0 - 1 3.10 190 51.5 12.0

Combi 90 V3 (Riello RDB1 burner)

Heat Output Net Heat Input Net eff. * Head Nozzle Oil press. Smoke Fuel Flow Net flue gas Flue gas mass CO

(kW) (Btu/h) (kW) (Btu/h) % type size (bar) No. rate (kg/h) temp. (˚C) flow rate (kg/h) (%)

26.4 90 000 28.5 97 402 92.4 LD3 0.60/60˚S 12.0 0 - 1 1.97 200 38.7 12.0

Combi MAX (Riello RDB2.2 burner)

Heat Output Net Heat Input Net eff. * Head Nozzle Oil press. Smoke Fuel Flow Net flue gas Flue gas mass CO

(kW) (Btu/h) (kW) (Btu/h) % type size (bar) No. rate (kg/h) temp. (˚C) flow rate (kg/h) (%)

32.9 112 463 36.0 122 910 90.5 T5 0.75/80˚S 11.0 0 - 1 3.02 200 51.5 12.0

Notes:

1 The data given above is approximate only

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 the low level discharge of the Outdoor modules

4 Net flue gas temperatures given are ± 10%.

5 * Net thermal efficiency (Notified Body).

6 Flue gas temperatures taken at combustion door test point will be approximately 25˚C higher.

Note: The burner is supplied factory set at the output given in Section 4.3.

When commissioning, or when the type of fuel is changed, the air damper must be adjusted to obtain the correct C0

level and the

installer must amend the data label.

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Note: Condensing Combi boilers are only for use with kerosene.

Model Burner Heat Output Net Nozzle Oil Smoke Burner Fuel flow Flue gas C0

type eff * press. No. head rate temp.

(kW) (Btu/h) % (bar) (kg/h) (˚C) (%)

26 Riello RDB1 26.0 88 700 101.0 0.75/80˚EH 8.0 0 - 1 T2 2.16 78 12.0

36 Riello RDB2.2 36.0 123 000 101.5 1.00/80˚EH 9.1 0 - 1 T5 3.01 78 12.0

Notes:

1 The data given above is approximate only and is based on the boiler being used with a low level balanced flue.

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 a Condensing Combi boiler.

4 * Net thermal efficiency.

5 The net flue gas temperatures given above are ± 10%.

6 When commissioning the air damper must be adjusted to obtain the correct CO

level.

7 The combustion door test point may be used for CO2and smoke readings only. Do not use this test point for temperature or

efficiency readings.

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:

1 . The test point is for CO2and smoke readings only.

2. The temperature and efficiency readings must be taken from the flue terminal.

utdoor Condensing Combi Boilers using Class C2 kerosene

4.6

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Page 12

6 Check to see if the overheat thermostat has operated (see

note 4 in Section 3.6).

7 Check that the black pointer on the pressure gauge is not

below the red pointer.

8 If the heating system water pressure falls below 0.2 bar the

boiler low pressure cut-out switch will activate and an amber neon on the control panel (see Fig. A or B) will light. The system must be recharged to between 0.5 and 1 bar. If

the heating system loses pressure on a regular basis then contact your Installer to investigate the cause.

4.7

oiler dimensions - Outdoor Combi 90 V3 and Combi Max

Fig. 1

Fig. 2

4.8

Water schematic of boiler - Outdoor Combi 90 V3 and Outdoor Combi Max

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Page 13

4.9

oiler dimension - Outdoor Condensing Combi

Fig. 3

Fig. 4

4.10

Water schematic of boiler - Outdoor Condensing Combi

Outdoor Combi 90 V3, Combi Max and Condensing Combi

4 – BOILER TECHNICAL INFORMATION

Page 14

The Grant Outdoor Combination boilers are automatic pressure jet oil appliances designed for use with a sealed central heating system and to provide domestic hot water at mains pressure.

All boilers are supplied with the control panel and burner factory fitted and set for use on Class C2 kerosene.

Where required, a twin-wall stainless steel high -level flue system (Green system) is available from your local stockist. Refer to Section 6.3 for details.

If a high-level flue system is used, the Outdoor Combi 90 V3 and Combi Max models can be adapted for use on Class D gas oil. Refer to the technical information in Section 4.4 for gas oil burner settings.

Condensing Combi boilers are only suitable for use with Class C2 kerosene.

To change the nozzle, remove the burner from the boiler and then remove the nozzle as described in Section 10.4. The installer/commissioning engineer must amend the information on the boiler data label accordingly.

All burners are ready to be connected to a single pipe system with a loose flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor supplied with the boiler. If required, an additional flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from your local stockist, for two-pipe oil supply systems, Part No. RBS 104.

The boiler control panel is fitted with an ON/OFF switch, boiler thermostat control knob and the manual reset button for the overheat thermostat.

The temperature of the primary water leaving the boiler to heat the radiators may be adjusted using the boiler thermostat.

he temperature of the domestic hot water leaving the boiler is controlled by a thermostatic mixing valve, located in the rear c

ompartment of the boiler on the Outdoor Combi 90 V3 and Combi Max, and in the front burner compartment on the Outdoor Condensing Combi 26 and 36 boilers. Refer to Section

5.13 for boiler operating details.

To achieve the optimum hot water performance from the O

utdoor Combi 90 V3 and Combi Max, the boiler thermostat

should be set to maximum.

The setting of the boiler thermostat on the Outdoor Condensing Combi boilers has no effect on the domestic hot water temperature.

A remotely located timer and room thermostat, or alternatively a programmable room thermostat, can be connected to the boiler to allow the User to set the central heating operating times and temperature.

Alternatively a remote programmer, located in a convenient position for the User, can be connected to the boiler to control the operating times of both the central heating and domestic hot water.

The Grant Outdoor Combi boilers are supplied in one pack with the burner and control panel factory fitted.

The low level discharge flue terminal and terminal guard are supplied loose inside the boiler enclosure, as is the wall flashing strip, for fitting on site.

5.1

Boiler description

5.2

Delivery

5 - GENERAL BOILER INFORMATION

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Note: As Class D gas oil should not be used unless the flue terminal concerned is more than 2 metres above ground level, only kerosene can be used with the low level discharge flue system factory fitted to all Grant Outdoor Combi boilers.

IMPORTANT: If the boiler is to be used on gas oil, it must not be operated on that fuel until the burner nozzle and pump pressure have been changed to suit.

Page 15

Installation of a Grant Combi boiler must be in accordance with the following recommendations:-

a Building Regulations for Ireland, England or Wales, and

the Building Standards for Scotland issued by the Department of the Environment and any local Byelaws etc.

b Model and local Water Undertaking Byelaws.

c Applicable Control of Pollution Regulations.

d 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 Information Book 3 (Installation requirements for oil fired boilers and oil storage tanks).

The installation should also be in accordance with the latest edition of the following British Standard Codes of Practice:-

BS 715 Metal flue pipes, fittings, terminals and

accessories.

BS 799:5 Oil storage tanks.

BS 1181 Clay flue linings and flue terminals.

BS 4543:3 Factory made insulated chimneys for oil fired

appliances.

BS 4876 Performance requirements for oil burning

appliances.

BS 5410:1 Code of Practice for oil firing appliances.

BS 5449 Forced circulation hot water systems.

BS 7593 Code of Practice for treatment of water in

heating systems.

BS 7671 Requirements for electrical installations, lEE

Wiring Regulations.

5.4.1 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 galvanised tank must not be used.

A plastic tank may be used and must comply with OFS T100.

Note: Plastic tanks should be adequately and uniformly supported on a smooth level surface, across their entire base area.

5.4.2 Fuel pipes

1 Fuel supply pipes should be of copper tubing, of a suitable

internal diameter.

Galvanised pipe must not be used.

2 Flexible pipes must not be used outside the boiler case.

3 A remote sensing fire valve must be installed in the fuel

supply line. Recommendations are given in BS 5410:1:1997.

4 A metal bowl type filter with a replaceable micronic filter

must be fitted in the fuel supply line. A shut-off valve should be fitted before the filter, to allow the filter to be serviced.

5 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 (600 mm) and 3/8" to 1/4" BSP male adaptor are available from your local stockist.

5 - GENERAL BOILER INFORMATION

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5.3

Regulations to comply with

Failure to install and commission appliances correctly may invalidate the boiler warranty.

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 15 on page 58.

ome Regional statutory requirements may deem this appliance to be a 'controlled service'. Where this is the case, it is a legal requirement that the appliance is installed and commissioned either under the remit of b

uilding control or by a 'Competent person' such as a suitably qualified OFTEC registered technician.

5.4

Fuel supply

Page 16

The flexible fuel lines supplied should be inspected annually when the boiler is serviced and replaced at least every two y

ears.

5.4.3 Single pipe system - (See Fig. 5)

1 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.

2 As supplied the burner is suitable for a single pipe system.

5.4.4 Two pipe system - (See Fig. 6)

1 When the storage tank outlet is below the burner, the two

pipe system should be used. The pipe runs should be as shown in Fig. 5. The return pipe should be at the same level in the tank as the supply pipe, both being 75 to 100 mm 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 m below the burner.

3 A non-return valve should befitted in the supply pipe

ogether 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.

5 The pump vacuum should not exceed 0.4 bar. Beyond this

limit gas is released from the oil. A vacuum gauge must be fitted to the fuel pump to check the vacuum reading.

To be used with a two-pipe system, the burner must be fitted with an additional flexible fuel line (a flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from your local stockist.

For guidance on installation of top outlet fuel tanks and suction oil supply sizing, see OFTEC booklet T1/139. Available at www.oftec.org.uk

Fig. 5 - Single pipe system

Head A Maximum pipe run (m)

(m) 10mm OD pipe 12mm OD pipe

0,5 10 20

1.0 20 40

1.5 40 80

2.0 60 100

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 17

5.4.5 Tiger Loop system - (See Figs. 7 and 8)

1 When the storage tank is below the burner, an alternative to

a two pipe system can be achieved using the Tiger Loop oil deaerator. This effectively removes the air from the oil supply on a single pipe lift.

2 The Tiger Loop is connected close to the boiler as a two pipe

system (omitting the non-return valve) as shown in Fig. 7. Refer to the manufacturers instructions supplied with the Tiger Loop. The Tiger Loop must be mounted vertically.

3 To be used with a Tiger Loop system, the burner must be

fitted with an additional flexible fuel line (a flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from your local stockist. See Section

5.3.6.

Fig. 6 - Two pipe system

Fig. 7 - Tiger loop system

Head A Maximum pipe run (m)

(m) 10 mm OD pipe 12 mm OD pipe

0 35 100

.5 30 100

1.0 25 100

1.5 20 90

,0 15 70

3.0 8 30

3.5 6 20

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 18

5.4.6 Two pipe oil supplies

See Fig. 9

1 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 (see Fig. 9) into the tapping in the return port.

2 The By-pass screw is supplied in the boiler accessory pack.

3 Remove the plastic burner cover (two screws).

4 Remove and discard the blanking plug from the return

connection of the pump and fit the By-pass screw using an hexagonal key.

5 Connect the return oil flexible fuel line to the pump.

6 Connect the 3/8" to 1/4" BSP adaptor to the flexible fuel

line.

7 Flexible fuel lines and adaptors are available to purchase

from your local stockist.

8 The burner cover may be left off until the boiler is

commissioned.

Fig. 8 - Tiger loop

Fig. 9 - RDB pump

1 Oil inlet connection 5 Pressure adjuster

2 Return connection 6 Vacuum gauge connection

3 By-pass screw 7 Solenoid

4 Pressure gauge connection 8 Supply to nozzle

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 19

A 230/240 V ~ 50 Hz mains supply is required.

2 The supply must be fused at 5 Amp and there must only be

one common isolator for the boiler and control system, and i

t must provide complete electrical isolation.

3 A fused double pole switch or a fused three pin plug and

shuttered outlet socket should be used for the connection.

4 The power supply cable should be at least 0.75 mm

PVC as

specified in BS 6500, Table 16.

5 All the wiring external to the boiler must be in accordance

with the current I.E.E. Wiring Regulations.

6 Any room thermostat or frost thermostat used must be

suitable for use on mains voltage.

7 The boiler requires a permanent mains supply, do not

interrupt it with any external time control.

8 In the event of an electrical fault after installation of the

boiler, the following electrical system checks must be carried out:- Short circuit, Polarity, Earth continuity and Resistance to earth.

1 Grant Outdoor Combi boilers are supplied with a factory

fitted frost protection thermostat. It is prewired to the boiler control system and factory set to 5˚C. This thermostat is located inside the control panel of the Outdoor Combi 90 V3 and Combi Max boilers, and on the back of the control panel of the Condensing Combi 26 and 36 models.

2 For total system protection against freezing, particularly

during extended periods without electrical power, Grant recommend the use of a combined heating system antifreeze and corrosion inhibitor, used in accordance with the manufacturer's instructions.

See Fig. 17

On underfloor systems it is essential that the return is pre-heated by mixing flow water into the return before it enters the boiler. To prevent internal corrosion of the boiler water jacket, the return water temperature must be maintained above 55˚C for the Combi 90 V3 and Combi Max and 40˚C for the Condensing Combi.

Fig.. 10 - Underfloor system

General - 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 729 1:Part 1:

1990) for the application concerned.

IMPORTANT: The first metre of pipework connected to both the heating flow and return connections of the boiler must be made in copper.

If plastic pipe is to be used, the installer must check with the plastic pipe manufacturer that the pipe to be used is suitable for the temperature and pressures concerned. Pipe must be Class S to BS 729 1: Part 1: 1990.

The boiler is fitted with a low-pressure switch to shut off power to the boiler if the system pressure drops below 0.2 bar.

Underfloor systems (see Section 5.6) - 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.

5.4

Electricity supply

5.5

Frost protection

5.6

Underfloor heating systems

5.7

Pipework materials

The boiler must be earthed.

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 20

1 The Outdoor Module 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 Fig. 11, are achieved.

Adequate clearance must be left around the Module for servicing. In particular, a minimum clearance of 600 mm a

bove the Module for removal of the top panel and 600 mm

at the opposite end to the flue outlet for access to the burner.

5.8

Boiler location

The flue terminal must be a minimum distance of 1.8 m from an oil storage tank.

The flue terminal should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings.

Fig. 11 - Flue terminal positions

Distances measured to rim of terminal.

Note: *75 mm with protection.

Clearances recommended by Grant Engineering (Irl) Limited in accordance with relevant Standards and Building Regulations.

Notes: 1 An opening means an

openable element, such as an openable window, or a permanent opening such as a permanently open air vent.

2 Notwithstanding the dimen-

sions given, a terminal should be at least 300 mm from combustible material, e.g. a window frame.

3 A way of providing protec-

tion of combustible material would be to fit a heat shield at least 750 mm wide.

Terminal position Min. distance (mm)

A Below gutters (without protection) *600

B Horizontal from a door, window or air vent 600

C Above ground, flat roof or balcony level 300

D Below gutters, eaves or balconies (without protection) *600

E From an external corner 300

F From a terminal facing the terminal 1200

G From a surface facing the terminal 600

H Vertical from a terminal on the same wall 1500

1 Horizontally from a terminal on the same wall 750

J Directly below an opening, air brick, window etc. 600

K From a vertical drain pipe or soil pipe 300

L From an internal corner 300

M From an oil storage tank (not shown) 1800

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 21

A flow restrictor is factory fitted to all models except the Combi Max and Condensing Combi 36, to limit the flow rate to approximately 15 litres/min. The flow restrictor is located in the outlet side of the cold water inlet isolating v

alve.

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/min.

3 To ensure economic use, the pipe runs between the boiler

and hot taps should be as short as possible and in 15 min copper pipe or 22 mm for the Combi Max and Condensing Combi 36 only. Where possible the pipework should be insulated to reduce heat loss.

4 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.

5 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 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 fitted at the point of the flexible hose connection.

6 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 over-rim flushing type. The outlets should be shrouded and unable to have a temporary hand held spray attached. Arrangements for anti-syphonage are not necessary.

8 The mains water connection to the boiler must be the first

connection from the mains supply.

A water hardness kit is supplied with the boiler. This should be used to determine the water hardness as follows:

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 on the strip are fully wetted.

Shake off the surplus water and wait for one minute.

Assess the hardness of the water by the colouration of the test zones on the strip using the following chart.

Note: (1 mg/l = 1 ppm (part per million)

Should the total hardness of the water exceed 125 ppm it is essential that an in-line scale inhibitor or, preferably, a water softener is fitted in the cold water supply to the boiler to reduce scale formation within the boiler. Failure to do so may invalidate both the manufacturers warranty and any extended warranty covering the appliance. Consult the local water undertaking if in any doubt about the hardness of the water or the use of a water softener.

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 (IRL) Limited cannot be held responsible for any damage or misuse caused by the fitting of any water conditioning device.

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.

IMPORTANT: Do not immerse the test strip in running water and avoid contact.

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 warranty.

7 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.

5.9

Domestic hot water system

5.10

To use the water hardness kit

Green areas Violet areas Hardness Total hardness mg/l (ppm)

40very soft <50 mg/l calcium carbonate

31soft >70 mg/l calcium carbonate

22medium >125 mg/l calcium carbonate

13hard >250 mg/l calcium carbonate

04very hard >370 mg/l calcium carbonate

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 22

When thermostatic radiator valves are fitted, the system must incorporate an adequate automatic by-pass.

Fig. 12 - Sealed System

Sealed central heating system

5.11

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

See Fig. 16

1 The boilers are only suitable for use with a sealed system

complying with the requirements of BS 5449. The maximum temperature of the central heating water is 85˚C for the Combi 90 V3 and Combi Max and 75˚C for the Condensing Combi models.

Design notes - when designing the system, the pump head, expansion vessel size, radiator mean temperature, etc. must all be taken into account.

2 The boilers are supplied with the following items factory

fitted:

a 12 litre diaphragm expansion vessel complying with BS

4814, pre-charged at 1.0 bar. A 14 litre vessel is fitted in the Condensing Combi 36 model.

b System pressure gauge, with an operating range of 1 to

4 bar.

c Pressure relief safety valve complying with BS 6759 and

set to operate at 2.5 bar. The discharge pipe must be routed clear of the boiler to a drain, in such a manner that it can be seen, but cannot cause injury to persons or property.

d Automatic air vent, fitted to the top of the boiler, ensures

the boiler is vented.

e Filling loop. This must be isolated and disconnected

after filling the system.

3 Refer to Sections 4.1 or 4.2 for maximum heating system

volume and BS 7074: for further guidance. If the system volume exceeds the maximum value given for the boiler, an additional vessel will be required. This should be connected to the system on the return. Refer to Fig. 12.

Refer to Section 6.5 for further details of the expansion vessel.

The system design pressure (cold) should be between 0.5 and 1.0 bar. This pressure is equivalent to the maximum s

tatic head (see Fig. 16) in bar + 0.3 (1 bar = 10.2 metres of

water).

5 When thermostatic radiator valves are fitted, a system by-

pass must be fitted. The by-pass must be an automatic type.

6 Provision should be made to replace water lost from the

system. This may be done manually (where allowed by the local Water Undertaking) using the filling loop arrangement supplied with the boiler.

7 Filling of the system must be carried out in a manner

approved by the local Water Undertaking. Where allowed, the system may be filled via the filling loop supplied (the loop arrangement includes a double check valve assembly).

8 All fittings used in the system must be able to withstand

pressures up to 3 bar.

9 Radiator valves must comply with the requirements of BS

2767(10):1972.

10 One or more drain taps (to BS 2879) must be used to allow

the system to be completely drained.

11 The expansion vessel is connected via a flexible hose to

allow it to be moved to gain access to the cleaning cover. When replacing the vessel, care should be taken to ensure that the flexible connecting hose is not twisted.

Page 23

When in condensing mode the Condensing Combi boiler p

roduces condensate from the water vapour in the flue gases. Provision must be made for the safe and effective removal of the condensate.

Condensate can be disposed either internally - into an internal domestic waste system or directly into the soil stack, or externally - to an external soil stack, gully, hopper or soakaway.

It should be noted that connection of a condensate pipe to the drain may be subject to local Building Control requirements.

Pipework

The internal diameter of condensate disposal pipes should not be less than 20 mm - e.g. 22 mm plastic plumbing pipe or 19 mm (3/4") plastic overflow pipe.

For boilers installed 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, 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.

External pipework should be kept as short as possible (less than 3 metres) and 32 mm waste pipe used to minimise the risk of freezing.

The number of bends, fittings and joints on external pipes should be kept to a minimum to reduce the risk of trapping condensate.

Condensate trap

Grant Outdoor Condensing Combi boilers are supplied with a factory fitted condensate trap to provide the required 75 mm 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 rubber bung), See Fig. 13. A short length of flexible pipe is supplied connected to the outlet of the trap. The end of this flexible pipe should be connected to the condensate discharge pipe.

Fig. 13 - Condensing condensate trap

If connecting the condensate discharge internally - into a waste system or soil stack - the bung must be fitted in the overflow outlet of the trap.

On external discharge systems to a gully or soakaway, the bung should be removed from the overflow outlet. If connected to an external soil stack, the bung must be fitted on the trap.

If there is any discharge of condensate from the overflow outlet, this could indicate a blockage (possibly due to freezing). Turn off the boiler and contact your service engineer.

5.12

Condensate disposal - Condensing models only

Condensate disposal pipework must be plastic (plastic waste

pipe is suitable). Copper or steel pipe is NOT suitable and

should NOT be used.

IMPORTANT: 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.

Condensate disposal pipes must be fitted with a fall of 2.5˚

(1: 20).

Condensate disposal pipes MUST be fitted with a trap.

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 24

Once the boiler is switched on, and the store is up to temperature, it will provide domestic hot water on demand.

A timer and room thermostat, or alternatively a programmable room thermostat, connected to the boiler will only control the operation of the central heating.

When central heating is not required, e.g. in the summer months, the timer switch should be set to OFF.

Combi 90 V3 and Combi Max - If the Grant TCR programmer is fitted, the hot water operation is turned off if the right hand 'Boiler' switch is set to OFF.

Condensing Combi boilers - If the Grant 2-channel programmer is connected to the boiler, hot water will not be provided if the 'Hot Water' channel is switched OFF.

Domestic hot water supply always takes priority over central heating. If a demand for hot water occurs during a period of central heating, the boiler mode will automatically change to provide hot water until the demand ceases. This interruption in the central heating only lasts for as long as hot water is required and should not be noticed by the User.

Central Heating Mode - If there is a call for heat, i.e. the timer/programmer and room thermostat (if fitted) are calling for heat, the pump will start to circulate the central heating water and the burner will light. When the temperature in the boiler reaches that set on the boiler thermostat, the burner is

turned off. The pump continues to run, circulating water around the system, for as long as both the timer/programmer and room thermostat (if fitted) are calling for heat. As the heating system water cools, the temperature drop is detected by the boiler thermostat and the burner is automatically restarted for the cycle to continue until either the timer or room thermostat stops calling for heat. The burner and pump are then turned off.

Domestic Hot Water Mode (Combi 90 V3 and Combi Max)

- When there is a demand for hot water (from a hot water tap,

shower, etc.) the water flow operates the diverter valve and in turn the flow switches. The pump starts and the primary water from the boiler is diverted through the domestic hot water plate heat exchanger, heating the incoming mains water.

The hot water produced is mixed with incoming mains cold water in the thermostatic blending valve to automatically ensure that the leaving hot water temperature does not exceed 65˚C.

When the hot water demand ceases (the hot tap or shower valve is turned off), the diverter valve and flow switches are no longer operated.

The boiler will return to the central heating mode, if there is a heating demand from the timer/programmer and room thermostat, with the pump and burner running.

If there is no heating demand from the timer/programmer and room thermostat, the pump stops but the burner will continue to run for a short period until the primary water in the boiler reaches the required temperature ready for another hot water operation.

Fig. 14 - Purpose made condensate soakaway

5.13

Method of operation

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 25

omestic Hot Water Mode (Condensing Combi) - When

there is a demand for hot water (from a tap, shower, etc.) the w

ater flow operates the flow switch. The Hot Water pump starts and circulates water from the primary store through the domestic hot water plate heat exchanger, heating the incoming mains cold water.

The hot water produced is mixed with incoming mains cold w

ater in the thermostatic blending valve to automatically ensure that the leaving hot water temperature does not exceed 65˚C.

When the hot water demand ceases (the hot tap or shower valve is turned off), the flow switch is no longer operated. The Hot Water pump will continue to run and the burner continues to fire until the primary store reaches the required temperature and the store temperature control is satisfied.

The boiler will return to the central heating mode, if there is a heating demand from the timer/programmer and room thermostat, with the Heating pump and burner running.

Note: As the temperature of the boiler will now be higher than the boiler thermostat setting, the burner may not fire immediately, but only after the primary flow temperature has fallen to below the thermostat setting.

If there is no heating demand from the timer/programmer and room thermostat, the Heating pump will not operate.

For optimum performance the thermostatic blending valve has been factory set to provide a hot water temperature of approximately 50˚C.

If the water in the boiler is already up to temperature when a hot tap is opened, there will be a delay before the burner fires to maintain the hot water temperature in the boiler (to heat the hot water).

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.

he Condensing Combi condensing boilers contain an extra heat exchanger which is designed to recover the latent heat n

ormally lost by conventional boilers. This is done by cooling the flue gases to below 55˚C, thus extracting more sensible heat and some of the latent heat.

To ensure maximum efficiency, the boiler return temperature should be 55˚C or less, this will enable the latent heat to be c

ondensed out of the flue gases. The boiler will achieve nett

thermal efficiencies of 100%.

To achieve maximum performance from a Condensing Combi boiler, 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 boiler 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 max flow temperature of 80˚C.

To achieve the maximum efficiencies possible from a Condensing boiler, the heating system should be designed to the following parameters:

Radiators:-

Flow temperature 70˚C

Return temperature 50˚C

Differential 20˚C

Underfloor:-

Flow temperature 50˚C

Return temperature 40˚C

Differential 1O˚C

1 Size radiators with a mean water temperature of 60˚C.

2 Design system controls with programmable room

thermostats or use weather compensating controls to maintain return temperatures below 55˚C.

The boiler should not be allowed to operate with return temperatures of less than 40˚C when the system is up to operating temperature.

5.14

How Grant condensing boilers work

5.15

Condensing heating system design considerations

Outdoor Combi 90 V3, Combi Max and Condensing Combi

5 - GENERAL BOILER INFORMATION

Page 26

1 Carefully remove the packaging from the boiler and lift it

off the pallet. If the optional high level flue (Green system) is to be used, follow the instructions supplied with the kit.

2 The low-level discharge flue terminal, terminal guard and

wall flashing strip are supplied loose inside the boiler.

3 Remove the casing top panel (four screws).

4 The flue may exit the boiler from the left, right or rear of

the casing. To allow for this the boiler is supplied with three removable panels - two blank panels and one with the flue outlet hole and seal.

Note: A spare blanking plate with a 112 mm dia. hole is supplied with the Outdoor Condensing Combi boilers. This is intended to provide an opening into the boiler if a 110 mm soil pipe is used as a pipe duct through the wall.

The panel with the flue hole is supplied fitted at the rear of the boiler, but can be re-positioned on either side to give the flue outlet position required. If so, a hole for the flue must be cut in the insulation (inside the casing side panel) using the hole in the plate as a guide.

5 Slacken the wing nuts holding the flue elbow and rotate the

elbow to the required direction for the flue to exit the casing.

6 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.

Carefully insert the terminal into the flue elbow until the bend of the terminal contacts the outer casing, then, pull the t

erminal forward approximately 25 mm and rotate the bend

so that the outlet is horizontal.

8 Tighten the wing nuts holding the flue elbow and fit the

stainless steel flue guard using the two screws provided.

9 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 Fig. 15.

10 A 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 30 mm between the bottom edge and the top of the casing top panel, to allow removal of the top panel for servicing.

6.1

Unpack the boiler

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 re-entering 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.

Fig. 15

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 27

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 Fig. 1 or 3 for the positions of the pipework openings in the enclosure sides.

If the boiler is to be installed 'free standing' (i.e. away from a wall) and the pipework run underground, slide away the covers to open the two 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.

2 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

1.0 mm2 cross section should be used within the boiler enclosure.

3 The oil supply line should be installed up to the position of

the boiler. Refer to Section 5.4.2 for details. The final connection into the boiler enclosure can be made with 10 mm 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 Fig. 16

Where it is not practical to use the factory supplied low level flue, the Outdoor Combi boilers may be fitted with the Grant 'Green System'. This is a twin wall stainless steel insulated vertical flue system.

An insulated boiler connector elbow, complete with test point, replaces the low level terminal and flue guard supplied with the boiler.

The Grant Vertical flue system connects to the elbow and may terminate at high level or vertically as required. See Fig. 16.

1 The flue 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.

2 The flue 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.

3 Condensing Combi only - The condensate can be allowed

to run back into the boiler. A condensate drain at the base of the flue system is not required.

If the flue terminal is fitted less than 2 metres above a surface to which people have access, the terminal must be protected by a guard. The guard must be fitted centrally over the flue terminal and securely fixed to the wall

Condensing Combi only - It is important to ensure that all joints in the flue system are scaled and that condensate cannot escape. Up to 1.5 l/h of condensate can be produced in a conventional flue system.

Fitting instructions for the high level flue (Green system) is supplied with the flue kit.

6.3

High level flue - Green system

Note: Pipework should be insulated where it passes through the wall into the boiler enclosure.

Combi 90 V3 and Combi Max only - When using gas oil the flue must terminate a minimum of 2 metres above outside ground level.

The items listed below are available from your local stockist.

Item Combi 90 V3, Combi Max & Condensing Combi 26 Part No. Condensing Combi 36 Part No.

Outdoor starter elbow GKM90 GKM200 150 mm extension GX 50/90 GX 150/200 250 mm extension GX250/90 GX250/200 450 mm extension GX450/90 GX450/200 950 mm extension GX950/90 GX950/200 195-270 mm adjustable extension GXA250/90 GXA250/200 45˚ elbow GE45/90 GE45/200 High level 90˚ terminal GTH90 GTH200 Vertical terminal GTV90 GTV200 Wall bracket - standard GWB90 GWB200 Wall bracket - extended GEB90 GEB200 Outdoor starter - straight GKM90C GKM200C Straight terminal GTL90 GTL200

Preparations for installation

6.2

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 28

Fig. 16 - Outdoor high level flue (Green system)

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 29

The pipework can exit the boiler enclosure through the openings provided in either side (under the removable cover plates) 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.

Alternatively for free standing installations, pipework can be routed down and through the openings provided in the base of the enclosure, to be run underground to the building.

Combi 90 V3 and Combi MAX - see Figs. 1 and 17

1 The pipework connections are housed within the insulated

compartment at the rear end of the boiler casing (opposite end to the burner). These connections are accessed by removing the rear and top panels of the enclosure.

Flow and return connections - Both models are supplied with compression elbows for connection of the heating flow a

nd return pipes, allowing either left or right hand pipe entry

as required.

3 Hot water connections - Both models are supplied with

compression elbows for the connection of the cold water mains inlet and domestic hot water pipes, allowing either l

eft or right hand pipe entry as required.

4 Safety valve - A 15 mm discharge pipe is factory fitted to

the safety valve outlet. This is routed down the front of the boiler and passes through a hole in the bottom of the left side panel (viewed from the burner end). The outlet from this discharge pipe must be free of any restriction or obstruction.

Condensing Combi 26 and 36 - see Figs. 3 and 18

1 The pipework connections are located on the top of the

boiler and are accessed by removing the front and top panels of the enclosure.

Note: Always remove the front panel (burner end) before removing the top casing panel.

Although all models are supplied with metric compression elbows, these fittings allow for connection to imperial fittings i.e. 1/2”, 3/4” and 1”.

Note: Always remove the front panel (burner end) before

removing the top casing panel.

Fig. 17 - Outdoor Combi 90 V3 and Combi MAX

ake the water connections

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 30

Flow and return connections - Both models are supplied with compression elbows fitted on the heating flow and r

eturn pipes, allowing either left or right hand pipe entry as required - 22 mm for the Condensing Combi 26 and 28 mm for the Condensing Combi 36.

3 Hot water connections -Both models are supplied with

compression elbows fitted on the cold water mains inlet and d

omestic hot water pipes, allowing either left or right hand pipe entry as required. - 15 mm for the Condensing Combi 26 and 22 mm for the Condensing Combi 36.

4 Safety valve - A 15 mm push-fit elbow is factory fitted to

the safety valve outlet. A 15 mm pipe must be connected to this fitting and routed to either the back left or back right of the boiler where it must pass through the hole provided in the bottom edge of both side panels. The discharge pipe must be unrestricted (i.e. no valves) and the outlet must be free of any restriction or obstruction.

5 Condensate drain - Provision must be made for the safe

and effective removal of condensate. Refer to Section 5.12.

All models.

1 A drain tap is provided at the bottom on the front of the

boiler. A second drain tap is fitted on the primary store of the Condensing Combi boilers.

2 Carefully manoeuvre the boiler into position. Complete the

water connections.

If the boiler is installed against a wall, fit the wall flashing strip. Position the strip with the bottom edge of the wider f

lange 30 mm above the enclosure top panel, with the

narrow flange (with the three fixing holes) flat against the wall. The strip should overhang the top panel by an equal amount at each end.

Mark the position of the three fixing holes onto the wall, d

rill and plug the wall and secure the strip with suitable

screws (not supplied).

4 The top panel of the casing has been designed so that it may

5 Fill and vent the water system and check for leaks, rectifying

where necessary. Refer to Section 7. 1.

6 Do not replace the top panel until the power supply has been

connected. See Section 6.6.

6 - BOILER INSTALLATION

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Fig. 18 - Outdoor Condensing Combi

Page 31

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 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 BS 4841) 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 BS 7074:1 for further guidance.

See wiring diagrams in Section 12

Note: A test switch is fitted to the control panel to allow the boiler to be test-fired. When On, the switch by-passes the external control system.

Combi 90 V3 and Combi MAX

1 Undo the three screws from the left hand cover on the

control panel to gain access to the boiler wiring terminal block.

2 Pass the mains power supply cable through the cable

grommet into the control panel, through the cable clamp and connect to the 7-way terminal block as follows:

Permanent Live (brown) to terminal 3 - marked L3 Neutral (blue) to terminal 4 - marked N4 Earth (green/yellow) to terminal 5 - marked E5

Condensing Combi

The Condensing Combi boilers are supplied fitted with an electrical isolation plug - located in the left hand end of the boiler control panel. All electrical wiring to the boiler must be made to this plug.

1 Locate the plug, lift the retaining tab and pull the plug to the

left to remove it from the socket in the control panel.

2 Prise open the clips on either side of the plug and open the

top to access the five terminals.

3 Connect the electrical supply and heating/hot water controls

to the terminals in the isolating plug as follows:

Terminal 1 - Heating on (from timeswitch, thermostat

or programmer)

Terminal 2 - Hot water on (from programmer)

Terminal - Earth

Terminal N - Neutral

Terminal 3 - Mains live (including permanent live for

frost thermostat)

6 - BOILER INSTALLATION

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6.6

Connect the power supply

6.5

Expansion vessel pressure

To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly f

lushed out - before the boiler is connected and then again after the system has been heated and is still hot. This is e

specially 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 BetzDearborn's Sentinel X300 or X400, or Fernox Restorer. Full instructions are supplied with the products, but for immediate information, please contact BetzDearborn on 0 1514209563 or Fernox on 0179 9550811.

For Long term protection against corrosion and scale, after flushing, it is recommended that an inhibitor such as Betzdearborn's Sentinel X 100 or Fernox MB- 1 is dosed in accordance with the guidelines given in BS 7593:1992.

Failure to implement the guidelines will invalidate the warranty.

The air pressure in the vessel must be checked annually.

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.

IMPORTANT: Pass the cable from the electrical power supply and heating/hot water controls through the cable clamp on the underside of the control panel before making connections to the isolating plug.

Important: Ensure that the electrical supply as been isolated before commencing.

Note: The terminal numbers are marked on the top cover

of the plug.

Page 32

Replace the cover on the plug ensuring it is securely fitted. Measure a maximum of 350 mm of cable between the plug a

nd the cable clamp below the control panel and tighten the

cable clamp to secure the cable.

5 Re-fit the isolating plug into the socket in the control panel.

Do not switch on the electricity supply at this stage.

To control the central heating on/off periods only, it is recommended that the boiler be wired to a single channel timer and room thermostat, or a programmable room thermostat, sited at a convenient location within the property.

Combi 90 V3 and Combi MAX

The switched live from the central heating controls must be connected to terminal 1 on the 7-way terminal block - marked S/L1.

Condensing Combi 26 and 36

The switched live from the central heating controls must be connected to Terminal 1 on the electrical isolation plug.

Grant Outdoor Combi boilers are supplied with a factory fitted pre-set frost protection thermostat. In order to prevent overheating of the property when this frost thermostat operates, it is recommended that a pipe thermostat be used, e.g. a Danfoss type ATF pipe thermostat. This should be mounted on the heating return pipe to the boiler and set to 25˚C.

For Outdoor Combi 90V3 and Max boilers - Remove link from terminals P1 and P2 on the boiler terminal block. Connect the pipe thermostat (via 'common' and 'on' connections) between these terminals.

For Outdoor Condensing Combi 26 and 36 boilers - Remove link from terminals 4 and 5 on the boiler terminal block. Connect the pipe thermostat (via ‘common' and 'on' connections) between these fixing terminals.

Refer to boiler wiring diagrams in Section 12 for connection details.

See Fig. 9

1 Remove the oil inlet plug from the fuel pump and connect

the elbow of the flexible fuel line supplied with the boiler.

2 Connect the flexible fuel line to the rigid supply using the

adaptor supplied. The supply enters through one of the holes at the bottom of the case sides.

6.8

Pipe thermostat connection

6.9

Connect the fuel supply

MPORTANT: Check that the cable is securely clamped

and that the cable length between the clamp and plug is n

o more than 350 mm.

If a two pipe system is to be use refer to Section 5.4.6

Note: When connected in this way, a link must be fitted between terminal 2 and 3 - marked S/L2 and L3 to enable the boiler to operate for hot water.

Note: When connected in this way, a link must be fitted between terminal 2 and 3 - to enable the boiler to operate for hot water.

Connect the controls

6.7

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 33

Note:

Remove the factory fitted air inlet spigot adaptor (item 6, above) from the air intake on the top right hand side of the burner and fit the grey plastic air inlet grille in its place.

1 Pump

2 Control box

3 Reset button with lock-out lamp

4 Flange with gasket (do not remove from boiler)

5 Air damper adjustment screw

6 Air supply tube connection (balanced flue)

7 Pump pressure adjustment screw

8 Pressure gauge connection

Fig. 20 - RDB burner components

Outdoor Combi 90 V3, Combi Max and Condensing Combi

6 - BOILER INSTALLATION

Page 34

7.2

Completion

Ensure that User Information pack (supplied with the boiler) is handed over to the Householder.

Fill the system

7.1

Outdoor Combi 90 V3, Combi Max and Condensing Combi

7 - FILL AND VENT THE SYSTEM

1 To vent the boiler - The Combi 90 V3 and Combi Max

boilers are fitted with a single automatic air vent on the top of the boiler.

The Condensing Combi 26 and 36 boilers are fitted with two automatic air vents and two manual air vents. See Fig.

18.

On all boilers - Check that the small cap on the automatic air vent(s) is screwed in fully, then unscrew it one complete turn - leave the cap in this position.

2 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.

3 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.

4 Vent each radiator in turn, starting with the lowest one in

the system, to remove air. On the Condensing Combi boilers

- open the manual air vents in the boiler to vent air and then close them.

5 It is important the circulating pump(s) are properly vented

to avoid them running dry and the bearings being damaged.

Outdoor Combi 90 V3 and Combi Max - Remove the rear casing panel to access the single circulating pump.

Outdoor Condensing Combi boilers - Remove the front casing panel for access to the Hot Water pump and the top casing panel for access to the Heating pump.

Unscrew and remove the plug from the centre of the pump. Using a suitable screwdriver rotate the exposed spindle about one turn. When water starts to trickle out, replace the plug.

On the Condensing Combi both the Hot Water and Heating pumps must also be vented as described above.

6 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 t

he 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.

8 The system design pressure (cold) should be between 0.5

ar 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.

9 Close the valves either side of the filling loop and

disconnect the loop.

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 for your records.

Page 35

It is important that the following commissioning procedure is carried out to ensure safe and efficient operation of the boiler.

1 Check that the water system has been vented and

pressurised, and there are no leaks.

2 Check that all fuel line valves are open.

3 Remove the plastic burner cover (two screws) if it was not

previously removed.

Note: Check that the baffles are in position and that the cleaning cover is correctly fitted and a good seal made.

Check that the Condensing Combi turbulators are in position and that the ends are vertical, see Fig. 28.

Fig. 22 - Boiler controls (Outdoor Condensing Combi)

Fig. 21 - Boiler controls (Outdoor Combi 90 V3 and Combi MAX)

Outdoor Combi 90 V3, Combi Max and Condensing Combi

8 - COMMISSIONING

Page 36

Connect a combined vent manifold and pressure gauge to the pressure gauge connection port on the oil pump. See Fig. 2

0. Open the vent screw on your vent manifold to vent the

supply while the pump is running.

5 Check that all system controls are calling for heat and set

the boiler thermostat to maximum (on Combi 90 V3 and Max) or to give the required heating flow temperature (on C

ondensing Combi boilers). If a TCR programmer is fitted (with the Combi 90 V3 or Combi Max) set the 'boiler' switch to ON. If a VCR programmer is fitted (with the Condensing Combi 26 or 36) set the 'hot water' function to ON. Switch on the electricity supply to the boiler.

6 Fully open a hot tap and allow it to run for a few moments

to vent the internal primary circuit. The boiler pump in the Combi 90 V3 and Combi Max or the Hot Water pump in the Condensing Combi 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 first lighting. Close the hot tap. The burner will continue to fire to heat the primary water in the boiler or primary store (Condensing Combi) until the required temperature is reached.

Note: On the Condensing Combi the Hot Water pump will continue to run for a short period after the burner has stopped.

7 With the burner alight, check the fuel pressure. Refer to the

Technical Information, Section 4.3, 4.4 or 4.6. Adjust the pressure if necessary - see Fig. 20.

8 Operate the boiler until it reaches normal operating

temperature. Check oil supply/return pipe for leaks, rectifying where necessary.

9 Switch the boiler off, remove the pressure gauge and replace

the plug in the pump.

10 Having ensured that there are no oil leaks, replace the burner

cover. Tighten the two fixing screws. Ensure the flexible air tube is connected to the burner.

2 After allowing the burner to run for 20 minutes - Check the

smoke number, if satisfactory check the CO

level. Set the

o the value given in Section 4.3, 4.4 or 4.6. for the boiler and fuel used. Adjust the burner air regulator, see Fig. 24, turning the screw anti-clockwise closes the damper and increases CO

level, turning the screw clockwise opens the

amper and reduces CO

evel.

e-check the smoke number if the air damper has been

moved.

Under no circumstances must the smoke number be above

13 Check the flue gas temperature.

14 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 by-pass.

15 Switch off the boiler.

16 With the system hot, check again for leaks, rectifying where

necessary. Drain the heating system while it is hot to complete the flushing process.

17 Refill, vent and pressurise the system as described in Section

7.1, adding a suitable inhibitor. For further information concerning inhibitors contact your local stockist.

If the boiler is to be left in service with the User, set the controls, timer (see Section 1) and room thermostat (if fitted) to the User's requirements then refer to Section 9.

If the boiler is not to be handed over immediately, close the boiler fuel supply valve and switch off the electricity supply.

If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained.

8 - COMMISSIONING

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Note: The boiler will start as soon as the electricity supply to it is switched on

Note: It is important that the air damper is correctly set.

Note: After commissioning the boiler, complete the Commissioning Report on page 2 of these instructions.

11 Insert combustion probe into the end of the flue terminal

to measure the CO2level.

Do not use the test point on the boiler.

Page 37

he User must be advised (and demonstrated if necessary) of

the following important points:-

1 How to light and turn off the boiler and how to operate the

ystem controls.

2 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.

3 The importance of servicing the boiler to ensure safe and

efficient operation. This should normally only be required once a year.

4 The type of fuel used.

5 That any servicing or replacement of parts must only be

carried out by a suitably qualified engineer.

6 Ensure that the boiler controls and room thermostat (if

fitted) are set to the User's requirements.

Tell the User the system pressure and show them the position of the safety valve discharge pipe.

8 Show the User how to reset the overheat thermostat and how

o restart the boiler if it goes to 'Lock-out'.

To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate.

Servicing and replacement of parts must only be carried out by a suitably qualified engineer.

1 Check the flue 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/fuel system connections and fittings

are sound. Remake any joints and check the tightness of any fittings that may be leaking. Check the expansion vessel air charge. See Section 6.5. Check the system pressure. Refill, vent and re-pressurise the system as necessary. See Section

7. 1.

4 Remove any sludge/water from the fuel tank by opening the

sludge valve at the lower end of the tank.

5 With the fuel supply valve closed, clean/replace the filter

element and clean the filter bowl.

6 Flexible fuel supply Pipes should be inspected annually

when the boiler is serviced and replaced every two years. If in doubt replace the pipes.

9 - BOILER HANDOVER

10 - BOILER SERVICING

Outdoor Combi 90 V3, Combi Max and Condensing Combi

10.1

Important notes prior to servicing

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 15 on page 56.

Warning: Before servicing, set the boiler On/Off switch to 'OFF', isolate the electricity supply and close the fuel supply valve. Allow the boiler to cool.

The data label on the inside of the case side panel will indicate the fuel used and nozzle fitted.

Leave this Instruction manual with the User.

Page 38

1 Remove the front panel by turning the handle and

withdrawing it forwards at the bottom.

2 Remove the four screws securing the top panel and carefully

lift it off, taking care not to damage the insulation.

3 Remove the burner fixing nut (top of mounting flange) and

withdraw the burner.

If required, disconnect the flexible oil pipe(s), use a suitable container to prevent any oil spillage.

See Fig. 24, 25, 26 or 27

1 Remove the four nuts and washers securing the front

cleaning door and withdraw the door. Take care - it is heavy.

2 Remove the baffles as shown in Fig. 24, 25, 26 or 27.

3 Remove all deposits from the baffle plates and all the boiler

internal surfaces using a stiff brush and scraper if necessary.

4 Check the condition of the flue, clean as necessary.

5 Check the condition of the front cleaning door seal. Replace

if necessary.

6 Replace the baffles, ensuring they are- correctly fitted. See

Fig. 24, 25, 26 or 27.

10.2

Dismantling prior to servicing

Note. The top panel has been designed to provide a slight fall away from the side positioned against a wall, the side of the top panel with the fixing screws closer to the bottom edge is the highest side against the wall.

Note: If two flexible pipes are connected to the burner, identify (mark if necessary) which is the inlet and return if they are to be disconnected.

Fig. 23 - Outdoor Condensing Combi components

Cleaning the boiler

10.3

Outdoor Combi 90 V3, Combi Max and Condensing Combi

10 - BOILER SERVICING

Page 39

7 Condensing Combi - Pull out the spiral turbulators from

the heat exchanger tubes. See Fig. 28.

Clean the turbulators using a stiff brush

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.

8 All boilers - Replace the cleaning door, securing it in

position with the nuts and washers previously removed.

9 Condensing Combi - Remove the condensate trap and

check that it is not blocked and is operating correctly, i.e. the float is free to move. Clean the trap and float as required.

Check that the boiler condensate outlet is unobstructed. Clean if necessary.

IMPORTANT: The condensate trap and condensate outlet must be checked on every service and cleaned as necessary.

Fig. 24 - Combi 90 V3 baffle positions

Fig. 25 - Combi Max baffle positions

Fig. 26 - Condensing Combi 26

Fig. 2 7 - Condensing Combi 36

Outdoor Combi 90 V3, Combi Max and Condensing Combi

10 - BOILER SERVICING

Page 40

See Section 14.1

1 Combustion head - Loosen the two screws securing the

combustion head to the burner flange and withdraw the head. Clean and refit the combustion head.

2 Inspect the ignition electrodes - With the combustion head

removed, loosen the electrode clamp screw and withdraw the electrode assembly. Wipe clean and check for any cracks in the ceramic insulation. Replace if necessary.

Check the electrode settings - Electrode tips approximately 4 mm apart and 3 to 3.5 mm in front of the nozzle, see Fig

29.

3 Nozzle - The nozzle should be replaced on an

annual service.

Check that the nozzle fitted is the correct size and

type , refer to tables in Section 4.3, 4.4 or 4.6 and

boiler data label.

Do NOT attempt to clean the nozzle.

Remove and replace the nozzle using a good fitting spanner (16 mm). The use of an ill-fitting spanner will damage the nozzle and could lead to an incorrect flame pattern. Always check the electrode settings after replacing the nozzle, see Fig. 29.

4 Photocell - The photocell is a push-fit in the burner

body. Carefully pull out the photocell to clean.

5 Fan - With the plastic air intake grille removed, remove the

screws securing the fan housing cover (R/H side of burner) and remove the cover. Inspect the fan and housing and clean as necessary. Replace the cover and re-fit the plastic grille.

6 Pump filter - With the burner cover removed, remove the

four screws securing the pump end cover. Remove the filter and wash in kerosene. Replace the filter and end cover, ensure the '0' ring is in position.

Refer to the Commissioning instructions starting on page 35.

Fig. 29

IMPORTANT: The electrode settings given above MUST be observed

To ensure safe and efficient operation of the boiler it is important that re-commissioning is carried out, especially combustion checks (CO2level, flue gas temperature and smoke number) after the boiler has been serviced.

Fig. 28 Outdoor Condensing Combi turbulators

Cleaning the burner

10.4

Outdoor Combi 90 V3, Combi Max and Condensing Combi

10 - BOILER SERVICING

Page 41

Fig. 30 - Combi 90 V3 and Combi Max components/connections

Outdoor Combi 90 V3, Combi Max and Condensing Combi

11 - BOILER COMPONENTS

Main Components

A Cold water inlet isolating valve C Lower pump union D Upper pump union - isolating valve E Heating check valve I Thermostatic mixing valve J Circulating pump K Microswitch assembly L Diverter valve M Plate heat exchanger P Flow restrictor Q Heating flow isolating valve R Heating return isolating valve S Pressure switch

Connections

1 Diverter valve - cold water inlet 2 Diverter valve -primary inlet 3 Diverter valve - primary outlet 4 Plate heat exchanger - hot water outlet 5 Cold water inlet isolating valve - outlet 6 Plate heat exchanger - primary outlet 7 Plate heat exchanger - cold water inlet 8 Plate heat exchanger - primary inlet 9 Mixing valve - cold water inlet 10 Primary return isolating valve - inlet 11 Mixing valve - hot water inlet 12 Mixing valve - blended water outlet 13 Primary flow from boiler

Page 42

Main Components

1 Circulating pump - heating 2 Circulating pump - hot water (primary store) 3 Plate heat exchanger 4 Pressure switch 5 Flow switch 6 Thermostatic mixing valve 7 Automatic air vent 8 Manual air vent (x 2) 9 Pressure relief valve 10 Filling hose 11 Filling loop - cold inlet isolating valve 12 Filling loop - heating system isolating valve 13 Isolating valve - cold inlet 14 Isolating valve - heating return 15 Non return valve (x 2)

Connections/pipe

A Heating system flow - push-fit elbow B Heating system return - push-fit elbow C Cold water inlet - push-fit elbow D Hot water outlet - push-fit elbow E Pump isolating valves - heating pump F Pump isolating valves - hot water (store) pump G Primary inlet to store H Primary outlet from store I Primary inlet to condensing heat exchanger J Primary outlet from condensing heat exchanger K Primary return to main heat exchanger L Primary flow manifold M Primary return manifold N Primary flow to heating (store) pump O Primary flow to plate heat exchanger P Primary return to boiler Q Cold water inlet manifold R Hot water flow to blending valve S Hot water outlet from blending valve

11 - BOILER COMPONENTS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Fig. 31 - Condensing Combi components/connections

Page 43

Refer to Section 6.

12 - WIRING DIAGRAMS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

12.1

Control panel wiring diagram - Outdoor Combi 90 V3 and Combi Max

Note: If a single channel timer is used, a link must be fitted b

etween terminals 2 and 3.

If a room thermostat is fitted, it must be wired in series with the time control and the boiler terminal S/L 1.

Colour code: Br - Brown, R - Red, Bl - Blue, Y - Yellow, G/Y - Green/Yellow, Blk - Black, Or - Orange

Page 44

12.3

Typical connection of external timer - Outdoor Combi 90 V3 and Combi Max only

unctional flow wiring diagram - Outdoor Combi 90 V3 and Combi Max

2.2

Outdoor Combi 90 V3, Combi Max and Condensing Combi

12 - WIRING DIAGRAMS

Page 45

Colour code: Br - Brown, R - Red, Bl - Blue, Y - Yellow, G/Y - Green/Yellow, Blk - Black, Or - Orange

12.4

Control panel wiring diagram - Outdoor Condensing Combi

12.5

Functional flow wiring diagram - Outdoor Condensing Combi

Outdoor Combi 90 V3, Combi Max and Condensing Combi

12 - WIRING DIAGRAMS

Page 46

12 - WIRING DIAGRAMS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

12.6

Typical connections of external timer - Outdoor Condensing Combi only

12.7

Connection of typical two - channel programmer - Outdoor Condensing Combi only

Page 47

1 - COMBI V3, COMBI MAX & CONDENSING USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

13.1

Combi 90 V3, Combi Max and Condensing Combi - Boiler faults on central heating and hot water

FAULT

Boiler will not start

Burner lights but goes to lock-out

Burner not lighting

Oil & electricity present at burner

Burner fires but smoke visible from

flue or high smoke number

Burner pulsates

Burner cycles On and Off

POSSIBLE CAUSE

Low pressure cut-out activated (amber neon oil panel lit).

No electrical supply to burner.

No electrical supply to boiler.

Check controls are switched on and calling for heat.

Overheat thermostat has operated (red neon ON panel lit).

Boiler thermostat and/or overheat thermostat faulty

Fault with burner.

No fuel supply

Oil tank empty.

Isolating valve(s) in fuel supply line closed

Fire valve closed

Fuel line filter is blocked.

Oil supply line is air locked.

Excessive combustion air.

Fault with burner.

Insufficient combustion air supply to burner.

Incorrect or faulty nozzle fitted.

Fuel pressure too high.

Insufficient combustion air supply to burner.

Contaminated combustion air (balanced flue).

Insufficient oil flow to burner due to restriction in supply line.

Excessive combustion air.

ACTION

Refill system to 0.5 - 1.0 bar.

Check for 230 V at boiler terminal block.

Check boiler On/Off switch is set to 'ON'.

Set boiler thermostat to maximum.

Check and reset thermostat as necessary.

Check for 230 V output from BURNER LIVE terminal of PCB.

Check continuity of overheat thermostat - replace as necessary.

Press reset button - no more than twice.

If burner (does not operate refer to burner fault finding chart.

Check tank and refill as necessary,

Check and open valves as necessary.

Check and reset as necessary.

Check and clean as necessary.

Vent oil supply line at pump.

Reset burner air damper and check combustion.

Refer to burner fault finding chart.

Check flue terminal is clear (balanced flue).

Check room ventilation is adequate (Conventional flue). Check

condition of burner fan.

Check air damper setting on burner.

Check nozzle size and type and replace if necessary.

Check fuel pressure and adjust as necessary.

Check as for high smoke number (above).

Check the flue terminal is unobstructed

Connect vacuum gauge to pump and check pump vacuum.

Check for blockage in filter, fire valve, valves or pipe and rectify.

Reset burner air damper and check combustion.

Page 48

13 - FAULT FINDING

13.2

Combi V3, Combi Max and Condensing Combi - Boiler faults on central heating and hot water - continued

FAULT POSSIBLE CAUSE ACTION

Fumes and puffing on starting

Flue is blocked. Check flue is clean and unobstructed - rectify as necessary.

(Conventional flue) Insufficient flue draught. Check flue draught and improve flue as necessary.

Flue pipe or liner is too large or existing stack is unlined. Check flue condition/size and alter as necessary.

Insufficient combustion air supply to burner. Check as for high smoke number (above).

Check that an extract fan is not pulling combustion gases from burner.

Flame slow to stabilise on starting Insufficient combustion air supply to burner. Check as for high smoke number (above).

Incorrect or faulty nozzle fitted. Check nozzle size and type and replace if necessary.

Fuel pressure too low. Check fuel pressure and adjust as necessary.

Oil smells Oil leak in supply line or burner. Check all joints and flexible hose for leaks and rectify as necessary.

Combustion fume smells Leak around boiler cleaning door. Check gasket, re-tighten nuts or replace gasket as necessary.

Burner not correctly fitted on mounting flange. Remove and re-fit burner ensuring correct fitting.

Burner seal 'O' ring damaged or missing. Check and replace 'O' ring as necessary.

Leakage around flue connection. Check and re-seal flue as necessary

Leakage at condensation trap (Condensing Combi only) Check discharge pipe correctly fitted into trap.

Overheat thermostat operating Faulty boiler thermostat. Check and replace as necessary.

Thermostat sensor not connected to PCB Check and rectify as necessary.

(Condensing Combi only).

Faulty overheat thermostat. Check and replace as necessary.

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 49

13 - FAULT FINDING

13.3

Combi V3 and Combi Max only - Central heating OK - poor or no domestic hot water

FAULT

No water flowing from hot tap

No hot water operation

Low water temperature at tap

Hot water for short period only

POSSIBLE CAUSE

Mains water supply is not connected to cold water inlet of boiler.

One or more isolating valves, stop cocks, etc. in the pipework are closed.

The cold water isolating valve in the boiler is closed.

There is a blockage (or blockages) in the pipework.

Hot tap is not connected to hot water outlet of boiler.

Insufficient flow of water through boiler.

Boiler cold water and hot water connections reversed.

Thermostatic mixing valve incorrectly fitted.

Pump is not operating in hot water mode.

Diverter valve microswitch(es) faulty.

Diverter valve microswitches not operated.

Diverter valve seized.

Diverter valve diaphragm failed.

Flow of water through boiler too high.

Boiler thermostat incorrectly set

Thermostatic mixing valve incorrectly set.

Faulty boiler thermostat.

Pump speed setting too low.

Pump is incorrectly fitted.

Burner not firing for hot water (after a short time).

Burner oil pressure set too low at oil pump.

Incorrect oil nozzle fitted to burner.

ACTION

Check and rectify as necessary.

Open all valves in pipework to and from boiler.

Open valve (situated above pump in front of boiler).

Check and rectify as necessary.

Check flow is at least 3 litres/min - rectify as necessary.

Check and rectify as necessary.

Check hot and cold inlets are connected correctly.

Check operation of diverter valve.

Check pump is free to rotate and is vented.

Check for 230V supply to pump.

Check electrical continuity of pump microswitch.

Check wiring continuity from pump to microswitch.

Check switch continuity, replace if faulty.

Check diverter valve diaphragm.

Remove, dismantle and clean.

Replace diaphragm or complete diverter valve.

Reduce flow and check water temperature.

Set boiler thermostat to maximum.

Set mixing valve to setting '45'.

Check continuity and replace if necessary.

Set pump speed switch to maximum (top position).

Check and rectify as necessary.

Check operation of burner on central heating.

If burner faulty, refer to burner fault finding chart.

Check electrical continuity of burner microswitch.

Check electrical continuity of thermostat.

Check operation of diverter valve.

Check wiring continuity from burner to microswitch.

Check and set oil pressure to correct value (see Section 4.3, 4.4, 4.6).

Check and fit correct nozzle (see Section 4.3, 4.4, 4.6).

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 50

13 - FAULT FINDING

13.4

Combi V3 and Combi Max only - Domestic hot water OK - poor or no central heating

FAULT

No operation on heating

Flow temperature low

POSSIBLE CAUSE

Timeswitch either not set, or not in an 'ON' period.

Timeswitch not operating.

Faulty timeswitch.

Faulty timeswitch switch contacts.

Timeswitch OK but not switching boiler on.

Heating switch set to 'HOT WATER ONLY’.

Room thermostat not calling for heat.

Faulty room thermostat.

No room thermostat or external timeswitch connected to boiler.

Boiler thermostat is set too low.

Boiler thermostat faulty.

Boiler is underfired.

Combustion setting of burner incorrect.

Boiler heat exchanger is sooted up.

ACTION

Check setting and set to 'Constant' to test.

Check power supply to timeswitch.

Check and replace if necessary.

Check continuity of switch, replace if necessary.

Check continuity of wiring to timeswitch.

Check and set switch to 'ON' to test.

Set thermostat to call and check boiler operates.

Check continuity of thermostat, replace if necessary.

Check on boiler terminal block for 230 V supply to S/L1.

Check and reset as necessary.

Check and replace if necessary.

Check nozzle size & fuel pressure, correct as necessary.

Check settings and correct as necessary.

Check boiler & baffles and clean as necessary.

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 51

13 - FAULT FINDING

13.5

Condensing Combi only - Central heating OK - poor or no domestic hot water

FAULT POSSIBLE CAUSE ACTION

No water flowing from hot tap

Mains water supply is not connected to cold water inlet of boiler. Check and rectify as necessary.

One or more isolating valves, stop cocks, etc. in the pipework are closed. Open all valves in pipework to and from boiler.

The cold water isolating valve in the boiler is closed, Open valve fully (located in the top right of boiler).

There is a blockage (or blockages) in the pipework. Check and rectify as necessary.

No hot water operation Hot water channel of programmer is set to OFF. Check programmer is set to ON for hot water.

Insufficient flow of water through boiler. Check flow is at least 3 litres/min - rectify as necessary.

Hot tap is not connected to hot water outlet of boiler. Check and rectify as necessary.

Boiler cold water and hot water connections reversed. Check and rectify as necessary.

Flow switch is not operating. Check flow switch is correctly fitted - in line with flow.

Check continuity across flow switch between terminals 10 and 11.

Primary store is not up to temperature. Set HW channel on programmer to ON - burner and hot water pump

should start.

Primary store (hot water) pump is not operating. Check for 230 V supply to pump with water on.

Faulty Hot Water PCB sensor. Replace sensor and check operation.

Faulty Hot Water PCB. Check for 230 V output from 'B 'Burner' terminal on PCB.

If no output - replace Hot Water PCB and check operation.

Relay No. 1 faulty -not switching. Check for 230 V to 'Flow switch' terminal of Heating PCB.

Low water temperature at tap Flow of water through boiler too high. Reduce flow and check water temperature.

Thermostatic mixing valve incorrectly set. Set mixing valve to setting '4.5'.

Primary store (hot water) pump speed too low. Check pump speed is set to maximum - setting 3.

Faulty Hot Water PCB sensor. Replace sensor and check operation.

Faulty Hot Water PCB. Check for 230 V output from 'Burner' terminal on PCB.

If no output - replace Hot Water PCB and check operation.

Hot water for short period only Burner not firing for hot water (after a short time). Check operation of boiler on heating - set switch to 'Constant'.

Note: Burner will not necessarily fire as soon as tap is opened. If burner faulty, refer to burner fault finding chart.

Burner oil pressure set too low on oil pump. Check and set oil pressure to correct value (see Section 4.3, 4.4, 4.6).

Incorrect nozzle fitted to burner. Check and fit correct nozzle (see Section 4.3, 4.4, 4.6).

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 52

13 - FAULT FINDING

13.6

Condensing Combi only - Domestic hot water OK - poor or no central heating

FAULT POSSIBLE CAUSE ACTION

No operation of boiler on

Boiler switch is set to OFF. Check boiler On/Off switch is set to ON (on boiler control panel).

heating Room thermostat (if fitted) not calling for heat. Set thermostat to call for heat and check boiler operates.

Programmer / Timeswitch either not set or not in an ON period. Check setting and set to CONSTANT to check boiler operates.

Programmer / Timeswitch not operating. Check power supply to timeswitch.

Faulty programmer / timeswitch. Check and replace as necessary.

Faulty programmer / timeswitch contacts. Check continuity of switch and replace if necessary.

Faulty room thermostat. Check continuity of thermostat and replace if necessary.

No room thermostat or external timeswitch fitted. Check for 230 V supply to terminal 1.

Faulty Heating PCB sensor. Replace sensor and check operation.

Faulty Heating PCB. Check for 230 V output from BURNER LIVE terminal.

If no 230 V output - replace PCB.

Faulty relay No. 2. Check for 230 V supply to burner - between terminals 6 & 10.

Check for 230 V supply to heating pump - between terminals 5 & 9.

Flow temperature low Boiler temperature control set too low. Check and set as necessary.

Little or no heating flow Heating pump speed too low. Check pump speed and set as required.

Heating pump not operating. Check for 230 V supply to pump.

Primary store sensor not operating correctly. Check sensor is correctly located in pocket on front of store.

Check sensor lead is correctly connected to Hot Water PCB.

Faulty relay No. 1. Check for 230 V supply to Hot water pump.

ATTENTION

If either sensor is disconnected from it's respective PCB, then that PCB will operate as if a demand was present and supply 230 V from the BURNER LIVE

terminal will be interrupted, producing the following conditions:

Heating PCB sensor disconnected - Burner and heating pump will stop.

Store (hot water) PCB sensor disconnected - Store pump will stop. The boiler will continue to operate and provide flow to heating system, but will not heat the

store or provide domestic hot water.

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 53

13 - FAULT FINDING

13.7

Riello RDB burner fault finding

Outdoor Combi 90 V3, Combi Max and Condensing Combi

13 - FAULT FINDING

Page 54

14 - BURNER SPARE PARTS

Key Description Key Description

No. Part No. No. Part No.

1 Not applicable - 15 Regulator 3008651 2 Flange 3005786 16 Pump seal 3000439

3 Combustion head LD (90V3) 3008768 17 Pump 3008654

3 Combustion head T2 (Condensing 26) 3002423 18 'O' ring 3007162

3 Combustion head T5 (Max & Condensing 36)3002533 19 Fitter 'O' ring 3008653

4 Electrode assembly 3007513 20 Connector 3003602

5 Electrode bracket 3006552 21 Flexible pipe 3007672

6 Nozzle holder 3008642 22 Tube 3008644

7 Collar 3008643 23 Pressure gauge connector 3008876

8 High voltage lead 3008794 24 Drive coupling 3000443

9 Air damper assembly 3008647 25 Solenoid 3008648

10 Fan (90V3 & Condensing 26) 3005708 26 Motor 3002836

10 Fan (Max & Condensing 36) 3005788 27 Cover 3008649

11 Photocell 3008646 28 Control box assembly 3008652

12 Capacitor 4.5 gF 3002837 29 Solenoid lead 3008851

13 Seal kit 3008878 30 Cover 3008879

14 Needle valve 3007582 31 Air intake cover -

iello RDB burner - exploded view

14.1

Outdoor Combi 90 V3, Combi Max and Condensing Combi

14 - BURNER SPARE PARTS

Page 55

14 - BURNER SPARE PARTS

Burner Heads

Outdoor Combi 90 V3, Combi Max and Condensing Combi

14 - BURNER SPARE PARTS

Page 56

dhesives, 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:

nsulation materials

Material Types: Ceramic fibre 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.

Use disposable gloves, face mask and eye protection.

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 dustlfibres. Ingestion - Drink plenty of water.

Sealants

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 confined 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.

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 first-aid treatment at once for an injury, however slight. Do not inhale any vapours from mineral oils.

1 - COMBI V3, COMBI MAX & CONDENSING USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

15 - HEALTH AND SAFETY INFORMATION

Page 57

e declare that the Grant Outdoor Combi Range of Oil Boilers equipped with Riello RDB burner approved to EN 267: 1991 satisfy

the requirements of the following European Directives:

1 . 891336/EEC - Electromagnetic Compatibility Directive

Referred to the generic standards EN 55014:1993, EN 50082:1: 1992

2. 73/23/EEC - Electrical Equipment Safety Regulations Directive

Referred to the generic standard NO: 3260: The Electrical Equipment (Safety) Regulations: 1994

3. 92/42/EEC - Hot Water Boiler Efficiency Directive

Referred to the generic standard The Boiler (Efficiency) (Amendment) Regulations 1994

(SI 1994/3083)

Signed:________________________________________________

Managing Director Grant Engineering (Ireland) Ltd.,

Crinkle, Birr, Co. Offaly, Ireland.

1 - COMBI V3, COMBI MAX & CONDENSING USER INSTRUCTIONS

Outdoor Combi 90 V3, Combi Max and Condensing Combi

16 - DECLARATION OF CONFORMITY

Page 58

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Page 59

Outdoor Combi 90 V3, Combi Max and Condensing Combi

Page 60

TERMS OF GUARANTEE

. The company shall mean Grant Engineering (Ireland) Limited.

2. The Boiler is guaranteed for a period of 12 months from the date of installation providing that any work undertaken is authorised by the company and carried out by an approved service agent.

3. The shell (heat-exchanger) of oil boilers supplied by Grant Engineering (Ireland) Limited are guaranteed for a period of 5 years from the date of installation. All other boiler components, excluding consumables (such as nozzles and filters), for 1 year from the date of installataion.

4. This guarantee does not cover breakdowns caused by incorrect installation, neglect, misuse, accident or failure to operate this boiler in accordance with the manufacturers instructions.

5. This guarantee is not transferable unless sanctioned by the Company.

6. The Company will endeavour to provide prompt service in the unlikely event of a problem occurring, but cannot be held responsible for any consequence of delay however caused.

7. This guarantee does not cover labour, handling or shipping.

8. This guarantee applies to boilers installed on the island of Ireland both North and South. Provision for warranty cover elsewhere is subject to agreement with Grant Engineering (Ireland) Limited.

GRANT ENGINEERING (IRELAND) LTD.,

CRINKLE, BIRR, CO. OFFALY.

Telephone: (057) 9120089 / 9120352

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.

All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.

IRL005

Grant Combi 90 V3, Combi 26, Combi Max, Combi 36 User, Installation & Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual