grant vortex pro internal combi - millside...

Grant VORTEX Pro Internal CombiCombi 21e, Combi 26e and Combi 36e Condensing Oil Boiler Range

Installation & Servicing Instructions

Part No. DOC 88. Rev 00. May 2012

Commissioning Report

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GRANT ENGINEERING (UK) LIMITEDHopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EUTel: 01380 736920 Fax: 01380 736991Email: [email protected] www.grantuk.com

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/orappearances are changed in the interests of continued product improvement.All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.

For use with Kerosene* only.After installing the boiler leave theseinstructions with the User.

This appliance is deemed a controlledservice and specific regional statutoryrequirements may be applicable.

*Operation on Bio-fuelAll Grant Vortex Pro condensing boilers,manufactured since May 2011, aresuitable for operation on both standardkerosene (Class C2 to BS2869) andalso bio-kerosene – up to a 30% blend(B30K).

All burner settings and nozzle sizes (asdetailed in Section 2.3 of this manual)are correct for both standard keroseneand bio-kerosene (B30K).

In order to operate this boiler on bio-kerosene it will be necessary to take the following actions:

a) Use a bio-kerosene (B30K)compatible flexible oil line in place of the oil line supplied with this boiler.

b) Have your oil storage tank and oilsupply line (including all pipework, sightgauges, filters, isolating valves, firevalves, de-aeration devices, etc.)checked for their compatibility with bio-kerosene (B30K).

Where necessary some, or all, of theseitems may have to be replaced with abio-kerosene compatible alternative.

c) Check the suitability of the fluesystem with Grant UK.

d) Use only bio-kerosene (B30K) thatconforms to OPS24.

IMPORTANTUnder no circumstances should theboiler be used with bio-kerosenewithout the above actions being takenfirst.

Date:

Commissioning engineer:

Tel. No:

Boiler model: Boiler output: kW

Fuel type: Kerosene

Nozzle size: Pump pressure:

Air setting: Flue gas % CO2:

Net flue gas temp: Smoke No:

System flushed: Yes / No

Corrosion inhibitor added: Yes / No

Antifreeze added: Yes / No

(where there is a Yes / No - please circle appropriate answer)

For sealed systems only:Expansion vessel size : litres

Expansion vessel change pressure : bar

Sealed system fill pressure (cold) : bar

Service LogIt is recommended that the boiler should be regularly serviced, at least once a year,and the details entered in the Boiler Handbook by the service engineer.

Contents

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1 Introduction 41.1 How a Condensing Boiler Works 4

1.2 Boiler Description 4

1.3 Boiler Components 5

2 Technical Data 62.1 Boiler Technical Data 6

2.2 Burner Settings 7

2.3 Vortex Combi e Boilers using Class C2 Kerosene 7

2.4 Flue Gas Analysis 7

2.5 Boiler Dimensions 8

3 Oil Storage & Supply System 103.1 Fuel Supply 10

3.2 Burner Oil Connection 13

4 Boiler Installation Information 144.1 Introduction 14

4.2 Boiler Location 14

4.3 Preparation for Installation 14

4.4 Installing the Boiler 14

4.5 Expansion Vessel 14

4.6 Filling and Venting the System 14

4.7 Regulations Compliance Requirements 15

4.8 Completion 15

4.9 Before you Commission 15

4.10 Underfloor Heating Systems 15

4.11 Pipework Materials 15

4.12 Sealed Systems 15

4.13 Underfloor Pipework 15

5 Pipe Connections 165.1 Water Connections 16

5.2 Making the Water Connections 16

5.3 Domestic Hot Water System 17

5.4 To use the Water Hardness Kit 17

6 Condensate Disposal 186.1 General Requirements 19

6.2 Connections 18

6.3 Pipework 18

6.4 External Pipework 18

6.5 Condensate Soakaway 18

6.6 Condensate Trap 19

6.7 Condensate Disposal Pipework 19

6.8 Inspection and Cleaning of Trap 19

6.9 External Condensate Trap Fitting 19

7 Sealed Systems 217.1 System Models 21

8 Electrical 228.1 Connecting the Power Supply 22

8.2 Connecting the Controls - Heating Only 24

8.3 Connecting the Controls - Heating and Hot Water 28

8.4 Connecting an External Frost Thermostat 31

9 Flue System & Air Supply 329.1 Air Supply 32

9.2 Conventional Flue Systems 33

9.3 Connecting a Conventional Flue 35

9.4 Balanced Flue Systems 35

9.5 Prepare the Wall 39

9.6 High Level and Vertical Balanced Flue 39

10 Commissioning 4010.1 Boiler Controls 41

10.2 Commissioning the Vortex Pro Combi 21e Riello RDB Burner 41

10.3 Information for the User 42

10.4 Balancing the System 42

10.5 Completion 42

10.6 Air Adjuster Disc - Combi 21 only 43

10.7 Information for the User 43

11 Boiler Servicing 4411.1 Checking before Servicing 44

11.2 Dismantling Prior to Servicing 44

11.3 Cleaning the Boiler 44

11.4 Cleaning the Burner 46

12 Fault Finding 4712.1 Initial Checklist - for Installer or

Service Engineers 47

12.2 Main Fault Finding Procedures 48

12.3 Poor Hot Water Checklist 51

12.4 Riello RDB Burner Fault Finding 52

13 Spare Parts 53

14 Health & Safety Information 5514.1 Insulation Materials 55

14.2 Insulation Materials 55

14.3 Kerosene and Gas Oil Fuels (mineral oils) 55

15 EC Declaration of Conformity 56

16 Warranty 5616.1 The Vortex Oil Boiler Warranty 5616.2 Extended Warranty 57

1 Introduction

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Warning of possible human injury asa consequence of not following theinstructions in the warning.

To ensure maximum efficiency, the boilerreturn temperature should be 55° C orless, this will enable the latent heat to becondensed out of the flue gases.

The boiler will achieve net thermalefficiencies of 100%.

To achieve maximum performance fromthe Grant VORTEX Pro Combi e boilers,it is recommended that the heatingsystem is designed so that atemperature differential of 20° Cbetween the flow and return ismaintained.

The Vortex Pro Combi e boilers willhowever still operate at extremely highefficiencies even when it is not incondensing mode and therefore issuitable for fitting to an existing heatingsystem without alteration to the radiatorsizes. The boiler is capable of amaximum flow temperature of 78° C.

1.2 Boiler DescriptionThe Vortex Pro Combi e boilers areautomatic pressure jet oil boilersdesigned for use with a sealed centralheating system and will providedomestic hot water at mains pressure.

All boilers are supplied with the controlpanel and burner factory fitted.

All boilers can be connected to either aconventional flue system or a balancedflue system, as required.

The boilers are suitable for use in sealedcentral heating systems only.

All models are supplied with the controlpanel and burner factory fitted. Theboilers can be connected to either aconventional flue system or a balancedflue system, as required.

For Conventional Flue ApplicationsWhere a chimney is to be lined - Grantrecommends the use of the Grant‘Orange’ flue system, specificallydesigned for the Vortex range ofcondensing boilers. Refer to Section 9.2for further details.

Caution concerning likely damage toequipment or tools as aconsequence of not following theinstructions in the caution.

The flue system materials andconstruction MUST be suitable foruse with oil-fired condensing boilers.Failure to fit a suitable conventionalflue may invalidate the warranty onthe boiler.

For Balanced Flue ApplicationsThe following flue kits are available fromGrant UK.

Refer to Section 9 for further details.

Yellow SystemStandard low level concentric balancedflue - components available:

• Low level concentric balanced flueshort

• Extensions 225mm, 450mm and 675mm

• 90° extension elbow

• 45° extension elbow

• 45° elbow

• Plume Diverter Kit

Green SystemStandard external high level/vertical fluestarter kit (room sealed) - componentsavailable:

• External high level/vertical fluestarter kit short (room sealed)

• Extensions 150mm, 250mm,450mm, 950mm and adjustable195 to 270mm

• 45° elbow

• High level terminal

• Vertical terminal

Note text. Used for emphasis orinformation not directly concernedwith the surrounding text but ofimportance to the reader.

1.1 How a CondensingBoiler WorksDuring the combustion process,hydrogen and oxygen combine toproduce heat and water vapour. Thewater vapour produced is in the form ofsuperheated steam in the heatexchanger. This superheated steamcontains sensible heat (available heat)and latent heat (heat locked up in theflue gas). A conventional boiler cannotrecover any of the latent heat and thisenergy is lost to the atmospherethrough the flue.

The Grant VORTEX Pro Combicondensing boilers contain an extraheat exchanger which is designed torecover the latent heat normally lost bya conventional boiler. It does this bycooling the flue gases to below 90° C,thus extracting more sensible heat andsome of the latent heat. This is achievedby cooling the flue gases to their dewpoint (approximately 55° C).

! WARNING

! CAUTION

! NOTE

! NOTE

Where a rigid conventional flue - internalto external - is required, Grantrecommends the use of a hybrid systemconsisting of Grant 'Green' and'Orange' flue system components. Asno flue adaptor is supplied with theboiler it will be necessary to purchasethe Grant CF adaptor kit to connect thissystem to the boiler correctly.

Flue adaptor kit - Ref. CFA15/70 - isused for all models as they all use the100mm 'Green' and 'Orange' systemcomponents to construct a flue ofmaximum vertical height 8 metres.

This manual is intended to guideengineers in the installation andmaintenance of Grant Pro InternalCombi e boilers. A separate manualis available to guide users in theoperation of these boilers, and isprinted inverted at the end of thismanual.

The following special text formats areused in this manual for the purposeslisted below:

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White SystemHigh level concentric balanced flue kit -components available:

• Vertical concentric balanced flue kit.

• Extensions 225mm, 450mm,950mm and adjustable 275 to450mm.

• 45° elbow.

Red System (for Combi 21e and 26eonly)A flexible vertical balanced flue systemdesigned to be fitted inside an existingmasonry chimney.

Consisting of three sections:

• Concentric white painted flue pipe connected to the boiler.

• Vertical concentric flexible flue(flexible stainless steel flue linerinside a flexible plastic air inlet liner).

• Terminal assembly for chimney top mounting.

Flue extensions and 45° elbows from theWhite system may be used.

Fitting instructions for the Low level,High level and Vertical balanced fluesystems are supplied with the kits.

1.3 Boiler ComponentsThe Vortex Pro Combi e boilers are onlysuitable for use with Kerosene.

All burners are ready to connect to asingle pipe system with a loose flexiblefuel line (900mm) and 3/8" to 1/4" BSPmale adaptor supplied with the boiler. Ifrequired, an additional flexible fuel line(900mm) and 3/8" to 1/4" BSP maleadaptor are available to purchase fromGrant Engineering (UK) Limited, for two-pipe oil supply system, Part No.RBS36.

The temperature of the water leavingthe boiler to heat the radiators is Useradjustable.

The setting of the boiler thermostat onthe Vortex Pro Combi boilers has noeffect on the hot water performance.

The boiler is fitted with an overheatthermostat (which allows it to be usedon a sealed central heating system)which will automatically switch off theboiler if the heat exchanger exceeds apre-set temperature of 111°C ± 3°C.

Figure 1-1 shows the components inthe Vortex Pro Combi e boilers and theposition of the control panel. Figure 1-2shows the details of the control panel.

The control panel is fitted with an ON/OFF switch, Heating switch, Hotwater switch, Indicator lights, Boiler (heating), Pressure gauge andmanual reset button for the overheat thermostat.

Figure 1-1: Vortex Pro Combi e boiler with front panel removed

Figure 1-2: Vortex Pro Combi e boiler control panel

Heating (CH)pump

Hot water (DHW) pump

Plug-inprogrammerposition (if fitted)

Heatingswitch

Hot waterswitch

Boilerthermostat

Over heatresetbutton(underblack cap)

Boiler On / Offswitch

Indicatorlights

Pressuregauge

Non returnvalve

Non returnvalve

Expansion vessel

Condensate trap

Burner lock-out button

2 Technical Data

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2.1 Boiler Technical Data

Vortex Pro Combi Vortex Pro Combi Vortex Pro CombiModel 21e 26e 36e

Boiler water content Litres 48.0 48.5 53.5

(including 32 litre primary store) Gal 10.6 10.7 11.8

Weight (dry)* kg 146 188 218

lbs 322 415 481

Connections: Heating flow and return mm 22 22 28

Cold water mains inlet mm 15 15 22

Domestic hot water outlet mm 15 15 22

Pressure relief valve discharge mm 15

Condensate connection 22mm plastic pipe

Flue size (conventional) 100 mm (4 in) diameter

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

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

Boiler thermostat range °C 65 to 78

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

Maximum heating system pressure (cold) bar 1.0

Minimum heating system pressure (cold) bar 0.5

Pressure relief valve bar 2.5

Expansion vessel (pre-charged at 1 bar) litres 10 12 14

Maximum heating system volume** litres 106 128 148

Maximum operating pressure bar 2.5

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

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

Maximum mains water inlet pressure bar 8.0

Minimum recommended mains water inlet pressure

bar 2.5

Maximum hearth temperature °C Less than 50

Electricity supply 230V ~ 50Hz Fused at 5 Amp

Motor power 90 W max.

Starting current Amp 4.2 2.60

Running current Amp 0.85

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

Conventional flue Minimum flue draught - 8.7 N/m² (0.035 in wg)Maximum flue draught - 37 N/m² (0.15 in wg)

* Weight includes burner but excludes flue

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

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Heat SEDBUK Nozzle Oil Smoke Burner Fuel Flue gas CO2

output SAP 2009 pressure number head flow temp

Model Burner type kW Btu/h % bar kg/h °C %

21e Riello RDB 2.2 21.0 71,650 89.5 0.60/80ºEH 9.0 0-1 T1 1.8380 (flue) 12

235 (door)

26e Riello RDB 1 26.0 88,700 90.2 0.75/80ºEH 8.0 0-1 T2 2.16 75 - 80 12

36e Riello RDB 2.2 36.0 123,000 91.6 1.00/80ºEH 9.1 0-1 T5 3.01 78 12

2.2 Burner Settings

Burners are supplied factory set atthe outputs shown.

When commissioning, the air dampermust be adjusted to obtain thecorrect CO2 level and the Installermust amend the data label.

2.3 Vortex Combi e Boilers using Class C2 Kerosene

Vortex Combi e boilers are only foruse with kerosene.

! NOTE

! NOTE

The data given below is approximateonly and is based on the boiler beingused with a low level balanced flue.

The above settings may have to beadjusted on site for the correctoperation of the burner.

Gas Oil is not suitable for use with aGrant Vortex Pro Combi e boiler.

The net flue gas temperatures givenabove are ± 10%.

When commissioning the air dampermust be adjusted to obtain the correctCO2 level.

The combustion door test point may beused for CO2 and smoke readings only.Do not use this test point fortemperature or efficiency readings.

2.4 Flue Gas AnalysisTo allow the boiler to be commissionedand serviced, the boiler is supplied witha combustion test point on the frontcleaning door. When this test point isused please note the following:

• The test point is for CO2 and smoke readings only.

• The boiler efficiency andtemperature must be taken from theflue test point on high level, verticaland conventional flue adaptors.

• Concentric low level flues do not contain a test point. The temperatureand efficiency readings must betaken from the flue terminal.

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Figure 2-1: Vortex Pro Combi Internal 21e and 26e dimensions

2.5 Boiler Dimensions

All dimensions in the diagram above are in millimetres.

2 Technical Data

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190

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125

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98

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9Figure 2-2: Vortex Pro Combi 36e dimensions All dimensions in the diagram above are in millimetres.

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170

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5

170

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900

456

82 86

307.

5

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605

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3.1 Fuel SupplyFuel StorageThe tank should be positioned inaccordance with the recommendationsgiven in BS 5410:1:1997, which givesdetails of filling, maintenance andprotection from fire.

A steel tank may be used and must beconstructed to BS 799:5:1987 and OFST200.

A galvanised tank must NOT be used.

A plastic tank may be used and mustcomply with OFS T100.

Plastic tanks should be adequatelyand uniformly supported on asmooth level surface, across theirentire load bearing base area, that is,the area in contact with the ground.

Fuel PipesFor gravity fuel supply systems, fuelsupply pipes should be of copper tubingwith an external diameter of at least 10 mm.

Flexible pipes must NOT be usedoutside the boiler case.

A remote sensing fire valve must beinstalled in the fuel supply line (outside)where it enters the building, with thesensing head located above the burner.

Recommendations are given in BS 5410:1:1997.

A metal bowl type filter with areplaceable micronic filter must be fittedin the fuel supply line adjacent to theboiler. A shut-off valve should be fittedbefore the filter, to allow the filter to beserviced.

A flexible fuel line, adaptor and 1/4" BSPisolation valve are supplied loose withthe boiler for the final connection to theburner. If a two pipe system or TigerLoop system is used, an additionalflexible fuel line (900mm) and 3/8" to 1/4"BSP male adaptor are available fromGrant Engineering (UK) Limited (Part No.RBS36).

Metal braided flexible pipes should bereplaced annually when the boiler isserviced. Long life flexible pipes shouldbe inspected annually and replaced atleast every 60 months.

! CAUTION

! CAUTION

Galvanised pipe must not be used.

All pipe connections should preferablyuse flared fittings. Soldered connectionsmust not be used on oil pipes.

! CAUTION

! NOTE

Grant UK recommend that a fire valvewith a temperature rating of 95°C beinstalled on any Grant Vortex ProCombi.

! NOTE

3 Oil Storage & Supply System

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Single Pipe System

Where the storage tank outlet is abovethe burner the single pipe systemshould be used. The height of the tankabove the burner limits the length ofpipe run from the tank to the burner.

As supplied the burner is suitable for asingle pipe system.

Head A Max Pipe Length (m)

(m) ø 8mm ø 10mm

0.5 10 20

1 20 40

1.5 40 80

2 60 100Figure 3-1: Single pipe system

Two Pipe System

With the storage tank outlet below theburner, a two pipe system should beused. The pipe runs should

be as shown in Figure 3-2. The returnpipe should be at the same level in thetank as the supply pipe,

both being 75 to 100 mm above thebase of the tank. The pipe ends shouldbe a sufficient distance apart

so as to prevent any sediment disturbedby the return entering the supply pipe.

Avoid the bottom of the tank beingmore than 3.5m below the burner.

A non-return valve should be fitted inthe supply pipe together with the filterand fire valve. A non return valve shouldbe fitted in the return pipe if the top ofthe tank is above the burner.

The pump vacuum should not exceed0.4 bar. Beyond this limit gas is releasedfrom the oil.

For guidance on installation of topoutlet fuel tanks and suction oilsupply sizing, see OFTEC technicalbook 3.

Available at www.oftec.org.uk.

Figure 3-2: Two pipe system

Head A Max Pipe Length (m)

(m) ø 8mm ø 10mm

0 35 100

0.5 30 100

1 25 100

1.5 20 90

2 15 70

3 8 30

3.5 6 20

Firevalve

Fire valve sensor

Vent pipe Fill pipe

Sludgevalve

Shut-offvalve

Shut-offvalve

Levelgauge

Filter

Fuelstoragetank

Pump (see section 3.2)


Firevalve

Firevalvesensor

Ventpipe

Fillpipe

Sludgevalve

Shut-offvalve

Shut-offvalve

Shut-off valve

Level gauge

Nonreturnvalve

Filter

Fuelstoragetank

A

Supply

Return

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Fire valve

Supply

Return

Fire valve sensor

Vent pipe

Fill pipe

Sludgevalve

Tiger Loop System -(See Figures 3-3 and 3-4)When The storage tank is below theburner, an alternative to a two pipesystem can be achieved using a 'TigerLoop' type oil de-aerator. This effectivelyremoves the air from the oil supply on asingle pipe lift.

The de-aerator is connected close tothe boiler as a two pipe system (omittingthe non-return valve) as shown in Fig. 3-3. Refer to the manufacturersinstructions supplied with the de-aerator. The de-aerator must bemounted vertically, as shown in Figures3-3 and 3-4.

To prevent any possibility of fuelfumes entering the building, thede-aerator must be fitted outside inaccordance with BS 5410:1:1997.

! WARNING

Tankmaster

Fuelstoragetank

De-aeration device e.gTiger Loop see Figure 3-4


Figure 3-3: De-aeration device system

Figure 3-4: Tiger loop de-aeration device

To burnerFrom burner

From tank

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Figure 3-5: Burner pump connections

3.2 Burner Oil ConnectionThe fuel pump is supplied for use with asingle pipe fuel supply system. For useon a two pipe system, it is necessary tofit the By-pass screw into the tapping inthe return port. See Figure 3-5.

The By-pass screw is supplied in theboiler accessory pack.

The procedure is as follows:

1. Remove the plastic burner cover(two screws).

2. Remove and discard the blankingplug from the return connection ofthe pump and fit the By-pass screwusing a hexagonal key.

3. Connect the return oil flexible fuelline to the pump.

4. Connect the 3/8" to 1/4" BSPadaptor to the flexible fuel line.

Flexible fuel lines and adaptors areavailable to purchase from GrantEngineering (UK) Ltd.

The burner cover may be left off until theboiler is commissioned.

Oil inletconnection

Return connection

By-pass screw

Pressure gauge connection

Pressure adjuster

Vacuum gauge connection

Solenoid

Supply tonozzle

The blanking plug supplied in theinlet (suction) port may now beplastic and will not provide an oiltight seal when the pump is running.

Ensure the supply from the tank isconnected to this port and the plasticplug is discarded.

! WARNING

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4 Boiler Installation Information4.1 IntroductionThe boiler is supplied already fullyassembled in a carton which is carefullypacked with packing materials. Theinstallation procedure therefore beginswith unpacking and uninstalling of thepacked boiler.

4.2 Boiler LocationThe boiler must stand on a surface thatis firm and level. It does not require aspecial hearth as the temperature of theboiler base is less than 50°C.

Sufficient clearance must be allowed atthe front of the boiler to remove theburner and baffles for servicing.

The Vortex Pro Combi 21e and 26eboilers can be serviced from the front,but it is preferable for any worktopabove the boiler to be removable.

The Vortex Pro Combi 36e requires aremovable section of worktop above theboiler to provide access to componentson top of the boiler and for servicing.

Care should be taken when siting thecondensate trap if it is to be fittedoutside the boiler. Refer to Section 6.

4.3 Preparation for InstallationCarefully remove the packaging from theboiler and remove it from the transitpallet.

Pull off the boiler front panel and removethe literature pack.

Lift off the two parts of the case top andremove the water connecting fittings.

4.4 Installing the BoilerYou are now ready to install the boiler.The main procedures are as follows:

• Make the water connections - seesection 5.2.

• Fit flue terminal - see section 9.

• Check the expansion vessel - seesection 4.5 below.

• Connect the power supply.

• Connect the fuel supply - seesection 3.

• Fill and vent the system - seesection 4.5.

4.5 Expansion VesselThe expansion vessel fitted is suppliedwith a charge pressure of 1.0 bar(equivalent to a max. static head of 10.2metres). The charge pressure must notbe less than the actual static head atthe point of connection. Do notpressurise the vessel above 1.5 bar.

The central heating system volume,using the expansion vessel assupplied, must not exceed therecommended volumes. Refer toSection 2.1. If the system volume isgreater, an extra expansion vessel(complying with BS4841) must befitted as close as possible to thecentral heating return connection onthe boiler. The charge pressure of theextra vessel must be the same as thevessel fitted in the boiler.

Refer to BS7074:1:1989 for furtherguidance.

The air charge pressure may bechecked using a tyre pressure gauge onthe expansion vessel Schraeder valve.The vessel may be re-pressurised usinga suitable pump. When checking the airpressure the water in the heatingsystem must be cold and the systempressure reduced to zero.

4.6 Filling and venting thesystemThe expansion vessel fitted is suppliedwith a charge pressure of 1.0 bar(equivalent to a max. static head of 10.2metres). The charge pressure must notbe less than the actual static head atthe point of connection. Do notpressurise the vessel above 1.5 bar.

Automatic and Manual Air Vents

The boiler is fitted with two Automaticair vents at the top of the boiler, locatedas follows:

• One on the top of the primary store.

• One on the heating flow pipe.

Refer to Figure 5-1.

Check that the small black plug on theside of each air vent is screwed in fully.

Then unscrew it one complete turn - thecap remains in this position thereafter.

A single manual air vent is also fitted atthe top of the boiler - on the return pipe.Unscrew the cap one turn vent air fromthe pipe during filling and then fully closethe cap.

Filling loop

If the flexible filling loop is used to fill thesystem, ensure it is connected and thatthe valve connecting it to the boiler isopen and the valve at the front isclosed.

A valve is open when the operating leveris in line with the valve, and closedwhen it is at right angles to it.

Ensure that the mains cold water supplyvalve is open (operating lever in line withthe valve), then turn on the mains coldwater supply and gradually open thefront valve on the filling loop until wateris heard to flow.

Vent each radiator in turn, starting withthe lowest one in the system, to removeair.

It is important the circulating pumps areproperly vented to avoid them runningdry and the bearings being damaged.

To gain access to the heating pump inthe Vortex Pro Combi e, it is necessaryto lower the control panel.

Loosen (but do not remove) the fourfixing screws securing the control panelto the side panels, hinge the panelforward to gain access to the pump.

Unscrew and remove the plug from thecentre of the pump. Using a suitablescrewdriver rotate the exposed spindleabout one turn. When water starts totrickle out, replace the plug.

The Hot water pump must also bevented as described above.

Check the operation of the safety valveby turning the head anticlockwise until itclicks. The click is the safety valve headlifting off its seat allowing water toescape from the system. Check thatthis is actually happening.

Continue to fill the system until thepressure gauge indicates between 0.5and 1.0 bar. Close the fill point valveand check the system for watersoundness, rectifying where necessary.Water may be released from the systemby manually operating the safety valveuntil the system design pressure isobtained.

The air pressure in the vessel mustbe checked annually.

! NOTE

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The system design pressure (cold)should be between 0.5 bar and 1.0 bar.The pressure is equivalent to themaximum static head in bar + 0.3 (1 bar= 10.2 metres of water), where thestatic head is the vertical height from thecentre of the expansion vessel to thehighest point of the system.

Close the valves either side of the fillingloop and disconnect the loop.

4.7 Regulatory ComplianceRequirementsInstallation of a Grant VORTEX ProCombi e boiler must be in accordancewith the following recommendations:-

• Building Regulations for Englandand Wales, and the BuildingStandards for Scotland issued bythe Department of the Environmentand any local Byelaws which youmust check with the local authorityfor the area.

• Model and local Water UndertakingByelaws.

• Applicable Control of PollutionRegulations.

• 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 obtainedfrom the OFTEC Technical Book 3(Installation requirements for oil storagetanks) and OFTEC Technical Book 4(Installation requirements for oil firedboilers).

The installation should also be inaccordance with the latest edition of thefollowing British Standard Codes ofPractice:

• BS 715 Metal flue pipes, fittings,terminals and accessories.

• BS 799:5 Oil storage tanks.

• BS 4543:3 Factory made insulatedchimneys for oil fired appliances.

• BS 4876 Performance requirementsfor oil burning appliances.

• BS 5410:1 Code of Practice for oilfiring appliances.

• BS 5449 Forced circulation hotwater systems.

4.8 CompletionPlease ensure that the OFTEC CD/10installation completion report (providedwith the boiler) is completed in full.

Leave the top copy with the User.

Retain the carbon copy.

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

4.9 Before you CommissionTo avoid the danger of dirt and foreignmatter entering the boiler the completeheating system should be thoroughlyflushed out - before the boiler isconnected and then again after thesystem has been heated and is still hot.This is especially important where theboiler is used on an old system.

For optimum performance afterinstallation, this boiler and its associatedcentral heating system must be flushedin accordance with the guidelines givenin BS 7593:1992 'Treatment of water indomestic hot water central heatingsystems'.

This must involve the use of aproprietary cleaner, such as BetzDearborn's Sentinel X300 or X400, orFernox Restorer. Full instructions aresupplied with the products, but for moredetails of Betz Dearborn’s products,view the website www.sentinel-solutions.net and for more details ofFernox products view the websitewww.fernox.com.

For Long term protection againstcorrosion and scale, after flushing, it isrecommended that an inhibitor such asBetz Dearborn's Sentinel X100 orFernox MB-1 is dosed in accordancewith the guidelines given in BS7593:1992.

Failure to implement the guidelines willinvalidate the warranty.

4.10 Underfloor HeatingSystemsIn underfloor systems it is essential thatthe return temperature must be maintainedabove 40°C to prevent internalcorrosion of the boiler water jacket.

4.11 Pipework MaterialsIn Grant boilers are compatible withboth copper and plastic pipe. Whereplastic pipe is used it must be of theoxygen barrier type and be of thecorrect class (to BS 7291:Part 1:2001)for the application concerned.

4.12 Sealed SystemsIf plastic pipe is used, the installer mustcheck with the plastic pipemanufacturer that the pipe to be used is suitable for the temperature andpressures concerned.

Plastic pipe must be Class S to BS 7291: Part 1:2001.

4.13 Underfloor PipeworkPlastic pipe may be used on Underfloorsystems where the plastic pipe is fittedafter the thermostatic mixing valve.Copper tube must be used for at leastthe first metre of flow and return primarypipework between the boiler and theunderfloor mixing/blending valves.

• BS 7593 Code of Practice fortreatment of water in heatingsystems.

• BS 7671 Requirements for electricalinstallations, IEE Wiring Regulations.

Failure to install and commissionappliances correctly may invalidatethe boiler warranty.

! NOTE

Before starting any work on theboiler, or fuel supply please read thehealth and safety information given inSection 14.

! WARNING

The first metre of pipeworkconnected to both the heating flowand return connections of the boilermust be made in copper on all typesof system - sealed or open-vented.

! NOTE

The boiler incorporates a low-pressure switch to shut off power tothe boiler if the system pressuredrops below 0.2 bar.

! WARNING

5 Pipe Connections

16

Pip

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ons

5.1 Water ConnectionsWater connections may be from therear, left or right hand side. If using lowlevel side exit flue, connections must beon the opposite side to the flue.

Flow and return connections - Allmodels are supplied with a push-fitelbow connection for the heating flowand return - 22 mm (Vortex Pro Combi21e and 26e) or 28 mm (Vortex ProCombi 36e).

Hot water connections - All models aresupplied with push-fit elbowconnections for the cold water mainsinlet pipe and hot water outlet pipe.These are 15mm for the Vortex ProCombi 21e and 26e, and 22mm for theVortex Pro Combi 36e.

5.2 Making the WaterConnectionsFlow and return pipework can be routedto either side of the boiler, dependant onthe flue system used, from the push-fitelbows (supplied) on the flow and returnconnection. Refer to Figure 5-1.

Holes are provided in the rear of thecasing side panels to allow thecondensate pipe to be run through theback of the boiler. It will be necessary to

remove the back panel from the boilercasing to fit this pipework, and to refitthe panel before placing the boiler in itsfinal position. See Figure 6-3.

If access will be restricted, make anyconnections to the boiler before placingit in its final position.

If using a balanced flue system - Installthe balanced flue system beforeconnecting the heating systempipework to the boiler.

All Models

A 15 mm discharge pipe must beconnected to the safety valve outletconnection. The pipework between thesafety valve and the boiler must beunrestricted, that is, no valves. Thedischarge pipe should be run to theoutside of the building and terminate sothat it cannot cause injury to persons orproperty.

A drain tap is provided at the bottom onthe front of the boiler (and also on thehot water store on the Vortex Pro Combi e).

All pipes to be fitted into the push-fitconnectors provided should be cutusing a pipe slicer or pipe cutter - toleave the pipe ends with a slightradius and free from any burrs orsharp edges.

Pipes to be used with these fittingsshould not be cut square using ahacksaw.

! CAUTION

Figure 5-1: Vortex Pro Combi e pipe positions

Heating flowconnection

Heating circulatingpump

Heatingreturn

Flow switch

Cold water inletisolating valve

Cold water inlet

Automatic air vent

Safety valve

Pressureswitch

Manualair vent

Primary returnisolating valve

Non returnvalve

Automaticair vents

Boiler flowsensor andoverheatthermostatbulb

Safety valveoutlet

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5.3 Domestic Hot WaterSystemTo maintain a longer and moreconsistent hot water temperature, a flowrestrictor is factory fitted to all modelsexcept the Vortex Pro Combi 36e, tolimit the flow rate to approximately 15litres/minute.

The flow restrictor is located in theoutlet side of the cold water inletisolating valve.

The incoming mains water pressureshould be between 1 and 8 bar toensure efficient operation.

If the pressure is above 8 bar a pressurereducing valve must be fitted.

The boiler may still operate down to apressure of 1.0 bar but with a reducedflow rate. The minimum flow rateneeded for the flow switch to operate is3 litres/minute.

To ensure economic use, the pipe runsbetween the boiler and hot taps shouldbe as short as possible and in 15 mmcopper pipe or 22 mm for the VortexPro Combi 36e only. Where possible thepipework should be insulated to reduceheat loss.

All taps and mixing valves used in thedomestic hot water system must besuitable for operating at a mainspressure of up to 8 bar.

If required, a shower may be fitted in thedomestic hot water system. It isrecommended that thermostaticallycontrolled shower valves are used toprotect against a flow of water at toohigh a temperature. If a fixed head typeshower is used, no anti-syphonagedevices are required. If a loose orflexible head type shower is used, itmust be arranged so that the headcannot fall closer than 25 mm above thetop of the bath, thereby preventingimmersion in the bath water. If this is notpracticable, an anti-syphonage devicemust be fitted at the point of the flexiblehose connection.

The supply of hot and cold mains waterdirect to a bidet is allowed (subject tolocal Water Undertaking requirements)provided that the bidet is of the over-rimflushing type. The outlets should beshrouded and unable to have atemporary hand held spray attached.Arrangements for antisyphonage are notnecessary.

5.4 To use the Water HardnessKitFill a clean container with a sample ofwater from the mains cold water supplyto the boiler.

Immerse the test strip in the water forapproximately one second, ensuringthat all the test zones are fully wetted.

Shake off the surplus water and wait forone minute.

Assess the colouration of the test zonesusing the following chart.

If the hardness reading is found to be inthe medium to very hard range (theshaded area), it is essential that someform of water conditioner or softener isfitted to reduce scale formation withinthe combination boiler. Failure to do somay invalidate both the manufacturerswarranty and any extended warrantycovering the appliance.

The water conditioner or softenershould be fitted to the cold water supplyserving the appliance and in accordancewith the manufacturer’s instructions.Grant Engineering (UK) Ltd. cannot beheld responsible for any damage ormisuse caused by the fitting of anywater conditioning device.

Before the mains water supply pipe isconnected to the boiler, it should bethoroughly flushed out to avoid thedanger of dirt or foreign matter enteringthe boiler.

The mains water connection to theboiler must be the first connection fromthe mains supply.

Please protect the domestic hotwater system from harmful effects of scale. Problems caused by thebuild-up of limescale are not coveredunder the terms of the warranty.

! CAUTION

A water hardness test kit is suppliedwith the boiler. Should the totalhardness of the water supply exceed125 ppm, an in-line scale inhibitorshould be fitted in the cold watersupply to the boiler.

Consult the local Water Undertakingif in doubt.

Do not immerse the test strip inrunning water and avoid contact.

! NOTE

Green Areas Violet Areas Hardness Total Hardness mg/l (ppm)

4 0 Very Soft <50 mg/l calcium Carbonate

3 1 Soft <70 mg/l calcium Carbonate

2 2 Medium <125 mg/l calcium Carbonate

1 3 Hard <250 mg/l calcium Carbonate

0 4 Very Hard <370 mg/l calcium Carbonate

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

6 Condensate Disposal

18

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6.1 General RequirementsWhen in condensing mode the GrantVortex PRO Combi e boilers producecondensate from the water vapour in theflue gases. This condensate is slightlyacidic with a ph value of around 3(similar to vinegar). Provision must bemade for the safe and effective disposalof this condensate.

Condensate can be disposed of usingone of the following methods ofconnection:

Internal Connection (preferred option):• Into an internal domestic waste

system (from kitchen sink, washingmachine, etc.).

• Directly into the soil stack.

External Connection:• Into an external soil stack.

• Into an external drain or gulley.

• Into a rainwater hopper (that is partof a combined system where sewercaries both rainwater and foul water).

• Purpose made soakaway.

All condensate disposal pipes mustbe fitted with a trap - whether they areconnected internally or externally to adomestic waste system/soil stack or runexternally to a gully, hopper or soakaway.

6.2 ConnectionsConnections into a rainwater hopper,external drain or gulley should beterminated inside the hopper/drain/gulley below the grid level butabove the water level.

Condensate disposal pipes should notbe connected directly into rainwaterdownpipes or to waste/soil systemsconnected to septic tanks.

Condensate should not be dischargedinto ’grey water’ systems that re-usewater used in the home (not includingwater from toilets).

It should be noted that connection of acondensate pipe to the drain may besubject to local Building Controlrequirements.

6.3 PipeworkCondensate disposal pipework must beplastic (plastic waste or overflow pipe issuitable).

Condensate disposal pipes shouldhave a minimum ‘nominal’ diameter of22mm (3/4”) - e.g. use 21.5mm ODpolypropylene overflow pipe.

Condensate disposal pipes must befitted with a fall (away from the boiler) ofat least 2.5° (~45mm fall per metre run).

Copper or steel pipe is NOT suitableand MUST NOT be used.

For a boiler installed in an unheatedarea such as an outhouse or garage,all condensate pipework should beconsidered as an ‘external’.

6.5. Condensate SoakawayTo keep external pipework to aminimum, locate the soakaway as closeas possible to the boiler but ensure it isat least 500mm from buildingfoundations and away from otherservices, e.g. gas, electricity, etc.

The condensate pipe may be run aboveor below ground level and can entereither the top or side of the soakawaytube. Refer to Figure 6-1.

Ensure that the drainage holes in thesoakaway tube face away from thebuilding.

Backfill both the soakaway tube and thehole around it, with 10mm limestonechippings.

Only use a soakaway where the soil isporous and drains easily. Do not use inclay soils or where the soil is poorlydrained.

Any damage due to condensatebacking up into the boiler due to ahigh water table, in the case of asoakaway, or flooded drains whenthe condensate disposal is via agulley or soil stack, is not covered bythe Grant product warranty.

Where it is not possible for the pipeto fall towards the point of discharge- either internally into a waste systemor externally to a gulley (e.g. forboilers installed in a basement), it willbe necessary to use a condensatepump.

Condensate disposal pipes should bekept as short as possible and thenumber of bends kept to a minimum.

Pipes should be adequately fixed toprevent sagging, i.e. at no more than0.5 metre intervals.

6.4 External PipeworkIdeally, external pipework, or pipeworkin unheated areas, should be avoided. Ifunavoidable, external pipework shouldbe kept as short as possible (less than 3metres) and 32mm waste pipe used tominimise the risk of ice blocking thepipe in freezing conditions.

The number of bends, fittings and jointson external pipes should be kept to aminimum to reduce the risk of trappingcondensate.

! NOTE

! NOTE

! NOTE

! CAUTION

Figure 6-1: Purpose made condensate soakaway

32mm waste pipeexternal to the building

Two rows of 3 x 12mmholes at 25mm centres and50mm from the bottom ofthe tube. Holes facing awayfrom the property.

Backfill with10mm limestonechippings

Sealedend

100mmplastic tube

Cement seal

Ground level2.5° fall

25mm

300mm

400mm

min.

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6.6 Condensate Trap Grant Vortex PRO boilers are suppliedwith a factory-fitted condensate trap toprovide the required 75mm water seal inthe condensate discharge pipe from theboiler.

This trap incorporates a float (which willcreate a seal when the trap is empty)and an overflow warning outlet (fittedwith a plastic sealing cap). See Figure 6-2.

6.9 External Condensate TrapFittingTo re-locate the factory-fitted trapoutside the boiler casing, use thefollowing procedure:

6.8 Inspection and Cleaning ofTrapThe trap must be checked at regularintervals (e.g. on every annual service)and cleaned as necessary to ensurethat it is clear and able to operate.

To inspect and clean the trap, performthe following procedure:

1. Disconnect flexible condensatehose from inlet connector.

2. Unscrew the inlet connection nut.

3. Remove the ‘top hat’ inletconnector and nut from trap.

4. Disconnect the condensate disposalpipe from the trap outlet.

5. Remove trap from bracket.

6. Remove float from trap - clean ifnecessary.

7. Inspect inside of trap and clean asnecessary.

8. Re-assemble trap, re-fit to boilerand re-connect flexible hose. Ensurethat hose is fully pushed onto the‘top hat’ inlet connector.

With the trap fitted inside the boilercasing, the sealing cap must befitted. If the trap is re-located outsidethe boiler then the following applies:

• If connecting the condensate discharge- either internally or externally - into awaste system or soil stack - the sealingcap must be fitted in the trap outlet.

• On external discharge systems to ahopper, gully or soakaway, thesealing cap should be removed fromthe trap outlet.

• If there is any discharge ofcondensate from the overflowoutlet, this could indicate ablockage (possibly due to freezing).Turn off the boiler and investigatethe cause. If necessary contact yourservice engineer for assistance.

6.7 Condensate DisposalPipeworkThe condense trap outlet is at an angleof 48° below the horizontal. This is toautomatically gives a 3° fall on any‘horizontal’ runs of condense disposalpipe. Refer to Figure 6-1 and see trapoutlet/pipe.

The outlet of the trap will accept21.5mm OD to 23mm ODPolypropylene overflow pipe for thecondensate discharge pipe.

This discharge pipe can exit through theleft side of the boiler through one of twopre-cut ‘knock-outs’ in the lower part ofthe left casing panel. Push out the‘knock-out’ from the required holetaking care not to distort the side panel.Refer to Figure 2-1 for this on the ProCombi 21e or 26e, or Figure 2-2 for thison the Pro Combi 36e.

The trap is factory-fitted inside the boilercasing - mounted on the inside of theleft side panel - in an accessible positionto allow for routine maintenance.

A flexible hose connects the outlet ofthe condensing heat exchanger to thetrap inlet. Ensure the straight connectoron the hose is fully pushed onto the ‘tophat’ inlet connector of the trap.

Figure 6-2: Condensate trap

If required, this condensate trap maybe re-located outside the boilercasing. Refer to procedure given in‘external condensate trap’. Thisprocedure must be carried outbefore the boiler is installed.

! NOTE

The bottom bowl is sealed to the trapbody and cannot be removed.

! NOTE

End cap is sealed to trap body. DONOT attempt to remove it for cleaning.

! NOTE

Failure to regularly check and cleanthe condensate trap may result indamage to the boiler and will not becovered by the Product Warranty.

! NOTE

Condensate drain pipefrom boiler

Unscrew this cap formaintenanceaccess

Overflowwarningoutlet(with cap)

Condensate trap

Condensateoutlet to drain

End cap

Care should be taken when siting thetrap such that the overflow outlet isreadily visible and that anycondensate overflowing from theoutlet cannot cause either a hazardto persons or damage to surroundingproperty or equipment.

! WARNING

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Figure 6-3: Gaining access to thecondensate outlet

This procedure must be carried outbefore the boiler is installed.

! NOTE

The top of the trap must be belowthe condensate connection on theboiler.

! NOTE

The flexible hose must fallcontinuously from the outlet to thetop of the trap.

! NOTE

1. Remove both the top casingpanel(s) from the boiler.

2. Unscrew and remove the screwsfastening the left side panel to therear casing panel of the boiler.

3. Carefully separate the left side andrear panels just enough to gainaccess to the condensate outlet onthe left rear of the condensing heatexchanger (see Figure 6-3).

4. Push out pre-cut ‘knock-out’ fromcondensate outlet hole in rear of leftside casing panel.

5. Remove right angle end of flexiblecondensate discharge hose fromoutlet connection on condensingheat exchanger.

6. From front of boiler, remove straightconnector end of flexible hose fromtop of condensate trap.

7. Reverse flexible hose and pass thestraight connector end through thenew hole in the left hand casingpanel. Push the straight connectorfirmly onto the condensate outletconnection of the condensing heatexchanger as far as possible.

8. Refit the left hand casing panel tothe rear panel using the reverseprocedure, ensuring all fixing screwsare used.

9. Remove the trap from the mountingbracket.

10. Unscrew and remove the trapmounting bracket from the left sidepanel.

11. Fix the trap mounting bracket to thewall adjacent to the boiler in therequired position.

12. Re-fit the trap to the mountingbracket. The mounting bracketsupplied with the trap must be used- the trap should not be supportedby the condensate pipework only.

13. Connect the flexible condensatehose to the trap - pushing the rightangle hose connector onto the trapinlet connection.

Rearpanel

Left handside panel

Sea

led

Sys

tem

s

21

7 Sealed Systems7.1 System ModelsAll Grant Vortex Pro Combi e boilers aresupplied for use as part of a sealedsystem complying with the requirementsof BS 5449.

The maximum temperature of thecentral heating water is 78° C.

• Pressure relief safety valvecomplying with BS 6759 and set tooperate at 2.5 bar. The dischargepipe must be routed clear of theboiler to a drain, in such a mannerthat it can be seen, but cannotcause injury to persons or property.

• Automatic air vent, fitted to the topof the boiler, ensures the boiler isvented.

• Filling loop. This must be isolatedand disconnected after filling thesystem.

Refer to Section 4.5 for further details ofthe expansion vessel.

The expansion vessel charge pressureshould always be slightly greater thanthe maximum static head of the system,in bar, at the level of the vessel (1 bar =10.2 metres of water). See Figure 7-1.

The boilers are supplied with thefollowing items factory fitted:

• A diaphragm expansion vesselcomplying with BS 4814, pre-charged at 1.0 bar, size as follows:

10 litre for Vortex Pro Combi 21e

12 litre for Vortex Pro Combi 26e

14 litre for Vortex Pro Combi 36e.

System pressure gauge, with anoperating range of 1 to 4 bar.

The system fill pressure (cold) should be0.2-0.3 bar greater than the vesselcharge pressure - giving typical systemfill pressures of approx 0.5 bar for abungalow and 1.0 bar for a two-storeyhouse. Refer to the Domestic HeatingDesign Guide for more information ifrequired.

If thermostatic radiator valves are fittedto all radiators, a system by-pass mustbe fitted. The bypass must be anautomatic type.

Provision should be made to replacewater lost from the system. This may bedone manually (where allowed by thelocal Water Undertaking) using the fillingloop arrangement supplied with theboiler.

Filling of the system must be carried outin a manner approved by the localWater Undertaking.

Where allowed, the system may be filledvia the filling loop supplied (the looparrangement includes a double checkvalve assembly).

All fittings used in the system must beable to withstand pressures up to 3 bar.

Radiator valves must comply with therequirements of BS 2767(10):1972.

One or more drain taps (to BS 2879)must be used to allow the system to becompletely drained.

The expansion vessel is connected via aflexible hose to allow it to be moved togain access to the baffle cleaning cover.When replacing the vessel, care shouldbe taken to ensure that the flexibleconnecting hose is not twisted.

Figure 7-1: Sealed system

Static head of system

Heating flow

Heatingreturn

By-pass if required(automatic type)

350mm

Boiler

Expansionvessel

If thermostatic radiator valvesare fitted, the system mustincorporate an adequate by-pass.

When designing a system, the pumphead, expansion vessel size, andradiator mean temperature areamongst the factors that must beconsidered. See Section 4.5.

! NOTE

Ensure that the expansion vessel isof sufficient size for the systemvolume (including the volume of theboiler). If necessary a second vesselmay need to be fitted to the system.Refer to Section 2.1 for systemvolume. To determine total vesselvolume required refer toBS7074:1:1989 or the DomesticHeating Design Guide.

! NOTE

Stop valve

Water mains

Domestichot water

Domesticcold water

22

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8 Electrical

Ensure that the electrical supply hasbeen isolated before making anyconnections to the boiler.

8.1 Connecting the PowerSupplyA three core cable is required toconnect the boiler terminal block to thelive supply. Refer to Figure 8-1 for boilerwiring terminal details.

The procedure for connecting the boilerpower supply is as follows:

1. Loosen (do not remove) the fourscrews securing the control panel tothe side panels, hinge the panelforward and allow it to drop down togain access to the top of the panel.

2. Remove the two screws securingthe terminal block cover and lift offthe cover.

3. Remove the screws securing thecable clamp and open clamp.

4. Connect the power supply cable tothe left hand terminal block asfollows:

• Brown to mains Live (terminal 3)

• Blue to mains Neutral (terminal 2)

• Green/Yellow to mains earth (terminal 1)

! WARNINGAfter completing electricalconnections and before reconnectingthe electrical supply to the boiler,replace the terminal block cover andsecure it using the screws provided.

! WARNING

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Figure 8-2: Vortex Pro Combi e wiring terminals

Figure 8-1: Boiler wiring diagram

8 Electrical

CentralHeatingSwitch

DomesticHot WaterSwitch

4B

BL

BR

GR

GR

G/Y

BLTimer

Colour code:BR - BrownBL - BlueRD - RedG/Y - Green/YellowBLK - BlackOR - OrangeY - YellowGR - Grey

BR

Const

Off Off

Timed

Const

Timed

5B

4B

5B

1A

2A

6B

1 2 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

E N L E N L

EN

L

N L

4 5 6E N L

7 8 9E N L

10 11 12E N L

RD ORBLK

1314 1516 23242526 27 28171819 20 21 22

Mains CH Pump DHW Pump Burner Low

Pre

ssS

witc

h

Flow

Sw

itch

CH

Tim

ed o

n

Tim

er N

eutr

alTi

mer

Liv

e

DH

WTi

med

on

Roo

m S

tat (

from

)

ThermistorsStore FlowE

xt F

rost

Sta

t (fro

m)

Ext

Fro

st S

tat (

to)

Electrical MainsConnection Plug

Boiler Control Panel - PCB Connections

Printed Circuit Board

230V 5A FusedSupply

E N L

NE L

Mains

CH

Pum

p E

arth

CH

Pum

p N

eutr

alC

H P

ump

Live

DH

W P

ump

Ear

th

DH

W P

ump

Neu

tral

DH

W P

ump

Live

Bur

ner

Pum

p E

arth

Bur

ner

Pum

p N

eutr

alB

urne

r P

ump

Live

Flow

Sw

itch

Flow

Sw

itch

Pum

p S

witc

hP

ump

Sw

itch

Ext

. Fro

st S

tat

Ora

nge

Bla

ck

Red

Ext

. Fro

st S

tat

Sto

re T

herm

isto

r

Flow

The

rmis

tor

Roo

m S

tat

Roo

m S

tat

Tim

er N

eutr

alTi

mer

Liv

e

DH

W T

imer

On

CH

Tim

er O

n

230V 5A FusedSupply

CHPump

BlackCable

DHWPump

FlowSwitch

No No

PressureSwitch

StoreThermistor

FlowThermistor

Burner

WhiteCable

Black shroudindicates flowthermistor

Earth connectionboiler top bracket

LimitThermostat

G/Y

G/Y

2

C

24

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Figure 8-3: Connections for a remote timer and room thermostat

8.2 Connecting the Controls -Heating OnlyTo control the central heating on/offperiods only (and not the domestic hotwater), it is recommended to use one ofthe following options:

• A remote single channel timer androom thermostat.

• A ‘plug-in’ Grant Mechanical 24-hour timer (Ref. MTKIT) and roomthermostat.

• A ‘plug-in’ Grant Electronic 7-daytimer (Ref. ETKIT) and roomthermostat.

• A Grant programmable roomthermostat.

With any of these options the timer,room thermostat or programmableroom thermostat should be sited at asuitable and convenient location withinthe property.

Connection of an External RemoteTimer and Room Thermostat

Pass a 3-core cable (or 3-core andearth if the room thermostat to be usedhas an earth connection) through thecable clamp on the control panel.

Remove the Orange room thermostatlink wire from terminals 25 & 26 on theconnection block and connect the wiresfrom the room thermostat. Refer toFigure 8-3 for further details.

Connect the room thermostat to theterminal block in accordance with theroom thermostat manufacturer’sinstructions.

Pass a 4-core cable (or 4-core andearth if the timer to be used has anearth connection) through the cableclamp on the control panel.

Remove the Black link wire fromterminals 19 & 20 on the connectionblock. Connect the two switch wiresfrom the timer.

Connect the live, neutral (and earth ifrequired) from the timer to terminals 3, 2& 1 respectively on the boiler terminalblock. Refer to Figure 8-3 for furtherdetails.

Re-fit terminal block cover on controlbox and fasten with the two screwspreviously removed.

Hinge the control panel back intoposition on the two retaining screws.Replace top casing panels.

Re-connect electrical supply and checkoperation of the timer and roomthermostat.

Refer to the Fitting and User Instructionssupplied with the timer for operatingand setting.

Leave the Timer and Room ThermostatFitting and User instructions with theuser after installation.

Any remote timer must be of a singlechannel 230V type with voltage freeoutput contacts.

! WARNING

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

N

N L 3

N L ON

4 1 2

N COM ON

1 2N L 4

COM

Remote mountedTime Switche.g. Danfoss RandallTS715

Room Thermostate.g. Danfoss RandallRMT230

Frost Thermostat (if required)e.g. Danfoss RandallRET230F

HTGOFF

HTGON

E L

Mains

Ext

. Fro

st S

tat

Red

Ext

. Fro

st S

tat

Roo

m S

tat

Roo

m S

tat

Tim

er N

eutr

alTi

mer

Liv

e

DH

W T

imed

On

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4. Remove the Black wire links fromterminals 19 & 20 on control panel.

5. Carefully push through and removesquare pre-cut ‘knockout’ section inthe control panel front.

6. Feed the wires through hole incontrol panel front and then upthrough rectangular opening incontrol panel top. Connect wires toterminals on control panel asfollows:

• Brown wire (from Terminal 5 on timer) to Terminal 20 on PCB plug.


• Blue wire (from Terminal 1on timer) to Terminal 21 on PCB plug.

• Red wire (from Terminal 2 on timer) to Terminal 22 on PCB plug.

Refer to Figure 8-4 for the connection diagram.

7. Carefully fit the timer into the squarehole in the control panel.

8. From the rear of the control panel fitthe two fixing clamps - one into theslot on each side of the timerhousing - with the two ‘legs’towards the front of the timer.

9. With the front of the timer heldagainst the control panel fascia,push both clamps towards the frontof the timer as far as possible tofirmly secure it in place.

10. Re-fit the rear access cover to thecontrol panel and secure with thefour screws previously removed.

11. Re-fit terminal block cover oncontrol box and fasten with the twoscrews previously removed.

12. Hinge the control panel back intoposition on the two retainingscrews. Replace top casing panels.

13. Re-connect electrical supply andcheck operation of the timer.

Refer to the Fitting and User Instructions supplied with the timer for setting.

Leave the Timer Fitting & User instructions with the user after installation.

Fitting and connection of a Grant‘plug-in’ 24-hour timer(MTKIT) and room thermostat




Fit and connect the ‘plug-in’ timer asfollows:

1. Remove front and top boiler casingpanels. Loosen (do not remove) thefour screws securing control panelto the side panels. Hinge the panelforward to access top and rear ofcontrol panel.

2. Remove the two screws and lift offthe terminal block cover from top ofcontrol panel.

3. Remove the four screws from therear of the control panel and removethe rear access cover.

Figure 8-4: Connections for Grant 24-hour mechanical timer (MTKIT) and room thermostat

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

N

N L 3

N L ON

4 1 2

N COM ON

3 25 4 1

COM L N

Grant Plug-in (panel mounted)Mechanical Timer Grant Ref. MTKIT



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Fitting and connection of a Grant‘plug-in’ 7-day timer (ETKIT) androom thermostat




Fit and connect the ‘plug-in’ timer asfollows:

1. Remove front and top boiler casingpanels. Loosen (do not remove) thefour screws securing control panelto the side panels.

2. Hinge the panel forward to accesstop and rear of control panel.


4. Remove the Black wire link fromterminals 19 & 20 on control panel.Do not remove the Red link fromterminals 17 & 18.

5. Carefully push through and removesquare pre-cut 'knockout' section inthe control panel front. Disconnectand remove the plug from the endof the wiring harness. Do notdisconnect any of the four wiresfrom the terminals of the electronictimer. They must be connected asshown below.

6. Feed the wires through hole incontrol panel front and then upthrough rectangular opening incontrol panel top. Connect wires toterminals on control panel asfollows:



• Blue wire (from Terminal 1on timer) to Terminal 21 on PCB plug.

• Red wire (from Terminal 2 on timer) to Terminal 22 on PCB plug.

Refer to Figure 8-5 for theconnection diagram.

7. Locate the electronic timer in thesquare aperture in the control panelfront. Secure by pressing in andturning the two screws (in upperright and lower left corners) aquarter turn clockwise.



10. Re-connect the electricity supplyand check the operation of the timerand room thermostat.

Refer to the Fitting and Userinstructions supplied with the timerfor operating and setting.

Leave the Timer and RoomThermostat Fitting and Userinstructions with the user afterinstallation.

8 Electrical

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E N L

N

N L 3

N L ON

4 1 2

N COM ON

3 25 4 1

COM L N

Grant Plug-in (panel mounted)Electronic Timer Grant Ref. ETKIT



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Figure 8-5: Connections for Grant 7-day electronic timer (ETKIT) and room thermostat


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8. Re-connect the electricity supplyand check the operation of theprogrammable room thermostat.

Refer to the Fitting and Userinstructions supplied with theprogrammable room thermostat foroperating and setting.

Leave the Programmable RoomThermostat Fitting and Userinstructions with the user afterinstallation.

Connection of a GrantProgrammable Room thermostat(RSKIT)

Connect the programmable roomthermostat as follows:

1. Remove front and top boiler casingpanels. Loosen (do not remove) thefour screws securing control panelto the side panels.

2. Hinge the panel forward to accesstop and rear of control panel.


4. Remove the Orange roomthermostat link wire from terminals25 & 26 on the connection blockand connect the two wires from theprogrammable room thermostat.

5. Refer to Figure 8-6 for thethermostat connection details.

Figure 8-6: Connections for the Grant Programmable Room Thermostat (RSKIT)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

N

N L 3

N L ON

A B C

L

Grant ProgrammableRoom ThermostatRef. RSKIT


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E N L

N

N L 3

N L ON

4 1 2

N COM ON

3 15 4 2

L N

Grant Plug-in (panel mounted)Programmer Grant Ref. EPKIT



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Figure 8-7: Connections for the Grant Plug-In 2-channel Programmer (EPKIT) and room thermostat

8.3 Connecting the Controls -Heating and Hot WaterIf control of both heating and hot wateroperation of the boiler is required, it isrecommended to use one of thefollowing options:

• A Grant ‘plug-in’ two channelprogrammer (Ref. EPKIT) and roomthermostat.

• A Grant ‘wireless’ RF two-channelprogrammable room thermostat(Ref. RFTKIT).

• A Grant two-channel remoteprogrammer (Ref. ESKIT) and roomthermostat.

Fitting and connection of a Grant‘plug-in’ electronic programmer

(EPKIT) and room thermostat




Fit and connect the ‘plug-in’programmer as follows:

1. Remove front and top boiler casingpanels. Loosen (do not remove) thefour screws securing control panelto the side panels

2. Hinge the panel forward to accesstop and rear of control panel. Removethe two screws and lift off the terminalblock cover from top of control panel.

3. Remove both the Red and Blackwire links from terminals 17 & 18and 19 & 20 on control panel.

4. Carefully push through and removesquare pre-cut 'knockout' section inthe control panel front.

5. Connect four wires provided toterminals of the electronicprogrammer as shown below.

Note that the Yellow wire supplied in the kit must not be used.

6. Feed the wires through hole incontrol panel front and then upthrough rectangular opening incontrol panel top. Connect wires toterminals on control panel as follows:

• Orange wire (from Terminal 3 on programmer) to Terminal 17 on PCB plug.

• Red wire (from Terminal 5 on programmer) to Terminal 19 on PCB plug.

• Blue wire (from Terminal 2 on programmer) to Terminal 21 on PCB plug.

• Brown wire (from Terminal 1 on programmer) to Terminal 22 on PCB plug.

Refer to Figure 8-7 for connection diagram.

7. Locate the electronic programmer inthe square hole in control panel front- with the terminals pointing to theright. Secure by turning the twoscrews (in upper right and lower leftcorners) a quarter turn clockwise.



10. Re-connect electrical supply andcheck operation of the programmerand room thermostat.

Refer to the Fitting and User Instructions supplied with the programmer for operating and setting.

Leave the Programmer and Room Thermostat Fitting & User instructions with the user after installation.

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Fitting and connection of a Grant‘plug-in’ FM/2 Receiver Unit - forGrant Twin-channel ‘wireless’Programmable Room Thermostat(RFTKIT)

1. Remove front and top boiler casingpanels. Loosen (do not remove) thefour screws securing control panelto the side panels. Hinge the panelforward to access top and rear ofcontrol panel.


3. Remove both the Red and Blackwire links from terminals 17 & 18and 19 & 20 on control panel.

4. Carefully push through and removesquare pre-cut ‘knockout’ section inthe control panel front.

5. Connect four wires provided toterminals of FM/2 Receiver unit -refer to Figure 8-8.

6. Note that the Yellow wire supplied inthe kit must not be used.

7. Feed the wires through hole incontrol panel front and then upthrough rectangular opening incontrol panel top. Connect wires toterminals on control panel - refer toconnection diagram in Section 1.3.

8. Locate FM/2 unit in square hole incontrol panel front - with theterminals pointing to the right.Secure by pressing in and turningthe two screws (in upper right andlower left corners) a quarter turnclockwise.



11. Re-connect electrical supply andcheck operation of theprogrammable room thermostat.

Refer to the Fitting and User Instructions supplied with the programmable room thermostat for operating and setting.

Leave the Programmable Room Thermostat Fitting & User instructions with the user after installation.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

N

N L 3

N L ON

3 15 4 2

L N

Grant Plug-in (panel mounted) RF Receiver Grant Ref. EPKIT


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Figure 8-8: Connections for the Grant wireless 2-channel Programmable room thermostat (RFTKIT)

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1. Pass a 4-core cable (or 4-core andearth if the timer to be used has anearth connection) through the cableclamp on the control panel.

2. Remove the Red link wire fromterminals 17 & 18 and the Black linkwire from terminals 19 & 20 on theconnection block. Connect the twowires from the programmer toterminals 17 & 19. Refer to Figure 8-9.

2. Connect the live, neutral (and earthif required) from the programmer toterminals 3, 2 & 1 respectively onthe boiler terminal block. Refer toFigure Figure 8-9 for further details.

4. After making the electricalconnections to the boiler, re-tightenthe cable clamps.



7. Re-connect electrical supply andcheck operation of the programmerand room thermostat.

Refer to the Fitting and UserInstructions supplied with theprogrammer for operating andsetting.

Leave the Programmer and RoomThermostat Fitting & Userinstructions with the user afterinstallation.

Connection of a remote two-channel programmer (for exampleGrant ESKIT) and room thermostat




Connect the remote programmer asfollows:

Any remote two-channel programmermust be suitable for 230 V andinternally linked - for example, GrantType ESKIT programmer.

! NOTE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 21 2219 20 23 24 27 2825 26

E N L

N

N L 3

N L ON

4 1 2

N COM ON

1 2N L 3 4

Remote mounted Programmer eg Grant Programmer Ref. ESKIT



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Figure 8-9: Connections for the remote Grant 2-channel Programmer (ESKIT) and room thermostat


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8.4 Connecting an ExternalFrost ThermostatThe boiler is fitted with a pre-set internalfrost protection thermostat. Shouldeither the air temperature around theboiler, or the water temperature withinthe boiler, fall to below 5°C then thisthermostat will be activated to protectthe boiler from freezing.

If necessary, to protect any exposedheating system and any exposedpipework, an external frost thermostatcan also be connected to the boiler.This frost thermostat should be sitedwithin the house in such a place that itcan detect any rise and fall in theambient air temperature, such as, in aroom with a radiator. It is connected tothe boiler as follows:

1. Connect the wires from the frostthermostat to terminals 23 & 24 on theconnection block. Refer to Figure 8-6,Figure 8-3 and Figure 8-9 for furtherdetails.

2. Connect the frost thermostat inaccordance with the frost thermostatmanufacturer’s instructions.

This external frost thermostat willoperate in parallel with the internal frostthermostat.

9 Flue System and Air Supply

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For a boiler fitted in a compartment,which is ventilated as shown, noadditional allowance is necessary.

Open flue - Extract fans, where needed,should be in accordance with Section4.4.7 in BS 5410 Part 1 1997.

All ventilation is given for domesticapplications. For all other cases refer toBS 5410 Part 2 1978.

Vent Pro Combi 21e Pro Combi 26e Pro Combi 36e

cm2 in2 cm2 in2 cm2 in2

Vent A 116 18 143 22 198 31

Vent B 231 36 286 44 396 61

Vent C 116 18 143 22 198 31

Vent D 231 36 286 44 396 61

Vent E 347 54 429 67 594 92

! NOTE

In compliance with ApprovedDocument L1A 2006, the aboveventilation areas are based on thetotal appliance output withoutdeducting the 5 kW allowance foradventitious ventilation.

! NOTE

9.1 Air SupplyA sufficient permanent air supply to theboiler should be provided for thefollowing reasons:

• For proper combustion of fuel andeffective discharge of combustionproducts to the open air.

• For the ventilation of any confinedspace in which the boiler is installedto prevent overheating of the boilerany equipment in and near theboiler.

• For the satisfactory operation of anydraught stabiliser that may be fitted.

It should be both the designer's andinstaller's concern that the air requiredfor these functions be introduced so asto cause as little discomfort as possibleto the building occupants and thus tooffer them the least temptation toobstruct the ventilators.

Further details may be obtained fromBS 5410:1:1997.

Minimum Size of Air Vents Required

The table below right shows theminimum size of air vents required asillustrated in Figure 9-1 and Figure 9-2above.

Figure 9-1: Air supply for room sealed balanced flue boilers

Room sealed balanced fluecompartment ventilation from room

B

B

A

A

Room sealed balanced fluecompartment ventilation from outside

Conventional open flue

C

Conventional open fluecompartment ventilation from room

C D

E

Conventional open fluecompartment ventilation from outside

C

D

Room sealed balanced flue no ventilation required to room

Boiler inRoom

Boiler inCompartment

Boiler inRoom

Boiler inCompartment

Figure 9-2: Combustion and ventilation air supply for conventional flue boilers

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Under no circumstances can GrantVortex boilers be installed withexisting flue systems. Only fluesystems and components suitable forwet flues should be used.

Failure to install the correct type offlue system will invalidate thewarranty.

Grant condensing boilers have highoperating efficiencies and low flue gastemperatures. Care must be taken toensure the flue system is suitable for thevery low flue gas temperatures andcondensate in the flue gases.

Suitable conventional flue systems areavailable from Grant UK.

The flue must terminate in a downdraught free area, i.e. at least 600mmabove the point of exit through the roofor preferably above the ridge level.

The condensate may be allowed to runback into the boiler. A condensate drainat the base of the flue system is notrequired.

The high level flue terminal must beat least 600mm from any openinginto the building, and 600mm aboveany vertical structure or wall lessthan a horizontal distance of 750mmfrom the terminal.

If an existing chimney is to be used, it must be lined with a smooth borestainless steel liner suitable for use withoil fired condensing boilers. The top andbottom of the annular space must besealed.

Grant recommends the use of the Grant'Orange' flue system, specificallydesigned for the Vortex range ofcondensing boilers.

The internal flue liner diameter for allmodels is 100mm (4 in).

9.2 Conventional Flue Systems The maximum vertical height (from thetop of the boiler to the terminal) for the'Orange' system is 19 metres.

If a rigid flue is used externally, it mustbe of the twin-wall type incorporatingseals at all joints, constructed with astainless steel inner skin and be suitablyinsulated and weatherproofed. Theinternal flue diameter for a rigid flue forall models is 100mm (4 inches).

Grant recommends the use of a hybridsystem using Grant 'Green' and‘Orange’ flue system components forthis application. Refer to Section 1.2for details.

As no flue adaptor is supplied withthe boiler, in order to correctlyconnect the hybrid system, it will benecessary to purchase the Grant CFadaptor kit (Ref. CFA15/70).

If required, it is possible to use the whitepainted single-wall straight flueextensions, adjustable extensions andelbows from the Grant 'Orange' systemfor the internal section of the fluesystem, see Fig 9-5. These componentscan be fitted between the boilerconnector and flue adaptor. The flueadaptor, to which the external twin-wall'Green' flue components are connected,can therefore be situated just before theflue system passes through the wall.

Grant 'Orange' system single-wallflue components must not be usedexternally.

The maximum vertical height (from thetop of the boiler to the terminal) for the100mm diameter hybrid 'Green/Yellow'system is 8 metres.

Grant ‘Green’ twin-wall flue isrecommended for externally run fluesto reduce the possibility of thecondensate freezing in the flue.

No part of any flue system should bemade of an asbestos material;aluminium must not be used in any partof the flue. Only stainless steel fluecomponents should be used.

If the draught conditions aresatisfactory, the flue should terminatewith a standard cowl.

Refer to the locally applicable BuildingRegulations, BS 5410:1 and OFTECInstallation Requirements (OFTECBooks 2 and 3) for further guidance onconventional flue systems.

It is important to ensure that the fluesystem is sealed and that condensatecannot escape. Up to 1.5 l/h ofcondensate can be produced in aconventional flue system.

Use only flue systems suitable for oilfired condensing boilers.

Do not use fire cement. The use of hightemperature silicone sealants isrecommended.

! NOTE

! NOTE

The Grant “Orange” system flexiblestainless steel flue liner is directional.The arrows indicated on the linermust be facing vertically up thechimney, following the direction ofthe flue gases. Failure to comply withthis instruction could lead to aleakage of condense from the fluesystem.

! NOTE

To comply with the requirements ofthe Building Regulations ApprovedDocument J - conventional fluesystems must have a flue data plate.A suitable data plate is supplied withthe current orange flue system andshould be displayed next to theboiler or flue.

! NOTE

! NOTE

! CAUTION

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The rigid flue between the boiler andflexible flue liner should incorporatean adjustable section to allowremoval for inspection and cleaningof the flue system

! NOTE

Flue extensions cannot be cut.

Also available are:

• An adjustable extension.

• 45° elbow are also available.

! CAUTION

9 Flue System and Air SupplyFlue Lining KitsGrant EZ-Fit Flexi Pack conventionalflue system (Orange System)A range of Flexi pack conventional fluelining kits are available from Grant UK.The packs have been specificallyproduced for Grant Vortex oil firedcondensing boilers.

The pack includes a terminal/topplate/flexi flue adaptor, stainless steelsmooth bore flexible flue liner, a rigid toflexi adaptor and a boiler flue connector.

ExtensionsA range of white powder coated singlewall extensions are available to connectthe boiler to the flexible liner.

The external diameter of the extensionsis 100mm.

Extensions are supplied with lockingbands.

The ‘Orange’ system extensioncomponents with their part codesfollows:

The ‘Orange’ system kits componentswith their part codes follows:

Figure 9-3: Grant 'Orange' flue systemin a typical brick chimney

Figure 9-4: Hybrid flue system usingGrant 'Orange' and Grant 'Green'system components

Part Number Flexi Pack(Orange System)

GFKIT 6/100 100mm dia. x 6m length







Part Number Flexi Pack(Orange System)

WX150/100 100mm dia. x 150mm

WX250/100 100mm dia. x 250mm

WX450/100 100mm dia. x 450mm

WX950/100 100mm dia. x 950mm

Flaunching

Brickchimney

Liner isdirectionalsee Noteon p33

Terminal

Clamp

Top plate

Flexi pack

Lockingband

Lockingband

Boiler

Boiler flueconnector

Extension

Rigid to flexiflue connector

(bottom)Note: This

componentmust beinstalledvertically

45˚elbow

Adjustable section235/300mmWXA250/100100mm dia.

Adaptor (from CFA 15/70 kit)

Orange systemcomponents(refer to Fig10.a)

Green systemcomponents

(refer to Fig9-10)

Boiler

Boiler flueconnector(from CFA15/70 kit)

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9.3 Connecting a Conventional Flue1. Unscrew and remove top casing

panel.

2. Push out the pre-cut blanking panel.

If the Grant ‘Orange’ flue system isbeing used, follow the instructionssupplied with the flue kit.

If the Grant ‘Green’ system (100mmrigid twin wall flue) is to be fitted to theboiler then the Grant CF adaptor kit(Ref. CFA15/70) must be used - refer toSection 1.2.

To fit the adaptor kit, proceed asfollows:

1. Fully screw the length of threadedstudding (provided in the kit) into thenut located in the centre of theboiler flue outlet.

2. Fit the boiler connector (from the CFadaptor kit) over the threadedstudding.

3. Position flange on to the neoprenegasket around the boiler flue outlet,ensuring that small spigot on thebase of the connector is located inthe hole in the centre of theneoprene gasket and that the end ofthe studding passes through thehole in the base of the spacerbracket.

4. Fit the washer and wing nutprovided onto end of threadedstudding and secure the connectorin position by tightening down on thewing nut - as shown in Figure 9-5.

5. Re-fit the top casing panel to theboiler - fitting it over the boilerconnector.

6. Fit the flue adaptor (from the adaptorkit) into the boiler connector.

Figure 9-5: Boiler flue connector

9.4 Balanced Flue SystemsApart from a conventional flue, severalbalanced flue options are available foruse with the Grant Vortex Pro Combi eboilers. All are suitable for use withClass C2 kerosene.

Lubricate the seal on the flueconnector using the lubricantprovided before attempting to fit theflue connector.

7. Fit the first section of flue into theflue adaptor and secure using theclamp band provided.

8. Assemble the remainder of the fluesystem as required, lubricating theseal on each component beforefitting.

! NOTE

! NOTENone of the flue sections in thefollowing system can be cut.

Low Level Horizontal Balanced Flue(Yellow system)

The Grant ‘Yellow’ system low levelbalanced flue is available in either Short(for single thickness brick walls) andStandard kits.

Extensions are available which extendthe flue by 225mm, 450mm or 675mm.

90° and 45° elbows are also available.

The maximum flue length - from thecentre of the boiler flue outlet to theouter face of the wall - is 4 metres (withor without elbows included). No morethan 2 x 45° or 1 x 90° elbow should befitted per system.

The ‘Yellow’ system low level balancedflue is supplied with a stainless steelguard. This must be fitted in allcircumstances to prevent objects fromentering the flue outlet.

The guard must be fitted centrally overthe flue terminal and securely fixed tothe wall.

Figure 9-6: Low level balanced flue‘Yellow’ system)

Test pointscrew

Threadedstudding

Wing nut

Washer

Neoprenegasket

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9 Flue System and Air SupplyVertical Balanced Flue (White system)Allows the flue to rise vertically from theboiler to exit through the roof.

The maximum flue length - from the topof the boiler flue outlet to the terminal -is 12 metres for all Vortex boilers.

The following items are additionallyavailable:

• Extensions to extend the flue by225mm, 450mm or 950mm.

• An adjustable extension of 275 to450mm.

• A 45° elbow - No more than6 x 45° elbows should be fittedper system. Each elbow reduces theoverall maximum length of thesystem by 1 metre.

The flue pipe seals are factory fitted andmust be lubricated with the lubricantsupplied before assembly.

The Red system is supplied as a separatekit. Flue extensions and 45° elbows fromthe White system may be used to extendthe flue between the boiler and theflexible section of the system.

The maximum vertical straight length offlue, from the top of the boiler to the topof the terminal, is 20 metres - using nomore than four 45° elbows. Deduct 1metre of straight flue length for everyelbow used.

Flexible Vertical Balanced Flue(Red System) - for Combi 21e & 26eonlyThis is a flexible vertical balanced fluesystem designed to be fitted inside anexisting masonry chimney. See Figure 9-10.

It basically consists of three sections:

• Concentric white painted flue pipeconnected to the boiler.

• Vertical concentric flexible flue(flexible stainless steel flue linerinside a flexible plastic air inlet liner).

• Terminal assembly for chimney topmounting.

Figure 9-8: High level balanced flue‘White’ system

Figure 9-7: White system extensions

White System Components

Item - for models up Part No. Combi Part No. Combito 26 kW output 21e and 26e 36eHigh level flue kit - 1.2 metre HL K01 50/90 HL K02 90/200Vertical flue kit - 3 metre VT K05 50/90 V T K06 90/200225mm extension EXT K31 225/90 EXT K32 225/200450mm extension EXT K09 450/90 EXT K10 450/200950mm extension EXT K11 950/90 EXT K12 950/200275-450mm adjustable extension EXT K13 ADJ/90 EXT K14 ADJ/20045°elbow ELB K21 45/90 ELB K22 45/200Pitched roof flashing - aluminium(for VT K05 50/90) VT MF 90 VT MF200

Pitched roof flashing - lead(for VT K05 50/90) VT K25 P90 VT K26 P200

Flat roof flashing - aluminium(for VT K05 50/90) VT K27 F90 VT K28 F200

Wall bracket BRK 29 90 BRK 30 200

If the flexible liners have to passaround an offset inside the chimneydeduct 2 metres of straight fluelength to compensate for this.

Flue extensions cannot be cut, useadjustable extensions where required.

Three types of locking band aresupplied with the kit.

The first type is for connecting fluesections that butt together (2 of thistype of locking band are supplied).

The second type is to cover the joint onthe adjustable (telescopic) section.

! NOTE

The Grant “Red” system flexiblestainless steel flue liner is directional.The arrows indicated on the linermust be facing vertically up thechimney, following the direction ofthe flue gases. Failure to comply withthis instruction could lead to aleakage of condense from the fluesystem.

! NOTE

The locking band for the adjustablesection is labelled for easy identification.

The third locking band is plastic andsupplied in two halves. This is to securethe plastic flexible liner to the adaptor.

! NOTE

950mmextension

450mmextension

225mmextension

275 to450mmadjustableextension

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External Balanced Flue(Green system)Where it is not practical to use a lowlevel (Yellow system) or internal highlevel/vertical (White system) balancedflue, the boiler can be fitted with anexternal vertical/high level flue (Greensystem). See Figure 9-10.

The Starter kit fits to the boiler in thesame way as a low level balanced flue(Yellow system) and the external Teeallows the connection of a twin wallinsulated flue pipe and a combustion airinlet - providing a room sealed fluesystem.

The external system can terminate ateither high level or vertically (above rooflevel) as required.

The minimum dimensions for locatingthe terminal from building features(windows, doors, etc.) are shown inFigure 9-11.

If the flue terminal is fitted less than 2metres above a surface to which peoplehave access, the terminal must beprotected by a guard. The guard mustbe fitted centrally over the flue terminaland securely fixed to the wall.

The low level balanced flue (Yellowsystem) is supplied with a stainless steelguard. This must be fitted in allcircumstances to prevent objects fromentering the flue outlet.

The terminal must be positioned so asto avoid products of combustionaccumulating in stagnant pocketsaround the buildings or entering intobuildings. Care should be taken that theplume from condensed flue gases doesnot cause a nuisance.

Figure 9-10 shows the external flue(Green system) components that areavailable from Grant UK.

Typical FlueSystem

The flue kit includes a Black coatedterminal with upstand and is designedto be fixed (using the screws provided)to the top of a masonry chimney.

The flue system may be offset using 45°elbows (Ref. ELB K2145/90).No more than a maximum of fourelbows should be used per system.

Figure 9-10: External balanced flue(Green system)

Vertical terminal kitGTV90 (15 - 26 kW)GTV200 (26 - 70 kW)

45° elbow kitGE45/90 (15 - 26 kW)GE45/200 (26 - 70 kW)

High level terminal kitGTH90 (15 - 26 kW)GTH200 (26 - 70 kW)

Extended wall bracket

Extension kits

Starter kitGK90 (15 - 26 kW)GK200 (26 - 70 kW)GK90S - Short(15 - 26 kW)GK200S - Short (26 - 70 kW)

Wall bracketLocking band

Green System Components

Item - for models up Part No. Combi Part No. Combito 26 kW output 21e and 26e 36eStarter kit - standard GK90 GK200Starter kit - short GK90S GK200S150mm extension GX150/90 GX150/200250mm extension GX250/90 GX250/200450mm extension GX450/90 GX450/200950mm extension GX950/90 GX950/200195-270mm adjustable extension GXA250/90 GXA250/20045º elbow GE45/90 GE45/200High level terminal GTH90 GTH200Vertical terminal GTV90 GTV200Wall bracket - standard GWB90 GWB200Wall bracket - extended GEB90 GEB200

Air intakeDo notobstruct

Figure 9-9: Red system balanced flue

Terminal

Terminalupstand

Outer plasticliner

Support clamp

Topplate

Innerstainless

steel liner

Telescopicflue (upper)

Locking bandfor adjustable

joint section

Boiler

Startersection

Lockingband

Telescopicflue (lower)

Connector

Rigid/flexibleadaptor

Plastic lockingband

Lockingband

Liner isdirectional

See Noteon p36

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9 Flue System and Air Supply

Figure 9-11: Clearances for Balanced flue terminals

The minimum distances as shown in Figure 9-11 are given in the table below:

Terminal position Min. distance (mm)

A Below a gutter or sanitary pipework 600*

B Horizontal from an opening, air brick or window 600

C Above ground or balcony level 300

D Below eaves or balcony 600*

E From an internal or external corner 300

F From a terminal facing the terminal 1200

G From a surface facing the terminal 600

H Vertical from terminals on the same wall 1500

I Horizontal from terminals on the same wall 750**

J Below an opening, air brick, window, etc. 600

K From vertical sanitary pipework 300

L Vertical flue from wall 750

M From an oil storage tank 1800

Notes:* 75mm with protection.** Only applies if one or both terminals are balanced flues.

D

DL

C

C

B

B

B

D

F

E

K

A

E

C

G

M

J

J

H

I

1. An opening means an openableelement, such as an openablewindow, or a permanent openingsuch as a permanently open airvent.

2. Notwithstanding the dimensionsgiven, a terminal should be atleast 300mm from combustiblematerial, e.g. a window frame.

3. A way of providing protection ofcombustible material would be tofit a heat shield at least 750mmwide.

! NOTE

Distances measured to rim of terminal.

Clearances recommended by GrantEngineering (UK) Limited in accordancewith British Standards and BuildingRegulations.

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! NOTE

! NOTEDimension B given in Figure 9-13includes an extra 10 mm over thesize of the terminal to provideclearance for fitting.

Fitting instructions for the high levelbalanced flue and vertical balancedflue are supplied with the flue kits.

Adjustable ExtensionsThe adjustable extensions aretelescopic. The wall terminal section isadjustable and is suitable for a wallthickness of 215mm to 450mm.

Simply adjust to the required lengthusing a twisting motion. The outer pipesmust overlap by a minimum of 25mm.

9.6 High Level and VerticalBalanced FlueIf the boiler is to be used with the highlevel balanced flue (White system) makethe hole in the wall as shown in Figure9-13.

Figure 9-13: Flue hole dimensions and position for high level system (White)

Figure 9-12: Flue hole dimensions and position for low level systems (Yellow andGreen)

Model Dimension (mm)

A B C

Pro Combi 21e and 26e 768 127 115

Pro Combi 36e 780 162 105

Model Dimension (mm)

A B dia C

Pro Combi 21e and 26e 1215* 1715 - 2115 175 115

Pro Combi 36e 1280* 1700 - 2020 200 105

*Dimension A for Starter section and elbow/terminal only

Dimension B given in Figure 9-12includes an extra 10mm over the sizeof the terminal to provide clearancefor fitting.

9.5 Prepare the WallIf the boiler is to be used with a low levelbalanced flue (Yellow system) make thehole in the wall for the flue as shown inFigure 9-12.

A

B

A

B

C

Boiler centre line

Note: This dimension isgiven with the boilerpushed back against therear wall. Any clearancesmust be added to it.

Outline ofboiler

Hole to bedrilled in wall


Rear exit Side exit

Side wallRear wall

A

B

A

B

C

Boilercentre line

Note: This dimension isgiven with the boilerpushed back against therear wall. Any clearancesmust be added to it.

Standard kit with no extensions

Outline ofboiler



Rear exit Side exit

Side wallRear wall

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10 CommissioningIt is important that the followingcommissioning procedure is carried outto ensure safe and efficient operation ofthe boiler.

To access the controls, remove the frontpanel (pull forward at the top and thenlift off).

The controls are shown in Figure 10-1.

Figure 10-1: Vortex Pro Combi eboiler control panel

Figure 10-2: Position of boiler components -Vortex Pro Combi e boilers

Plug-inprogrammer position (if fitted)

Heatingswitch

Hot waterswitch

Boilerthermostat

Over heatreset button(under blackcap)


Indicatorlights

Pressuregauge

Flow sensor (black sleeve)

Store sensor (white sleeve)

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have equalised. The adjustable Boilerthermostat on the control panelregulates the boiler temperaturewhen in Heating mode only. Therecommended flow temperaturesetting is 70°C.

The Primary Hot Water storetemperature is controlled via the“store” thermistor and control circuitboard. The control thermostat hasNO influence on either the storetemperature or the hot watertemperature at the tap.

The Hot Water pump will continue torun for a short period after the burnerhas stopped.

The boiler will now be operating in thecentral heating mode.

The burner may not fire immediatelyin the central heating mode.

5. With the burner alight, check thefuel pressure. Refer to the TechnicalInformation, Section 2.3.

6. Adjust the pressure if necessary -see Figure 10-3.

It is important that the oil pressure iscorrectly set.

7. Operate the boiler until it reachesnormal operating temperature.Check oil supply/return pipe forleaks, rectifying where necessary.

8. Check the operation of the boilerthermostat. Ensure that by turning itanticlockwise it switches the burneroff.

9. With the burner alight, re-check thefuel pressure and re-adjust ifnecessary. Turn the boiler off,remove the pressure gauge andreplace the plug in the pump.

10. Ensure that there are no oil leaks,replace the burner cover.

10.1 Before Switching On1. Ensure the boiler On/Off switch is

set to OFF.

2. Check that the high limit thermostatbulb and both thermistor sensorsare correctly located in theirrespective pockets. Refer to Figure10-2. Check condition of boththermistor cables and thermostatcapillary. Ensure they are notdamaged, broken, kinked orcrushed.

3. Remove the nuts and washerssecuring the front cleaning door.Withdraw the door – take care as itis HEAVY!

4. Check that the turbulators are inposition and that the ends arevertical. Refer to Figure 11-4.

5. Check that the baffles are inposition. Refer to Figures 11-1, 11-2, or 11-3 as required.

6. Re-fit cleaning door and check it isfitted correctly and that a good sealis made.

7. Remove and check the burner.Check burner head is correct. Referto Section 2.3 and Figures 13-2,13-3 or 13-4 as required.

Check electrodes are set correctly.Refer to Figure 11-5.

Check the nozzle is correct for theoutput rating required. Refer toSection 2.3.

Check burner air adjuster disc is setto setting C (Vortex Combi 21eonly). Refer to Figure 10-4.

8. Check that the sealed system hasbeen vented and pressurised andthere are no leaks.

9. Ensure both automatic air vents,and also the manual vent on theflow pipe, are open.

10. Check that all fuel line valves areopen.

11. Remove the plastic burner cover if itwas not previously removed.

12. Connect a combined vent manifoldand pressure gauge to the pressuregauge connection port on the oilpump. See Figure 10-3.

13. Check that all system controls arecalling for heat and turn the boilerthermostat to maximum.

10.2 Switching On1. Switch on the electricity supply to

the boiler.

2. Set the boiler On/Off switch to ON.A neon on the switch lights when itis in the ON position.

Note that the neon lights when theboiler is switched on, but does notnecessarily indicate the burner isfiring.

Set both the Hot Water and Heatingswitches to ON.

The burner should then fire.

Open the vent screw on the ventmanifold to vent the supply while theoil pump is running

3. Fully open a hot tap and allow it torun for a few moments to vent theinternal primary circuit. The HotWater pump will operate and theburner should light within about 12seconds.

If the burner does not light and the‘Lock-out’ reset button lights, waitfor about 45 seconds then press thereset button to restart the ignitionprocess. This procedure may haveto be repeated during first lighting.

4. Close the hot tap. The burner willcontinue to fire to heat the primarywater in the boiler or primary storeuntil the required temperature isreached.

Grant Vortex e Combi boilersincorporate a “pump overrun”feature, within the control circuitboard, that operates as follows –

When reheating the Primary HotWater store; the burner will cut out when the boilerreaches 83°C (as detected by the boiler“flow” thermistor).

If there is a demand for CentralHeating;the hot water “store” pump will run onfor 90 seconds before it stops and the“central heating” pump then comes in.

If there is no demand for CentralHeating; the hot water “store” pump will continueto run until the temperatures in thePrimary Hot Water store and the boiler

! NOTE

! NOTE

! NOTE! NOTE

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1. Pump

2. Control box

3. Reset button with lockout lamp

4. Flange with gasket

5. Air damper adjustment screw

6. Air supply tube connection(balanced flue)

7. Pump pressure adjustment screw

8. Pressure gauge connection

10 Commissioning

Figure 10-3: RDB burner components

1

5

4

2

7

8

1

10.3 Running the Boiler1. Relight the boiler and allow it to run

for at least 20 minutes.

2. Check the smoke number, ifsatisfactory check the CO2. Set theCO2 to the value given in Section2.3 for the boiler concerned.

3. Use the hexagonal key supplied toadjust the burner air damper (seeFigure 10-3) as required. Turning thescrew anti-clockwise closes thedamper and increases CO2 level,turning the screw clockwise opensthe damper and reduces CO2 level.

4. Re-check the smoke number if thedamper has been moved. Under nocircumstances must the smokenumber be above 1.

It is important that the air damper iscorrectly set.

10.4 Balancing the System1. When the boiler has been adjusted

and is running satisfactorily, balancethe central heating system byadjusting the radiator lock shieldvalves. Start with the radiatornearest the boiler and adjust thevalves to achieve the requiredtemperature drop across eachradiator. If thermostatic radiatorvalves have been installed, checkthe system bypass.

2. Switch off the boiler.

10.5 Completion1. With the system hot, check again

for leaks, rectifying where necessary.Drain the system while it is hot tocomplete the flushing process. Refilland vent the sealed system.

2. A suitable central heating systeminhibitor must be added to protectthe system against the effect ofcorrosion.

3. A suitable antifreeze should be usedto prevent damage to the boiler inareas where electrical power failurecan occur in winter months.

4. Replace the top, front and rearpanels as necessary.

After commissioning the boilercomplete the Commissioning Reportin the front of this manual and theOFTEC CD/11 commissioning report.Leave the top copy with the User andretain the carbon copy.

If the boiler is to be left in service withthe User, set the controls and roomthermostat (if fitted) to the User'srequirements.

If the boiler is not to be handed overimmediately, close the boiler fuel supplyvalve and switch off the electricity supply.

If there is any possibility of the boilerbeing left during frost conditions,then the boiler and system should bedrained. Alternatively, a suitableantifreeze should be used.

To allow the boiler to be commissionedand serviced correctly a combustiontest point is provided on the frontcleaning door.

The CO2 and smoke test may all becarried out using this test point.

The test point is not suitable formeasuring boiler efficiency orconventional flue draught.

When using the test point on thecleaning cover note that the flue gastemperature reading will be higher thanthat measured in the flue thus resultingin an inaccurate efficiency reading.

To obtain an accurate flue gastemperature and efficiency, the readingcan only be measured outside throughthe low level flue terminal ( or the testpoint on the conventional flue startersection when used).

! NOTE! NOTE

! NOTE

! CAUTION

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10.6 Air Adjuster Disc – Combi21 onlyThe Riello RDB 2.2 burner fitted to thisboiler incorporates a secondary airadjustment shutter located within the airinlet housing.

It is essential that this internal shutterdisc be correctly set to position ‘C’.Refer to Figure 10-4.

To access the air adjuster disc:

1. Ensure the boiler is isolated from theelectrical supply.

2. Remove the burner from the boiler.

3. Undo the four screws and removethe air inlet cover from the side ofthe burner.

4. The secondary air shutter disc isfactory set in position ‘C’ – i.e. withthe cut-out marked C locatedagainst the die-cast boss on the fanhousing. See Figure 10-4.

5. If not set to position ‘C’: remove thescrew from the centre of the airshutter disc, and re-position it suchthat the cut-out ‘C’ is locatedagainst the cast boss on the fanhousing. Replace the screw in thecentre of the air shutter disc andtighten.

6. Re-fit the air inlet cover to the sideof the burner and reassemble inreverse order.

10.7 Information for the UserThe User must be advised (anddemonstrated if necessary) of thefollowing important points:-

• How to start and switch off theboiler and how to operate thesystem controls.

• The precautions necessary toprevent damage to the centralheating system and to the building,in the event of the boiler not being inoperation during frost conditions.

• The importance of servicing theboiler to ensure safe and efficientoperation. This should normally berequired only once a year.

• The type of fuel used.

• That any servicing or replacement ofparts must only be carried out by asuitably qualified engineer.

• Ensure that the boiler controls androom thermostat (if fitted) are set tothe User's requirements.

• Tell the User the system pressureand show them the position of thesafety valve discharge pipe.

• Show the User how to reset theoverheat thermostat and how torestart the boiler if it goes to 'Lock-out'.

Leave this Instruction manual withthe User.

Ensure the User information pack hasbeen given to the Householder.

! NOTE

Figure 10-4: Burner air adjuster disc(shown set to position C)

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11 Boiler ServicingTo ensure efficient operation of theboiler it is recommended that it ischecked and serviced as necessary atregular intervals. The frequency ofservicing will depend upon the particularinstallation conditions and usage, but ingeneral once per year should beadequate.

Servicing and replacement of partsmust only be carried out by a suitablyqualified engineer.

8. With the fuel supply valve closed,clean/replace the filter element andclean the filter bowl.

Braided flexible fuel supply hoses assupplied with the boiler should bereplaced annually when the boiler isserviced. If long-life hoses have beeninstalled, these should be inspectedannually. If in doubt replace the hoses.In any event, these hoses must bereplaced every five years.

11.3 Cleaning the Boiler

The procedure for cleaning the boiler isas follows:

1. Remove the nuts and washerssecuring the front cleaning door andwithdraw the door. Take care - it isheavy.

2. Remove the baffles as shown inFigure 11-1, Figure 11-2 and Figure11-3.

3. Remove all deposits from the baffleplates and all the boiler internalsurfaces using a stiff brush andscraper if necessary.

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

5. Check the condition of the frontcleaning door seal and replace ifnecessary.

6. Replace the baffles, ensuring theyare correctly fitted. See Figure 11-1,Figure 11-2 or Figure 11-3, asappropriate. Pull out the spiralturbulators from the heat exchangertubes. See Figure 11-4.

7. Clean the turbulators using a stiffbrush.

8. Test the heat exchanger condensatedrain by pouring water into one ofthe lower tubes and observewhether the water discharges fromthe 22 mm condensate outlet.Replace the turbulators.

9. Replace the front cleaning door,ensuring the seal is in goodcondition and secure it in positionwith the nuts and washerspreviously removed. Tighten to forma seal.

10. Remove the condensate trap andcheck that it is not blocked and isoperating correctly, i.e. the float isfree to move. Clean the trap andfloat as required.

11. Check that the boiler condensateoutlet is unobstructed. Clean ifnecessary.

! WARNING

! NOTE

! CAUTIONDetails of every service should beentered in the Service Log, in theBoiler Handbook.

This information may be required tovalidate the Grant extended warranty.

Before starting any work on theboiler, or fuel supply please read thehealth and safety information given inSection 14.

11.1 Checking Before Servicing

The following sequential checks shouldbe made before any servicing:

1. Check the flue terminal and ensure itis not blocked or damaged.

2. Run the boiler and check theoperation of its controls.

3. Ensure that all water/fuel systemconnections and fittings are sound.Remake any joints and check thetightness of any fittings that may beleaking.

4. The boiler is part of a sealed centralheating system, check the systempressure, check the operation of thepressure relief valve and check theexpansion vessel air charge. SeeSection 7.

5. Refill, vent and re-pressurise thesystem as necessary. See Section 7.

6. Check that any ventilation openingsare adequate and are clear. SeeSection 9.

7. Remove any sludge/water from thefuel tank by opening the sludgevalve at the lower end of the tank.

Before servicing, set the boilerOn/Off switch to Off, isolate theelectricity supply and close the fuelsupply valve.

Allow the boiler to cool.

The data label on the inside of the caseside panel will indicate the fuel used andthe nozzle fitted.

11.2 Dismantling Prior to Servicing

The procedure for dismantling the boileris as follows:

1. Remove the front panels.

2. Carefully lift up the expansion vesseland remove it from the boiler. Placeit on the floor, taking care not tostrain the flexible pipe.

3. Disconnect the flexible air tube fromthe burner.

4. Remove the burner fixing nut (top ofmounting flange) and withdraw theburner. If required, disconnect theflexible oil line(s), use a suitablecontainer to prevent any oil spillage.

With two flexible hoses connected tothe burner, identify (mark ifnecessary) which is the inlet andreturn if they are to be disconnected.

! NOTEThe condensate trap and condensateoutlet must be checked on everyservice and cleaned as necessary.The end cap is sealed to the trapbody. Do NOT attempt to remove itfor cleaning.

! WARNING

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Figure 11-2: Baffles in Vortex Pro Combi 26e


Figure 11-4: Turbulators in Vortex Pro Combi e boilers


IMPORTANTThe ends of theturbulators mustbe vertical

Turbulators

Bottom set

Top set

Rightbaffles

Leftbaffles

4

3

2

1

Position in vertical plane

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11 Boiler Servicing11.4 Cleaning the Burner

The procedure is:

1. Combustion head - Loosen the twoscrews securing the combustionhead and withdraw the head.

2. Clean the combustion head.

3. Inspect the ignition electrodes -Loosen the electrode clamp screwand withdraw the electrodeassembly. Wipe clean and check forany cracks in the ceramic insulation.Replace if necessary.

4. Check the electrode settings asshown in Figure 11-5.

5. Nozzle - The nozzle should bereplaced on an annual service -Check that the nozzle size and typeare correct, refer to table in Section2.3 and boiler data label.

6. With the combustion head removed,loosen the electrode assemblyclamp screw and slide theelectrodes away from the nozzle.

7. Do not attempt to clean the nozzle.

8. Remove the nozzle using a goodfitting spanner (16 mm).

! CAUTIONThe use of an ill-fitting spanner willdamage the nozzle and could lead toan incorrect flame pattern.

9. Always check the electrode settingsafter replacing the nozzle, see Figure11-5.

10. Refit the combustion head.

All models

Photocell - The photocell is a push-fit inthe burner body. Carefully pull out thephotocell to clean.

Burner fan - Remove the air intake fromthe burner. Check, inspect and cleanthe fan as required. Replace the cover.

Pump filter - Remove the four screwssecuring the pump end cover. Removethe filter and wash in kerosene. Replacethe filter and end cover, ensure the 'O'ring is in position.

Re-assemble in reverse order.

! CAUTIONTo ensure safe and efficient operationof the boiler it is important thatrecommissioning is carried out,especially combustion checks (CO2

level, flue gas temperature andsmoke number) after the boiler hasbeen serviced.

Refer to the Commissioninginstructions in Section 10.

! WARNING

Figure 11-5: Electrodes showing settings

4 +_ 0.3mm

3 to 3.5mm

Clamp screw

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12 Fault Finding

If the Boiler Fails to Light

First follow the procedure below

Power Supply Check that fused spur for heating system and boiler is switched on.

Check that fuse has not blown.

Check that electricity supply has not failed: check circuit breaker in consumer unit.

Heating System Controls Check that timer or programmer is working and set to an ‘ON’ period.

Check that all thermostats are set to the required temperature and are ‘calling’ for heat.

Boiler Controls Check boiler ‘On/Off’ switch is set to ‘ON’.

Check that “POWER” indicator on the control panel is lit.

Check that “DEMAND” indicator is lit.

Burner Check if the burner ‘Lockout’ reset button (on front face of burner) is lit.

If YES: press in the reset button to start the burner.

If burner fails to light and goes to ‘Lockout’ again refer to section 12.4.

Heating System Check Heating System water pressure.

Check if “LOW PRESSURE” indicator is lit.

If YES: system water pressure has fallen to below 0.2 bar and the low pressure cut-out has been activated.

Re-fill system to increase pressure to between 0.5 and 1.0 bar.

If Burner Still Fails to Light Follow the ‘BURNER NOT OPERATING’ procedure in Section 12.2(C).

For Hot Water – ALL the following indicator lights MUST be lit

POWER If NOT lit this indicates a problem with power supply to the boiler - switched off or possibly a blown fuse.

DHW PUMP If FLASHING this indicates either a ‘Store’ thermistor or PCB fault.

Refer to ‘Is the “DHW PUMP” Indicator flashing’ procedure in Section 12.2 (B)

FLOW If not lit when a hot tap is opened this indicates either lack of water flow or possible flow switch problem.

DEMAND If not lit this indicates either timer/programmer is not ‘calling’ for hot water or ‘Hot Water’ switch is not set to ‘CONSTANT’.

BURNER If flashing this indicates PCB fault.

Refer to ‘Is the “BURNER” indicator lit’ procedure in Section 12.2 (B)

NOTE:There may be a delay before the “BURNER” indicator is lit when the store is up to temperature

12.1 Initial Checklist - for Installer or Service Engineers

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12 Fault FindingFor Night Time Hot Water Function – ALL the following indicator lights MUST be lit

POWER If NOT lit this indicates a problem with power supply to the boiler - switched off or possibly a blown fuse.

DHW PUMP If FLASHING this indicates either a store thermistor or PCB fault. Refer to ‘Is the “DHW PUMP” Indicator flashing’ procedure in Section 12.2 (B)

FLOW If not lit this indicates either a lack of water flow or a possible flow switch problem.

DEMAND If not lit this indicates either timer/programmer is not ‘calling’ for hot water or ‘Hot Water’ switch is not set to ‘CONSTANT’.

BURNER If flashing this indicates PCB fault. Refer to ‘Is the “BURNER” indicator lit’ procedure in Section 12.2 (B)

NOTE: The “DHW PUMP” indicator may be lit if the boiler is operating to heat the store which has priority over the CH operation.There may be a delay before the “BURNER” indicator is lit when the the store is up to temperature.

For further guidance refer to the Main Fault Finding Procedures – Section 12.2.

A. No Central Heating - but Hot Water OK

First - Set Hot Water switch to OFF

Is the “DEMAND” NO Check programmer/timer and room thermostat are calling for heating.indicator lit?

NO Check ‘Heating’ switch is set to ‘TIMED’.

Is the “CH PUMP” YES Check electrical connections at the pump.indicator lit? PCB is supplying voltage Check for 230V at the pump terminals.

to the CH pump – but Check if CH pump is stuck:pump is not working. Remove pump vent screw and check for Rotation of shaft/impeller.

If stuck: Rotate shaft manually to restart.If still not operating; Replace the CH pump.

NOTE: A 6 metre pump must be used.

YES Check both pump valves are open.CH pump is working Check Non-return valve on CH pump is operational (not sticking).but no circulation. Check there are no air locks in the system. (if removal of air lock is

difficult – see additional check list).

Check the pump impeller is attached to the shaft.

Is the “CH PUMP” NO Check Non-return valve on CH pump - is it stuck blocked open - indicator lit? check/rectify.

Note – CH return will be hotter than flow if CH non-return valve is jammed open.Check by closing one heating pump valve to stop circulation - does the store then come up to temperature?If problem is not due to CH non-return valve - continue to next check.

Is the “CH PUMP” YES First – set boiler ‘On/Off’ switch to ‘OFF’.indicator flashing? Fast or Slow flash. Wait 5 seconds.

Then set ‘On/Off’ switch back to ‘ON’.

If the “CH PUMP” Fast flash Check CH ‘Flow‘ thermistor connection to PCB.continues flashing. (twice per second): Indicates Replace ‘Flow’ thermistor.

a possible fault with the ‘Flow’ thermistor.

Slow flash(once every 2 seconds): Replace PCB.Indicates a possible faultwith the PCB (relay).

Is the “BURNER” YES Is burner firing?indicator lit? If NO: Refer to ‘BURNER NOT OPERATING’ Procedure -

Section 12.2 (C).

12.2 Main Fault Finding Procedures

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B. No Hot Water - but Central Heating OK

First - Set Heating switch to OFF

Is the “DEMAND” NO Check programmer is calling for hot water.indicator lit? If no programmer is fitted: Check ‘Hot Water’ switch is set to

‘CONSTANT’.

NO Check ‘Heating’ switch is set to ‘TIMED’.

Is the “FLOW SWITCH” NO Check hot water tap is open.indicator lit? Check water flow rate is at least 3 ltr/min.

Cannot achieve 3 ltr/min Check the mains stop tap open fully.Check cold water isolation valve in boiler is open.Check if the flow restrictor (located in the cold water isolation valve) is clear.If not, clean restrictor or remove from valve.

NOTE: No flow restrictor is fitted to the Combi 36e model.

Is the water pressure OK? Check standing water pressure.Low water pressure = low 2 bar minimum standing pressure required water flow rate

Check running (dynamic) pressure.1 bar minimum dynamic pressure required.

If pressure is OK. Check for blockage in plate heat exchanger unit.

NOTE: In hard water areas scale will be produced that can block the plate heat exchanger if no anti-scale protection has been installed. Refer to Section 5 for further details.

If plate heat exchanger is OK. Check flow switch is correctly positioned: the arrow (on flow switch body) must point in direction of flow (i.e. towards front of boiler).

Check switch is free to operate: Close cold water isolation valve, remove flow switch from pipe work – manually operate switch paddle to check.

Remove any debris/blockage from the pipework body or switch paddle.

Check for electrical continuity between flow switch terminals when switch is closed.

No continuity – replace flow switch.

Check for 230V at flow switch terminals.

No 230V – check connections at PCB.

If still no 230V – replace PCB.

Is the “FLOW YES Flow switch is activated.SWITCH” indicator lit? Continue to the next check.

Is the “DHW PUMP” NO Continue to next check.indicator lit?

Is the “DHW YES First – set boiler ‘On/Off’ switch to ‘OFF’.PUMP” flashing? Fast or Slow flash Wait 5 seconds.


If the “DHW PUMP” Fast flash (twice per second): Check DHW ‘Store’ thermistor connection to PCB.indicator Continues Indicates a possible fault Replace ‘Store’ thermistor.flashing. with the ‘Store’ thermistor.

Slow flash (once every 2 Replace PCB.seconds): Indicates a possible fault with the PCB (relay).

12 Fault Finding

50

Faul

t Fi

ndin

g

C. Burner not Operating

First - Set either Hot Water or Heating to ON

Is the “BURNER” NO Refer to ‘Initial Checklist’ for guidance.indicator lit?

NO Continue to next check.

Is the “BURNER” YES First – set boiler ‘On/Off’ switch to ‘OFF’.indicator flashing? Fast or Slow flash. Wait 5 seconds.


If the “BURNER” Slow flash Replace PCB.indicator continues (once every 2 seconds):flashing. Indicates a possible fault

with the PCB (relay).

Is the “BURNER” YES Check all electrical connections to burner control Box.indicator lit? PCB is supplying voltage to Check for 230V at L & N terminals in control box.

the Burner – but burner is Is Lockout button (on control box) lit?not working. If YES: Press ‘Lockout’ button to reset burner.

If burner does not fire – refer to Section 12.4 Burner Fault Finding.

B. No Hot Water - but Central Heating OK continued

Is the “DHW PUMP” YES Check electrical connections at the pump.indicator lit? PCB is supplying voltage to Check for 230V at the pump terminals.

the DHW pump – but pump Check if CH pump is stuck:is not working. Remove pump vent screw and check for Rotation of shaft/impeller.

If stuck: Rotate shaft manually to restart.If still not operating; Replace the DHW pump.NOTE: A 6 metre pump must be used.

YES Check both pump valves are open.DHW pump is working but Check Non-return valve on DHW pump is operational (not sticking).no circulation. Check there are no air locks in the system. (If removal of air lock is

difficult – see additional check list).Check the pump impeller is attached to the shaft.

YES Hot or warm water should be present at hot tap.DHW pump is working If not refer to ‘Poor Hot Water’ Check List.and water is circulating.

Is the “BURNER” YES Is burner firing?indicator lit? If NO: Refer to ‘BURNER NOT OPERATING’ Procedure -

Section 12.2 (C).

Faul

t Fi

ndin

g

51

12.3 Poor Hot Water Checklist – Always check the basics before changing parts!

Burner If heat energy input is incorrect: Check nozzle is correct size.heat energy output will be Incorrect. Check oil pump pressure is correct.Poor heat input = poor hot water! Check combustion is correctly set.

DHW Pump Plate heat exchanger requires water Check pump speed setting: it must be maximum.circulation from primary store to operate Check pump valves are fully open.

Thermistors DHW “Store“ and CH “Flow“ thermistors Check both are fully inserted in their pockets.must detect temperatures correctly

Water Flow Rate Excessive flow rate exceeds heat input Check flow rate at tap.at Hot Tap from burner Combi 21e – 12 ltrs/min maximum

Excessive flow rate=poor hot water! Combi 26e – 15 ltrs/min maximumCombi 36e – 18 ltrs/min maximum

Water Pressure Excessive pressure has a major Check standing and operating water pressure.influence on flow rate. 2 bar minimum standing pressure required

8 bar maximum standing pressure.

If greater than 8 bar: fit a pressure reducing valve on the cold supply to the boiler.

1 bar minimum dynamic pressure required.

Water Condition Scale forming in the plate heat exchanger Check for scale in plate heat exchanger.= poor heat transfer in plate = poor hot Replace plate heat exchanger if necessary.water temperature. In hard water areas some form of anti-scale device or

water softener MUST BE FITTED.

NOTE: Faults due to hard water scaling are not covered by the Grant Product warranty.

Thermostatic Must be correctly set to provide Check if blending valve is scaled up (see ‘WaterBlending Valve Optimum hot water. Condition’ section above).

Clean or replace as necessary.

12 Fault Finding

52

Faul

t Fi

ndin

g

12.4 Riello RDB Burner Fault Finding

Bur

ner

mo

tor

runs

Yes

Lock

out

with

in 1

seco

nd

No

Lock

out

af

ter

12 s

ecp

urg

e

Yes

Igni

tion

spar

k p

rove

d

Yes

Pum

pp

rod

uces

pre

ssur

e

Yes

Yes

Yes

Yes

No

zzle

ato

mis

ing

fu

el

Yes

Co

mb

ustio

nai

r se

tC

om

bus

tion

head

set

Yes

No

Yes

No

No

No

No

No

No

No

No

No

Yes

Che

ck L

& N

to c

ont

rol

bo

x

Yes

Mo

tor/

pum

pse

ized

or

tight

Che

ck b

oile

rco

ntro

ls

Rep

lace

mo

tor

cap

acito

r

Yes

Rep

air

or

rep

lace

mo

tor/

pum

p

Che

ck a

nd

set

the

elec

tro

des

Was

hing

pre

ssur

e 1

to 2

bar

Yes

So

leno

id

valv

eo

per

atin

g

No

Rep

lace

nozz

leF

lam

e o

ff

and

rel

ight

s

Rep

lace

the

cont

rol b

ox

Dri

ve

coup

ling

bro

ken

Che

ck o

ilp

ress

ure

reg

ulat

or

No

No

No

No

OK

Rep

air

or

rep

lace

oil

pum

p

Rep

lace

co

ilan

d/o

r st

emva

lve

Pho

toce

llso

und

Co

il o

fso

leno

idso

und

Mo

tor

giv

es50

Vo

lts t

ow

hite

wire

Rep

lace

cont

rol b

ox

Con

tam

inat

edfu

el o

r fil

ter

If ba

lanc

ed fl

ue,

rem

ove

air t

ube

and

rete

st

Rep

lace

pho

toce

ll

Rep

lace

sole

noid

co

il

Rep

lace

bur

ner

mo

tor

Res

eal b

alan

ced

flue

or re

posi

tion

flue

Bo

iler

or

flue

bla

cked

Yes

No

No

!N

OT

ES

Pho

toce

ll te

stin

g is

ver

y di

fficu

lt w

ithou

tth

e us

e of

a lu

x m

eter

.

It is

bes

t to

repl

ace

the

phot

ocel

l if i

t is

susp

ect.

Mot

or w

hite

wire

retu

rns

50 -

53

V A

Cto

con

trol

box

.

Test

sol

enoi

d co

il fo

r co

ntin

uity

or

100

ohm

s.

Bur

ners

on

bala

nced

flue

sys

tem

s ca

nre

circ

ulat

e flu

e pr

oduc

ts c

ausi

ng b

urne

rre

cycl

ing.

If th

is h

appe

ns, c

heck

flue

posi

tion

and

seal

ing.

Sp

are

Par

ts

53

Figure 13-1 is an exploded view of the Riello RDB burner as used in the Grant VORTEXPro Combi 21e, 26e and 36e boilers, and the associated parts list follows the figure.

13 Spare Parts

28

3

4

56

13

13

25

24

21

20

1819

1415

16

10

9

31

11

12

17

23

2230

26

727

28

29

Figure 13-1: Riello RDB burner exploded view

54

Sp

are

Par

ts

Key Description Riello Grant Key Description Riello Grant No. Part No. Part No. No. Part No. Part No.

1 Not applicable 15 Regulator 3008651 RBS120

2 Flange 3005786 RBS28 16 Pump seal 3000439 RBS14

3 Combustion head T1 17 Pump 3008654 RBS101(Combi 21e) 3002507 RBS146

3 Combustion head T2 18 ‘ O’ ring 3007162 RBS08(Combi 26e) 3002423 RBS147

3 Combustion head T5 19 Filter - ‘O’ ring 3008653 RBS122(Combi 36e) 3002533 RBS150

4 Electrode assembly 3007513 RBS108 20 Connector 3003602 RBS35

5 Electrode bracket 3006552 RBS29 21 Flexible hose 3007672 RBS36

6 Nozzle holder 3008642 RBS111 22 Tube 3008644 RBS113

7 Collar 3008643 RBS112 23 Pressure gauge connector 3008876 RBS138

8 High voltage lead 3008794 RBS129 24 Drive coupling 3000443 RBS16

9 Air damper assembly 3008647 RBS116 25 Solenoid 3008648 RBS117

10 Fan (Combi 26e) 3005708 RBS39 26 Motor RBS102 3002836 RBS102

10 Fan (Combi 21e/36e) 3005788 RBS151 27 Cover 3008649 RBS118

11 Photocell 3008646 RBS115 28 Control box assembly 3008652 RBS103

12 Capacitor 4.5µF 3002837 RBS149 29 Solenoid lead 3008851 RBS139

13 Seal kit 3008878 RBS140 30 Cover 3008879 RBS141

14 Needle valve 3007582 RBS109 31 Air tube spigot 3062774 RBS143

13 Spare Parts

Figure 13-2 T1: Combustion head Vortex Pro Combi 21e Figure 13-3 T2: Combustion head Vortex Pro Combi 26e

Figure 13-4 T5: Combustion head Vortex Pro Combi 36e

15 x 4dia

18dia

5 x R3

15 x 5.5dia

23dia

5 x R5

15 x 4dia

20dia

5 x R5

Hea

lth

and

Saf

ety

Info

rmat

ion

55

Under the Consumer Protection Act1987 and Section 6 of the Health &Safety at Work Act 1974, we arerequired to provide information onsubstances hazardous to health(COSHH Regulations 1988).

Adhesives, sealants and paints used inthe manufacture of the product arecured and present no known hazardswhen used in the manner for which theyare intended.

The following other materials arepresent in the product:

14.1 Insulation MaterialsMaterial Types: Ceramic fibre board,mineral wool.

Description: Rigid board, slabs,sleeves, gaskets, ropes.

Known Hazards: May cause temporaryirritation or rash to skin. High dust levelsmay irritate eyes and upper respiratorysystem.

Precautions: Avoid unnecessary orrough handling, or harsh abrasion ofboards. Normal handling and use ofmaterial should not produce high dustlevels.

Avoid inhalation, and contact with skinand eyes.

After handling always follow normalgood hygiene practices.

Protection: Use disposable gloves, facemask and eye protection.

First Aid: Eyes - If irritation occurs,wash eyes with copious amounts ofwater. If symptoms persist, seek

immediate medical advice.

Skin - If irritation occurs, wash underrunning water before washing with soapand water.

Inhalation - Remove to fresh air, drinkwater to clear throat and blow nose toremove dust/fibres.

Ingestion - Drink plenty of water.

14.2 Insulation MaterialsMaterial Types: Silicone elastomer.

Description: Sealant and adhesive.

Known Hazards: Irritation to eyes.

Precautions: Avoid inhalation of vapour,contact with eyes and prolonged orrepeated contact with skin.

After handling always follow normalgood hygiene practices.

Protection: Use eye protection. Rubberor plastic gloves should be worn whererepeated contact occurs and a facemask worn when working in confinedspaces.

First Aid: Eyes - Flush eyes with waterfor 15 minutes. Seek immediate medicalattention.

Skin - Wipe off and wash with soap andwater.

Inhalation - Remove to fresh air.

14.3 Kerosene and Gas OilFuels (mineral oils)Known Hazards: The effect of mineraloils on the skin vary according to theduration of exposure and the type of oil.

The lighter fractions remove theprotective grease naturally present onthe skin, leaving it dry, liable

to crack and more prone to damage bycuts, abrasions and irritant chemicals.

Skin rashes (Oil acne) most often onarms, but also on any part of the bodyin contact with oil or oily clothing.

Contact with fuel oils can causedermatitis.

Precautions: Avoid as far as possibleany skin contact with mineral oil or withclothing contaminated with mineral oil.

The use of a lanolin-based barrier creamis recommended, in conjunction withregular washing with

soap and rinsing with water to ensure alloil is removed from the skin.

Take care to prevent clothing, especiallyunderwear, from becomingcontaminated with oil.

Do not put oily rags or tools in pockets,especially trouser pockets.

Have first-aid treatment at once for aninjury, however slight.

Do not inhale any vapours from mineraloils.

14 Health and Safety Information

56

EC

Dec

lara

tio

n o

fC

onf

orm

ity

/W

arra

nty

We declare that the Grant Vortex range of Oil Boilers equipped with Riello RDB burners approved to EN 267: 1991 satisfy the requirementsof the following European Directives:-

1. 89/336/EEC - ElectromagneticCompatibility Directive

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

2. 73/23/EEC - Electrical EquipmentSafety Regulations Directive

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

3. 92/42/EEC - Hot Water BoilerEfficiency Directive

Referred to the generic standard The Boiler (Efficiency) (Amendment) Regulations 1994 (SI 1994/3083).

In EU CountriesThe following information is provided toenable regulatory compliance with theEuropean Union (EU) directivesidentified and any amendments made to

In non-EU CountriesIn non-EU countries, dispose ofelectrical and electronic equipment andall surplus packaging in accordancewith national and regional regulations.

Complies with EC Low voltageElectromagnetic compatibility and Boiler efficiency Directives.

89/336/EEC73/23/EEC92/42/EEC

these directives when using electrical orelectronic equipment in EU countries.

Disposal of Electrical andElectronic EquipmentEuropean Union (EU) Directive2002/96/EC Waste Electrical andElectronic Equipment (WEEE).

Do not dispose of electrical or electronicequipment in landfill sites. In the EU, it isthe individual recipient’s responsibility toensure that discarded electrical orelectronic materials are collected andrecycled according to the requirementsof EU environmental law.

Disposal of Surplus PackagingEuropean Parliament and CouncilDirective 94/62/EC Packaging andPackaging Waste.

Do not dispose of surplus packaging inlandfill sites. In the EU, it is the individualrecipient’s responsibility to ensure thatpackaging materials are collected andrecycled according to the requirementsof EU environmental law.

15 EC Declaration of Conformity

16.1 The Vortex Oil BoilerWarranty

Dear Customer You are now the proud owner of a GrantVortex Pro condensing Combi Boilerfrom Grant Engineering (UK) Ltd, thathas been designed to give years ofreliable, trouble free operation.

Grant Engineering (UK) Ltd. guaranteesthe manufacture of the boiler includingall electrical and mechanicalcomponents for a period of twelvemonths from the date of purchaseprovided the boiler is installed in fullaccordance with the installationinstructions provided. This will beextended to a period of two years if theboiler is registered with Grant UK withinthirty days of installation and it isserviced at twelve month intervals. SeeTerms and Conditions below.

IMPORTANTPlease register your Grant Vortex ProCombi boiler with Grant UK within thirtydays of installation. To do so visitwww.grantuk.com and follow the linksto the ‘Householder Zone’, where youcan register your boiler for a further oneyear warranty (giving two years from thedate of purchase). This does not affectyour statutory rights.

Breakdown during theManufacturer’s WarrantyIf your Grant boiler should fail within thefirst two years, you must contact GrantEngineering (UK) Ltd, who will arrangefor the repair under the terms of theirWarranty, providing that the boiler hasbeen correctly installed andcommissioned, serviced (if older thantwelve months) and the fault is not dueto tampering, running out of oil, oilcontamination, system water

contamination, misuse, or the failure ofany external components not suppliedby Grant UK (e.g. fire valve, motorisedvalve, etc.). This extended two yearwarranty only applies if the boiler isregistered with Grant UK within thirtydays of installation.

In the first Instance: Contact your installer or commissioningengineer to ensure that the fault doesnot lie with the system or any othercomponents, or any incorrect setting ofthe system controls.

If a Fault is Found: Ask your installer to contact GrantEngineering (UK) Ltd ServiceDepartment on 01380 736920 who willarrange for a qualified service engineerto attend to the fault.

16 Warranty

Consult the boiler handbook forguidance.

Terms of Manufacturer’s Guarantee1. The Company shall mean Grant

Engineering (UK) Limited.

2. The boiler is guaranteed for twoyears from the date of purchaseproviding that after twelve monthsthe annual service has beencompleted and the boiler registeredwith the Company within thirty daysof the installation date. Any workundertaken must be authorised bythe Company and carried out by anapproved service agent.

3. The shell (heat exchanger) of the oilboiler supplied by the Company iscovered by a five year parts onlyguarantee from the date of purchasesubject to correct operation of theboiler. Proof of annual maintenancemust be provided.

4. This guarantee does not coverbreakdowns caused by incorrectinstallation, neglect, misuse,accident or failure to operate theboiler in accordance with themanufacturer’s instructions.

5. The boiler is registered with theCompany within thirty days ofinstallation. Failure to do so doesnot affect your statutory rights.

6. This guarantee is not transferableunless sanctioned by the Company.

7. The Company will endeavour toprovide prompt service in theunlikely event of a problemoccurring, but cannot be heldresponsible for any consequencesof delay however caused.

8. This guarantee applies to Grantboilers installed on the UK mainland,Isle of Man and Channel Islandsonly. Provision of in-warranty cover

War

rant

y

57

Free of Charge Repairs: During the first two years no charge forparts or labour will be made providedthat the boiler has been installed andcommissioned correctly in accordancewith the manufacturer’s instructions, itwas registered with Grant UK withinthirty days of installation and, for boilersover twelve months old, details ofannual maintenance is available.

The following documents must be madeavailable to Grant UK on request:

• Proof of purchase

• CD10 Installation Completion form

• CD11 Commissioning report form

• Service documents (CD11 orequivalent document)

Chargeable Repairs:A charge may be made (if necessaryfollowing testing of parts at Grant UK) ifthe cause of the breakdown is due toany of the following:

• Faults caused by the plumbing or heating system, e.g.contamination of parts due tosystem contamination, debris ortrapped air.

• Faults due to incorrectly sizedexpansion vessel(s) or incorrectvessel charge pressure.

• Faults caused by external electricsand external components.

• The boiler has not beencommissioned, or serviced inaccordance with the installation andservicing manual.

• Problems caused by lack of oil orfaults with the oil supply system.

• The flue system has been incorrectlyfitted or does not meet installationrequirements.

• The boiler has been installed forover two years and no extendedwarranty cover has been taken.

Note: The nozzle supplied with theboiler is only covered for the period upto the time of the first service (twelve months).

Remember - before you contact Grant:Ensure the boiler has beencommissioned and serviced inaccordance with the Installation andservicing manual.

Ensure there is oil to supply the burner.

Ensure the problem is not being causedby the heating system or its controls.

elsewhere in the UK is subject toagreement with the Company.

9. All claims under this guarantee mustbe made to the Company prior to anywork being undertaken. Invoices forcall out/repair work by any third partywill not be accepted unless previouslyauthorised by the Company.

10. Proof of purchase and date ofinstallation, commissioning andservice documents must beprovided on request.

11. If a replacement boiler is suppliedunder the warranty (due to amanufacturing fault) the productwarranty continues from theinstallation date of the original boiler,and not from the installation date ofthe replacement.

Hard Water Advice If you live in a hard water area,protection against scaling must be givento the domestic hot water heatexchanger of your combination boiler.You should fit an appropriate scaleinhibitor or water softener as anybreakdown caused by water scalingis not covered by either themanufacturer’s guarantee orinsurance. Ask your installer for advice.

16.2 Extended WarrantyFor further peace of mind GrantEngineering (UK) Ltd offer the option toinsure all the components of your GrantVortex Pro Combi boiler for a furtherthree years, following on from the twoyear product warranty period. For asingle premium payment (inclusive ofInsurance Premium tax) you get fiveyears of protection against breakdowncosts. At the end of this period you willhave the opportunity to continue thiscover on an annual basis.

To access full details and an applicationform for this extended cover, first visitwww.grantuk.com.

Follow the links to the ‘HouseholderZone’, register your Grant Vortex proboiler for a further one year productwarranty (giving two years from the dateof purchase), and then download theextended warranty details andapplication form.

Please note that this special offer is onlyavailable if the application form issubmitted to Bluefin Insurance ServicesLtd. within three months of theinstallation date.

16 Warranty

! NOTEDo not wait until the fuel supply runsout before you order some more.Sludge in the bottom of the tank maybe drawn into the fuel lines. It isrecommended that the boiler isswitched off when the new supply isdelivered and that the fuel is allowedto settle for an hour before restartingthe boiler.

Notes

58

Notes

Notes

59

No

tes

9

Notes

User Instructions

8

User Instructio

ns

You may have to wait for the boiler tocool down before the button willreset. If this condition repeats,contact your Service engineer.

Check the system pressure and re-pressurise as necessary beforeattempting to reset the overheatthermostat. Refer to Sealed centralheating system in these instructionsfor details on re-pressurising thesystem.

Ventilation- Always ensure that theboiler has adequate ventilation. Anyventilation openings in the boiler casingmust not be obstructed. Periodicallycheck that they are clear. Do not attemptto ‘box in’ the boiler or build acompartment around it. Do not placeany combustible material on or aroundthe boiler.

Flue terminal- The flue terminal mustnot be obstructed or damaged. Insevere conditions check that theterminal does not become blocked withsnow. Do not place any combustiblematerial on or around the flue terminal.

Frost Protection- Your boiler is fittedwith a pre-set internal frost protectionthermostat. Should either the airtemperature around the boiler, or thewater temperature within the boiler, fallto below 5°C then this thermostat will beactivated. The boiler will then operatebriefly to prevent it from freezing. Yourboiler may also be fitted with a remotefrost protection thermostat; check withyour installer. If you are intending to beaway for a long period, the boiler andsystem should be drained. Contact yourService engineer for draining and fillingthe system.

Cleaning and servicing- Lightly wipeover the case with a damp cloth and alittle detergent. Do not use abrasivepads or cleaners. You should have yourboiler serviced at least once a year toensure safe and efficient operation.Contact your Service engineer for furtherdetails.

Failure of electricity supply- If theelectricity supply fails, the boiler will notoperate. It should relight automaticallywhen the supply is restored.

!NOTEThe time and on/off settings on a 7-day or 24-hour timer or a 2-channelprogrammer may need to be resetafter a power failure.

The Grant Programmable RoomThermostat and WirelessProgrammable Room Thermostat arebattery powered and will beunaffected by a power failure.

Electricity SupplyThe boiler requires a 230/240 V - 50 Hzsupply. It must be protected by a 5 Ampfuse.

The Vortex boiler contains electricalswitching equipment and must beearthed.

Electricity ConnectionThe Vortex Pro Combi boilers can beserviced from the front, but it ispreferable for any worktop above theboiler to be removable to provide thebest access for servicing.

!NOTE

!WARNING

User Instructio

ns

7

Sealed Central Heating SystemThe boiler operates on a sealed heatingsystem. Your installer will havepressurised the system and set thewhite pointer on the pressure gauge(see Figure 2) to indicate a systempressure (when cold) of usually between0.5 and 1.0 bar. Do not adjust thispointer.

The white pointer indicates the actualsystem pressure which will increaseslightly when the boiler is operating. Ifthe white pointer falls below the redpointer (when the boiler is switched offand cold), you should contact yourInstaller to check the heating system forleaks.

If the heating system water pressurefalls below 0.2 bar the boiler lowpressure cut-out will be activated,cutting power to the burner, and the red‘LOW PRESSURE’ indicator on thecontrol panel (see Figure 2) will flash.The system must be re-charged tobetween 0.5 and 1 bar. If the heatingsystem loses pressure on a regularbasis then contact your Installer toinvestigate and rectify the cause.

The boiler is fitted with an automatic airvent which removes air trapped in theboiler. Any air trapped in the radiatorsneeds to be removed by venting theradiators via the vent screw at the top ofeach radiator. Only vent a radiator if thetop is cool when the bottom is hot.Venting will reduce the system pressure,as indicated on the pressure gauge, soonly vent when necessary and checkthe system pressure as mentionedabove.

Your sealed system may incorporatea ‘Top-up’ vessel. Advice on how touse this should be obtained fromyour installer.

The boiler is fitted with a safety (orpressure relief) valve to automaticallyrelease excess pressure from thesystem. If the water or steam is emittedfrom the end of the safety valvedischarge pipe, switch off the boiler andcontact your Installer or ServiceEngineer.

The Expansion vessel air charge mustbe checked annually. Failure to maintainan adequate air charge in the vesselmay invalidate the warranty.

To Re-pressurise the Systemby adding Water

Add water to the system only when itis cold and the boiler is switched off.Do not overfill.

The procedure is as follows:

1.Ensure the flexible filling loop isconnected and that the shut offvalve connecting it to the boiler isopen and the double check valve atthe front is closed. A valve is openwhen the operating lever is in linewith the valve, and closed when it isat right angles to it.

2.Gradually open the double checkvalve on the front of the filling loopuntil the water is heard to flow.

3.Vent each radiator in turn, startingwith the lowest one in the system, toremove air.

4.Continue to fill the system until thepressure gauge indicates therequired pressure between 0.5 and1.0 bar. Close the fill point valve.

5.Close the valves either side of thefilling loop and disconnect the loop.

General Notes and Care ofyour SystemBoiler controls- Refer to the sectionBoiler controls.

Pressure switch- If the heating systemwater pressure falls below 0.2 bar theboiler pressure cut-out switch willactivate and the red ‘LOW PRESSURE’indicator on the control panel (see Figure2) will flash.

The system must be recharged tobetween 0.5 to 1bar. If the heatingsystem loses pressure on a regular basisthen contact your Installer to investigatethe cause.

Burner Lock-out reset button- If thereis a burner malfunction, a built-in safetycircuit switches the burner off and the‘Lock-out’ reset button on the burner willlight. Usually such malfunctions are shortlived and pressing the reset button willrestore normal operation.

The reset button should not be pressedmore than twice in attempting to startthe burner.

If the burner continually goes to ‘Lock-out’ a fault exists or the fuel supply islow. If you have checked that you havesufficient fuel, you will need to call yourService engineer.

Overheat thermostat-Your boiler isfitted with a safety overheat thermostatwhich will automatically switch off theboiler in the case of a controlmalfunction causing overheating. Thered ‘OVERHEAT’ indicator on the controlpanel (see Figure 2) will flash indicatingthe overheat thermostat has operated.

If your boiler goes off and you try to lightit but nothing happens and the ‘Lock-out’ reset button on the burner is not lit,the overheat thermostat has probablyoperated. The boiler will not light until thethermostat is reset. To reset, unscrewthe small plastic cap (see Figure 2), andpress the button and the ‘OVERHEAT’indicator should go off. Replace theplastic cap.

!WARNING

!NOTE

6

User Instructio

ns

Lighting your BoilerBefore lighting your boiler, ensure that:

•There is sufficient fuel in the supplytank.

•All fuel supply valves are open.

•The water supply is on.

•The electricity supply to the boiler isoff.

•The Boiler On/Off switch is set toOFF.

•The Heating switch is set to TIMEDor CONSTANT.

•The Hot Water switch is set toTIMED or CONSTANT.

•The white pointer on the pressuregauge is not below the red pointer.

•The room thermostat is at thedesired setting.

•The timer or programmer is correctlyset.

Switch on the electricity supply to theboiler.

Set the On/Off switch to ON. Refer toFigure 2.

The boiler will light automatically to heatthe water stored in the boiler. If theProgrammer or Timer is set to a heating‘on’ period and the room thermostat is‘calling’ for heat, the boiler will continueto run to provide central heating, afterthe store reaches temperature.

Once the store has reachedtemperature, if a hot tap is opened theboiler will supply hot water.

Turning off your BoilerFor short periods - Set the On/Offswitch to OFF. Refer to Figure 2.

To re-start the boiler, simply set theswitch to ON.

For long periods - Set the On/Off switchto OFF and switch of the electricitysupply to the boiler. If required, the fuelsupply valve may be closed and thewater and electrical supplies turned offat the mains. To re-start the boiler, referto the full lighting instructions above.

Points to Check if the BoilerFails to LightPerform the following checks if yourboiler fails to light:

1.Ensure that a fuse has not blown orthat the electricity supply has notfailed.

2.Check that the boiler On/Off switchis set to ON and that the POWERindicator on the control panel is lit.

3.Check that the timer or programmeris working and is in an ‘on’ period.

4.Check that all thermostats are set tothe desired setting and are ‘calling’for heat.

5.Check the DEMAND indicator onthe control panel is lit.

6.Check if the burner ‘Lock-out’ resetbutton (on the front face of theburner) is lit. Refer to Figure 1.

7.If it is, press in the button to startthe burner. If the burner fails to lightand goes to ‘Lock-out’ again, checkthat you have sufficient fuel in thestorage tank and the fuel supplyvalves are open.

8.Check that remote fire valve has not‘tripped’. Reset if necessary.

9.Check to see if the red OVERHEATindicator on the control panel isflashing - indicating that theoverheat thermostat has operated.See Overheat Thermostat underGeneral Notes and care of yoursystem.

10.Check the heating system waterpressure. If it falls below 0.2 bar theboiler low pressure cut-out will beactivated, cutting power to theburner, and the red ‘LOWPRESSURE’ indicator on the controlpanel (see Figure 2) will flash. Thesystem must be re-charged tobetween 0.5 and 1 bar. If theheating system loses pressure on aregular basis then contact yourInstaller to investigate the cause.

If the burner still fails to light aftercarrying out these checks then a faultexists. Switch off the electricity supplyto the boiler and contact your serviceengineer.

Domestic Hot Water SystemThe boiler will supply domestic hotwater whenever a hot tap is opened,provided the boiler On/Off switch is setto ON and the Hot Water switch is setto either CONSTANT or TIMED. If a 2-channel programmer is fitted (either a‘plug-in’ or remote programmer), theHot water setting on the programmermust be ‘on’ for the boiler to providecontinuous hot water when the HotWater switch is set to TIMED.

‘Night time’ Hot Water FunctionThis is a feature built in to your boilerallowing a limited amount of hot waterto be drawn off during periods wheneither the hot water programmerchannel is ‘off’ (for example. during thenight) or the Hot Water switch is set toOFF - provided that the primary store inthe boiler is hot. When a hot tap isopened during this period, the flowswitch activates the hot water storepump and the incoming mains coldwater is heated using whatever heat ispresent in the primary store. The burnerwill not fire and so the heat in the storewill gradually be used up and the hotwater temperature will reduce with time.

If a 2-channel programmer is fitted -either a ‘plug-in’ or remote programmer,or the remote ‘wireless’ programmableroom thermostat - the Hot water settingon the programmer must be ‘on’ for theboiler to provide continuous hot waterwhen the Hot Water switch is set toTIMED.

User Instructions

!NOTEThe flow of water from the taps (hotor cold) depends on the mainspressure, and in some homes it maynot be possible to use more than onetap at a time.

User Instructio

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5

‘Plug-in’ two-channel programmer -allows separate timed control of theon/off times for both central heating andhot water. Refer to the operatinginstructions provided with the plug-inprogrammer.

The Hot water setting on theprogrammer must be ‘on’ for the boilerto provide continuous hot water whenthe Hot Water switch is set to TIMED.

‘Plug-in’ single-channel 24-hourmechanical timer (if fitted)- allows timedcontrol of the on/off times for centralheating but does not provide controlover hot water operation. Refer to theoperating instructions provided with theplug-in programmer.‘Plug-in’ single-channel 7-day electronictimer (if fitted)- allows timed control ofthe on/off times for central heating butdoes not provide control over hot wateroperation. Refer to the operatinginstructions provided with the plug-inprogrammer.‘Plug-in’ wireless receiver module (iffitted)- operated by the remotelymounted wireless programmable roomthermostat unit gives separate timedcontrol of the on' off times for bothcentral heating and hot water. Refer tothe operating instructions provided withthe ‘Wireless’ Programmable Thermostatkit.

About your FuelGrant Vortex Pro Combi e boilers onlyoperate on Class C2 Kerosene toBS2869:1998. You should always quotethe type of fuel you require whenordering from your supplier.

Do not wait until the fuel runs out beforeyou order some more. Sludge in thebottom of the tank may be drawn intothe fuel lines. If it is possible, switch offthe boiler when the new supply isdelivered and leave the fuel to settle foran hour before restarting the boiler.

!NOTE

Figure 2:Vortex Pro Combi control panel

Figure 1:Pro Combi e internal boiler with front panel removed showingposition of control panel

Plug-in timerprogrammer orwireless receiver (if fitted)

Heatingswitch

Hot waterswitch

Boilerthermostat

Over heatresetbutton(underblack cap)


Indicatorlights

Pressuregauge

Expansion vessel

Control panel

Condensate trap

Burner lock-out button

4

User Instructio

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User InstructionsHeating switch:When set to TIMED,the boiler will only provide centralheating when either the Programmer orTimer is in a ‘heating ‘on’ period and theroom thermostat is ‘calling’ for heat.When set to OFF, the boiler will notprovide central heating at all. When setto CONSTANT, the boiler providescentral heating continuously when theroom thermostat is calling, overriding allof the Timer or Programmer heatingsettings.

For Summer time operation, whencentral heating is not required, set theHeating switch to OFF.

Hot Water switch:Allows the hot wateroperation of the boiler to be manuallyswitched off if hot water is not required.With the switch set to OFF, the burnerwill not fire to maintain the watertemperature in the store and the hotwater (store) pump will not operate.

If a programmer or ‘wireless’ twochannel programmable room thermostatis connected to the boiler (as options D,E and F defined under About yourboiler), when the switch is set to TIMED,the boiler will provide hot water onlyduring the ‘on’ periods set on theprogrammer. When the switch is set toCONSTANT the boiler provides hotwater continuously on demand,overriding any programmer settings.

Also refer to the section ‘Night time’hot water functionfor furtherinformation.

Boiler indicator lights:These 8 redlights indicate the operating situation ofthe boiler.

Boiler (heating) thermostat:Controlsthe temperature of the water leaving theboiler to the central heating system.Operation of this control does not affectthe temperature of the hot water flowingto the taps.

The temperature of the water leavingthe boiler to the radiators can beincreased by turning the boiler (heating)thermostat clockwise. Figure 1 showsthe components in the Vortex ProCombi e internal boilers and the positionof the control panel. Figure 2 shows thedetails of the control panel.

IntroductionThis User Guide is intended to assistthe user in the operation of the GrantVORTEX Pro Combi boilers.The engineers manual for theinstallation and maintenance of thisboiler is attached to the reverse ofthese instructions.

The following special text formats areused in this manual for the purposeslisted below:

Warning of possible human injury asa consequence of not following theinstructions in the warning.

Note text. Used for emphasis orinformation not directly concernedwith the surrounding text but ofimportance to the reader.

About your BoilerYour Grant Vortex Pro Combi boiler isfully automatic and when the boilerOn/off switch is set to ON, will providedomestic hot water at mains pressureon demand and central heating whenthe hot water and heating systemcontrols call for it.

Your boiler may be fitted with one of thefollowing control options, located eitheron the boiler control panel or in aconvenient position remote from theboiler:

•Option A Programmable roomthermostat only.

•Option B Remote timer and roomthermostat.

•Option C Boiler-mounted ‘plug-in’single channel 24-hour mechanicaltimer and remote room thermostat.

•Option D Boiler-mounted ‘plug-in’single channel 7-day electronic timerand remote room thermostat.

•Option E Remote two-channelprogrammer and room thermostat.

•Option F Boiler mounted ‘plug-in’two-channel electronicprogrammable timer and remoteroom thermostat.

•Option G Remote ‘wireless’ twochannel programmable roomthermostat (with boiler mounted‘plug-in’ receiver unit).

Whatever type of control is connectedto your boiler, it will allow you to set theoperating times of your central heating.

In the case of options A, B, C and D -domestic hot water is availablecontinuously, providing the boiler isswitched on, irrespective of the heatingcontrol settings.

In the case of options E, F and G -, youcan set the operating times for bothheating and hot water using the heatingand hot water settings respectively onthe programmer, or wireless two-channel programmable roomthermostat.

!WARNING

!NOTE

The boiler will produce a limitedamount of hot water during the ‘off’Hot Water periods set on theprogrammer. Refer to ‘Night time’ hotwater operation - Section ‘Night time’hot water function.

Boiler ControlsTo access the controls, pull off the frontdoor from the boiler.

Boiler On/Off switch: This switches theboiler on and off. The boiler On/Offswitch incorporates a ‘mains on’ neon;see Figure 2, which lights when theboiler is switched on. Please note thatthe ‘mains on’ neon does notnecessarily indicate that the burner isfiring.

!NOTE

When the On/Off switch is set to ONthe POWER indicator on the controlpanel will light.

The boiler will not supply centralheating or domestic hot water if thisswitch is set to OFF, and also thebuilt in frost thermostat will notoperate.

!NOTE

Contents

Co

ntents

3

‘Night time’ Hot Water Function 6

Sealed Central Heating System 7

To Re-pressurise the Systemby adding Water 7

General Notes and Care ofyour System 7

Electricity Supply 8

Electrical Connection 8

Introduction 4

About your Boiler 4

Boiler Controls 4

About your Fuel 5

Lighting your Boiler 6

Turning off your Boiler 6

Points to Check if the BoilerFails to Light 6

Domestic Hot Water System 6

2

Service Lo

g

For use with Kerosene* only.After installing the boiler leave theseinstructions with the User.

This appliance is deemed a controlledservice and specific regional statutoryrequirements may be applicable.

*Operation on Bio-fuelAll Grant Vortex Pro condensing boilers,manufactured since May 2011, aresuitable for operation on both standardkerosene (Class C2 to BS2869) andalso bio-kerosene – up to a 30% blend(B30K).

All burner settings and nozzle sizes (asdetailed in Section 2.3 of this manual)are correct for both standard keroseneand bio-kerosene (B30K).

In order to operate this boiler on bio-kerosene it will be necessary to take the following actions:

a) Use a bio-kerosene (B30K)compatible flexible oil line in place of the oil line supplied with this boiler.

b) Have your oil storage tank and oilsupply line (including all pipework, sightgauges, filters, isolating valves, firevalves, de-aeration devices, etc.)checked for their compatibility with bio-kerosene (B30K).

Where necessary some, or all, of theseitems may have to be replaced with abio-kerosene compatible alternative.

c) Check the suitability of the fluesystem with Grant UK.

d) Use only bio-kerosene (B30K) thatconforms to OPS24.

IMPORTANTUnder no circumstances should theboiler be used with bio-kerosenewithout the above actions being takenfirst.

Service LogIt is recommended that the boiler shouldbe regularly serviced, at least once ayear, and the details entered in theBoiler Handbook by the serviceengineer.

GRANT ENGINEERING (UK) LIMITEDHopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EUTel: 01380 736920 Fax: 01380 736991Email: [email protected] www.grantuk.com

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/orappearances are changed in the interests of continued product improvement.All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.

Grant VORTEX Pro Internal CombiCombi 21e, Combi 26e and Combi 36e Condensing Oil Boiler Range

User Instructions

Part No. DOC 88 Rev 00. May 2012

grant vortex pro internal combi - millside...

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