Grant VORTEX Pro External Combi 21e Release note

Grant VORTEX Pro External Combi
Combi 21e, Combi 26e and Combi 36e Condensing Oil Boiler Range
Installation & Servicing Instructions
Part No. DOC 89. Rev 00. May 2012

Commissioning Report
2
Commissioning
Report
For use with Kerosene* only.
After installing the boiler leave these
instructions with the User.
This appliance is deemed a controlled
service and specific regional statutory
requirements may be applicable.
*Operation on Bio-fuel
All Grant Vortex Pro condensing boilers,
manufactured since May 2011, are
suitable for operation on both standard
kerosene (Class C2 to BS2869) and
also bio-kerosene – up to a 30% blend
(B30K).
All burner settings and nozzle sizes (as
detailed in Section 2.3 of this manual)
are correct for both standard kerosene
and bio-kerosene (B30K).
In order to operate this boiler on
bio-kerosene it will be necessary to
take the following actions:
a) Use a bio-kerosene (B30K)
compatible flexible oil line in place of
the oil line supplied with this boiler.
b) Have your oil storage tank and oil
supply line (including all pipework, sight
gauges, filters, isolating valves, fire
valves, de-aeration devices, etc.)
checked for their compatibility with
bio-kerosene (B30K).
Where necessary some, or all, of these
items may have to be replaced with a
bio-kerosene compatible alternative.
c) Check the suitability of the flue
system with Grant UK.
d) Use only bio-kerosene (B30K) that
conforms to OPS24.
IMPORTANT
Under no circumstances should the
boiler be used with bio-kerosene
without the above actions being taken
first.
Date:
Commissioning engineer:
Tel. No:
Boiler model: Boiler output: kW
Fuel type: Kerosene
Nozzle size: Pump pressure:
Air setting: Flue gas % 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)
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU
Tel: [phone] Fax: [phone]
Email: [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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or
appearances 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 sealed systems only:
Expansion vessel size : litres
Expansion vessel change pressure : bar
Sealed system fill pressure (cold) : bar
Service Log
It is recommended that the boiler should be regularly serviced, at least once a year,
and the details entered in the Boiler Handbook by the service engineer.

Contents
Contents
3
1Introduction 4
1.1 How a Condensing Boiler Works 4
1.2 Boiler Description 4
2Technical Data 6
2.1 Boiler Technical Data 6
2.2 Approximate Air Damper Setting 7
2.3 Vortex Pro Combi e Oil Boilers using
Class C2 Kerosene 7
2.4 Flue Gas Analysis 7
2.5 Boiler Dimensions 7
3Oil Storage & Supply System 8
3.1 Fuel Supply 8
3.2 Burner Oil Connection 11
4Boiler Installation Information 12
4.1 Introduction 12
4.2 Boiler Location 12
4.3 Preparation for Installation 12
4.4 Installing the Boiler 12
4.5 Expansion Vessel 13
4.6 Filling and Venting the System 13
4.7 Regulations Compliance Requirements 13
4.8 Completion 14
4.9 Before you Commission 14
4.10 Underfloor Heating Systems 14
4.11 Pipework Materials 14
4.12 Sealed Systems 14
4.13 Underfloor Pipework 14
5Pipe Connections 15
5.1 Water Connections 15
5.2 Making the Water Connections 15
5.3 Domestic Hot Water System 16
5.4 To use the Water Hardness Kit 16
6Condensate Disposal 17
6.1 General Requirements 17
6.2 Connections 17
6.3 Pipework 17
6.4 External Pipework 17
6.5 Condensate Soakaway 17
6.6 Condensate Trap 18
6.7 Condensate Disposal Pipework 18
6.8 Inspection and Cleaning of Trap 18
7Sealed Systems 19
7.1 System Models 19
8Electrical 20
8.1 Connecting the Power Supply 20
8.2 Connecting the Controls - Heating Only 22
8.3 Connecting the Controls - Heating
and Hot Water 23
8.4 Connecting a Remote Frost Thermostat 25
9Flue System & Air Supply 26
9.1 Low Level Discharge Flue 26
9.2 Grant Green System 27
9.3 Grant Hybrid System 27
9.4 Grant Horizontal System 28
9.5 General Guidance 28
9.6 Air Supply 28
10 Commissioning 30
10.1 Before Switching On 30
10.2 Switching On 30
10.3 Running the Boiler 31
10.4 Balancing the System 31
10.5 Completion 31
10.6 Air Adjuster Disc - Combi 21 only 32
10.7 Information for the User 32
11 Boiler Servicing 33
11.1 Checking before Servicing 33
11.2 Dismantling Prior to Servicing 33
11.3 Cleaning the Boiler 33
11.4 Cleaning the Burner 35
12 Fault Finding 36
12.1 Initial Checklist - for Installer or
Service Engineers 36
12.2 Main Fault Finding Procedure 37
12.3 Poor Hot Water Checklist 40
12.4 Riello RDB Burner Fault Finding 41
13 Spare Parts 42
14 Health & Safety Information 44
14.1 Insulation Materials 44
14.2 Insulation Materials 44
14.3 Kerosene and Gas Oil Fuels (mineral oils) 44
15 EC Declaration of Conformity 45
16 Warranty 46
16.1 The Vortex Oil Boiler Warranty 46
16.2 Extended Warranty 47

1Introduction
4
Introduction
Warning of possible human injury as
a consequence of not following the
instructions in the warning.
The Grant VORTEX Pro Combi e
condensing boilers contain an extra
heat exchanger which is designed to
recover the latent heat normally lost by
a conventional boiler. It does this by
cooling the flue gases to below 90° C,
thus extracting more sensible heat and
some of the latent heat. This is achieved
by cooling the flue gases to their dew
point (approximately 55° C).
To ensure maximum efficiency, the boiler
return temperature should be 55° C or
less, this will enable the latent heat to be
condensed out of the flue gases.
The boiler will achieve net thermal
efficiencies of 100%.
To achieve maximum performance from
the Grant VORTEX Pro Combi e boilers,
it is recommended that the heating
system is designed so that a
temperature differential of 20°C
between the flow and return is
maintained.
The Grant Vortex Pro Combi e boilers
will however still operate at extremely
high efficiencies even when it is not in
condensing mode and therefore is
suitable for fitting to an existing heating
system without alteration to the radiator
sizes. The boiler is capable of a
maximum flow temperature of 78° C.
1.2 Boiler Description
The Vortex Pro Combi e boilers are
automatic pressure jet oil boilers
designed for use with a sealed central
heating system and will provide
domestic hot water at mains pressure.
All boilers are supplied with the control
panel and the burner factory fitted, and
a factory fitted low level discharge fuel
system.
Caution concerning likely damage to
equipment or tools as a
consequence of not following the
instructions in the caution.
Note text. Used for emphasis or
information not directly concerned
with the surrounding text but of
importance to the reader.
1.1 How a Condensing
Boiler Works
During the combustion process,
hydrogen and oxygen combine to
produce heat and water vapour. The
water vapour produced is in the form
of superheated steam in the heat
exchanger. This superheated steam
contains sensible heat (available heat)
and latent heat (heat locked up in the
flue gas). A conventional boiler cannot
recover any of the latent heat and this
energy is lost to the atmosphere
through the flue.
!WARNING
!CAUTION
!NOTE
For conventional flue applications,
where required, Grant recommends
the use of the Grant 'Green' flue
system, to provide an insulated twin -
wall flue system. Refer to Section 9
for further details.
Only Kerosene must be used with a
low level discharge flue appliance.
The Vortex Pro Combi e boilers are
only suitable for use with Kerosene.
All burners are ready to connect to a
single pipe system with a loose flexible
fuel line (900mm) and 3/8” to 1/4” BSP
male adaptor supplied with the boiler. If
required, an additional flexible fuel line
(900mm) and 3/8” to 1/4” BSP male
adaptor are available to purchase from
Grant Engineering (UK) Limited, for two-
pipe oil supply system, Part No. RBS36.
The temperature of the water leaving
the boiler to heat the radiators is User
adjustable.
The setting of the boiler thermostat on
the Vortex Pro Combi e boilers has no
effect on the hot water performance.
Figure 1-1 shows the components in
the Vortex Pro Combi e boilers and the
position of the control panel. Figure 1-2
shows the details of the control panel.
!NOTE
This manual is intended to guide
engineers in the installation and
maintenance of Grant VORTEX Pro
External Combi e boilers. A separate
manual is available to guide users in
the operation of these boilers, and is
printed inverted at the end of this
manual.
The following special text formats are
used in this manual for the purposes
listed below:

Introduction
5
IMPORTANT
CABLETOPLUGMUSTBESECUREDINCABLECLAMPBELOWPANEL
MAXIMUMCABLELENGTHBETWEENPLUGANDCLAMP350mm
WARNING230VISOLATEMAINSPOWERSUPPLYBEFOREREMOVINGCOVER
1
2
N
3
N
L
Figure 1-1: Vortex Pro Combi 21e boiler with front panel removed showing position of control panel
IMPORTANT
CABLE TO PLUG MUST BE SECURED IN CABLE CLAMP BELOW PANEL
MAXIMUM CABLE LENGTH BETWEEN PLUG AND CLAMP 350mm
WARNING 230V ISOLATE MAINS POWER SUPPLY BEFORE REMOVING COVER
1
2
N
3
N
L
Figure 1-2: Vortex Pro Combi e boiler control panel
Electrical
connection socket
Service
switch
Boiler
thermostat
Pressure
gauge
Boiler On / Off switch
Expansion vessel
(In 26e and 36e
models, this is
mounted on the
front of the boiler)
panel
Burner lock-out
button
Indicator lights
Overheat reset button
(under black cap)
Hot water (DHW) pump
Non return
valve
Heating (CH) pump
Non return
valve

2Technical Data
6
2.1 Boiler Technical Data
Vortex Pro Combi Vortex Pro Combi Vortex Pro Combi
Model 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 147 188 218
lbs 325 415 481
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)*** 100mm (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 / 240V ~ 50Hz Fused at 5 Amp
Motor power 90 W max.
Starting current Amp 4.2 2.6
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
*** If used as alternative to low level terminal supplied with boiler (see section 9)
Technical Data

2.2 Approximate Air Damper
Setting
Burners are supplied factory set at
the outputs shown.
When commissioning, the air damper
must be adjusted to obtain the
correct CO2level and the Installer
must amend the data label.
2.3 Vortex Pro Combi Oil Boilers
using Class C2 Kerosene
.
Vortex Combi e boilers are only for
use with kerosene.
!NOTE
!NOTE
The data given above is approximate
only and is based on the boiler being
used with a low level discharge flue.
The above settings may have to be
adjusted on site for the correct
operation of the burner.
Gas Oil is not suitable for use with a
Grant Vortex Pro Combi e boiler.
The net flue gas temperatures given
above are ± 10%.
When commissioning the air damper
must be adjusted to obtain the correct
CO2level.
2.4 Flue Gas Analysis
To allow the boiler to be commissioned
and serviced, the boiler is supplied with
a combustion test point on the front
cleaning door. When this test point is
used please note the following:
• The test point is for CO2and smoke
readings only.
• The boiler efficiency and
temperature must be taken from the
flue.
• Final combustion readings must be
taken from the flue terminal (or test
point on flue elbow if Green system
is used) with all panels fitted.
Figure 2-1: Vortex Pro External Combi e dimensions
All dimensions in the diagram above are in millimetres.
2.5 Boiler Dimensions
966
239
Combi 21e, 26e
Combi 36e
Side flue exit
if required
Pre-cut hole 75 x 150mm in
each side of boiler enclosure
2 pre-cut holes in base
of boiler enclosure
115mm dia.
754
836
150
73
7533
945
33
75
150
49
49
150
658
Heat SEDBUK Nozzle Oil Smoke Burner Fuel Flue gas CO2
output SAP 2009 pressure number head flow temp
Model Burner type kW Btu/h % bar kg/h °C %
21e Riello RDB 2.2 21.0 71,650 89.5 0.60/80ºEH 9.0 0-1 T1 1.83 80 (flue) 12
235 (door)
26e Riello RDB 1 26.0 88,700 90.2 0.75/80ºEH 8.0 0-1 T2 2.16 75 - 80 12
36e Riello RDB 2.2 36.0 123,000 91.6 1.00/80ºEH 9.1 0-1 T5 3.01 78 12
Technical Data
7
Plan View

8
Oil Storage &
Supply System
3Oil Storage & Supply System
Single Pipe System
Where the storage tank outlet is above
the burner the single pipe system
should be used. The height of the tank
above the burner limits the length of
pipe run from the tank to the burner.
As supplied the burner is suitable for a
single pipe system.
Head A Max Pipe Run (m)
(m) 10mm 12mm
OD Pipe OD Pipe
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
Head A Max Pipe Run (m)
(m) 10mm 12mm
OD Pipe OD Pipe
0 35 100
0.5 30 100
1.0 25 100
1.5 20 90
2.0 15 70
3.0 8 30
3.5 6 20
Two Pipe System
With the storage tank outlet below the
burner, a two pipe system should be
used. The pipe runs should be as
shown in Figure 3-2. The return pipe
should be at the same level in the tank
as the supply pipe, both being 75 to
100mm above the base of the tank.
The pipe ends should be a sufficient
distance apart so as to prevent any
sediment disturbed by the return
entering the supply pipe.
Avoid the bottom of the tank being
more than 3.5m below the burner.
A non-return valve should be fitted in
the supply pipe together with the filter
and fire valve. A non-return valve should
be fitted in the return pipe if the top of
the tank is above the burner.
The pump vacuum should not exceed
0.4 bar. Beyond this limit gas is released
from the oil.
For guidance on installation of top
outlet fuel tanks and suction oil
supply sizing, see OFTEC technical
book 3.
Available at www.oftec.org.uk
3.1 Fuel Supply
Fuel Storage
The tank should be positioned in
accordance with the recommendations
given in BS 5410:1:1997, which gives
details of filling, maintenance and
protection from fire.
A steel tank may be used and must be
constructed to BS 799:5:1987 and
OFS T200.
A galvanised tank must NOT be
used.
A plastic tank may be used and must
comply with OFS T100.
Plastic tanks should be adequately
and uniformly supported on a
smooth level surface, across their
entire load bearing base area, that is,
the area in contact with the ground.
Fuel Pipes
Fuel supply pipes should be of copper
tubing with an external diameter of at
least 10mm.
Galvanised pipe must not be used.
All pipe connections should preferably
use flared fittings. Soldered connections
must not be used on oil pipes.
Flexible pipes must not be used
outside the boiler case.
A remote sensing fire valve must be
installed in the fuel supply line at least
one metre before it enters the boiler
casing, with the sensing head located
above the burner.
Recommendations are given in
BS 5410:1:1997.
A metal bowl type filter with a
replaceable micronic filter must be fitted
in the fuel supply line adjacent to the
boiler. A shut-off valve should be fitted
before the filter, to allow the filter to be
serviced.
A flexible fuel line, adaptor and 1/4" BSP
isolation valve is supplied loose with the
boiler for the final connection to the
burner. If a two pipe system or Tiger
Loop system is used, an additional
flexible fuel line (900mm) and 3/8" to 1/4"
BSP male adaptor are available from
Grant Engineering (UK) Limited (Part No.
RBS36).
Metal braided flexible hoses should be
replaced annually when the boiler is
serviced. Long life flexible hoses should
be inspected annually and replaced at
least every 60 months.
!NOTE
!CAUTION
!CAUTION
Grant UK recommend that a fire valve
with a temperature rating of 95°C be
installed on any Grant Vortex Pro
Combi.
!NOTE

Oil Storage &
Supply System
9
Figure 3-1: Single pipe system
Figure 3-2: Two pipe system
Fire
valve
1m
1m
A
Fire valve sensor
Vent pipe Fill pipe
Sludge
valve
Shut-off
valve
Shut-off
valve
Level
gauge
Filter
Fuel
storage
tank
Pump (see section 3.2)
Pump (see section 3.2)
Fire
valve
Fire
valve
sensor
Vent
pipe Fill
pipe
Sludge
valve
Non return
valve
Shut-off
valve
Shut-off valve
Level gauge
Non
return
valve
Filter
Fuel
storage
tank
A
Supply
Return

10
Oil Storage &
Supply System
3Oil Storage & Supply System
Tiger Loop System
When The storage tank is below the
burner, an alternative to a two pipe
system can be achieved using a ‘Tiger
Loop’ type oil de-aerator. This effectively
removes the air from the oil supply on a
single pipe lift.
The de-aerator is connected close to
the boiler as a two pipe system (omitting
the non-return valve) as shown in Fig.
3-3. Refer to the manufacturer’s
instructions supplied with the de-
aerator. The de-aerator must be
mounted vertically, as shown in Figures
3-3 and 3-4.
To be used with a Tiger Loop system,
the burner must be fitted with an
additional flexible fuel line (a flexible fuel
line (900mm) and 3/8” to 1/4” BSP male
adaptor are available to purchase from
Grant Engineering (UK) Limited - Part
No. RBS36).
To prevent any possibility of fuel
fumes entering the boiler, the de-
aerator must be fitted outside the
casing.
!WARNING
Figure 3-4: Tiger loop de-aeration device
To burner
From burner
From tank
Figure 3-3: De-aeration device system
Fire valve
Supply
Return
Fire valve sensor
Vent pipe
Fill pipe
Sludge
valve
Tankmaster
Fuel
storage
tank
De-aeration device e.g
Tiger Loop see Figure 3-4
Pump (see section 3.2)