Grant Combi 90 V3 User, Installation & Servicing Instructions Download Page 1

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Part No. IRL 005 Rev: 0 Jan 07

USER, INSTALLATION

and

SERVICING INSTRUCTIONS

Outdoor Combi 90 V3

Combi Max

Outdoor Condensing Combi 26 and 36

For use with Kerosene or Gas Oil (Condensing Combi Kerosene only)

After installing the boiler leave these instructions with the User

This appliance is deemed a controlled service and specific regional statutory

requirements may be applicable

Summary of Contents for Combi 90 V3

Page 1: ...90V3 Combi Max Outdoor Condensing Combi 26 and 36 For use with Kerosene or Gas Oil Condensing Combi Kerosene only After installing the boiler leave these instructions with the User This appliance is deemed a controlled service and specific regional statutory requirements may be applicable ...

Page 2: ... 26 7 Fill and vent the system 35 8 Commissioning 36 9 Boiler Handover 37 10 Boiler servicing 37 11 Boiler components 41 12 Wiring diagrams 43 13 Fault finding 49 14 Burner spares 54 15 Health and safety information 55 16 EC declaration of conformity 57 It is recommended that the boiler should be regularly serviced at least once a year and the details entered in the Boiler Handbook by the Service ...

Page 3: ...tors or the hot water via the hot water heat exchanger The boiler thermostat has an operating range of 75 C to 85 C For optimum hot water operation ensure this is set to maximum If a timer programmer has been fitted it is useful to remember when setting the times for the on periods that it might take up to an hour for the house to become warm especially in colder weather Also the effect of the cen...

Page 4: ...el by turning the handle at the bottom and pull it forward at the bottom 1 On Off switch This switches the boiler on and off Note The boiler will not supply central heating OR domestic hot water if this switch is set to OFF but the built in frost thermostat will still operate provided that the electrical supply to the boiler is still switched on 2 Test switch This is for the Service engineer to us...

Page 5: ...er controls Outdoor Combi 90 V3 and Combi MAX Fig B Boiler controls Outdoor Condensing Combi Outdoor Combi 90 V3 Combi Max and Condensing Combi 5 3 OUTDOOR COMBI 90 V3 COMBI MAX CONDENSING COMBI USER INSTRUCTIONS ...

Page 6: ...nstaller to investigate the cause If the burner still fails to light after carrying out these checks then a fault exists Switch off the electricity supply to the boiler and contact your Service engineer The boiler will supply domestic hot water whenever a hot tap is opened providing the Boiler On Off switch is set to ON and the hot water switch of the programmer if fitted is also set to ON The flo...

Page 7: ...is a burner malfunction a built in safety circuit switches the burner off and the Lock out reset button on the burner see Fig A or B will light Usually such malfunctions are short lived and pressing the reset button will restore normal operation If the burner continually goes to Lock out a fault exists or the fuel supply is low If you have sufficient fuel you will need to call your Service enginee...

Page 8: ... switch off temp 111 C 3 C Maximum heating system pressure cold 1 0 bar Minimum heating system pressure cold 0 5 bar Pressure relief valve 2 5 bar Expansion vessel 12 litres pre charged at 1 0 bar Maximum heating system volume 128 litres Maximum operating pressure 2 5 bar Minimum domestic hot water flow rate 3 0 litres min 0 66 gal min Maximum domestic hot water temperature 65 C factory set Maximu...

Page 9: ...0 mbar 9 5 mbar Boiler thermostat range 65 to 80 C Limit safety thermostat switch off temp 111 C 0 3 C Maximum heating system pressure cold 1 0 bar Minimum heating system pressure cold 0 5 bar Pressure relief valve 2 5 bar Expansion vessel pre charged at 1 bar 12 litres 14 litres Maximum heating system volume 128 litres 148 litres Maximum operating pressure 2 5 bar Minimum domestic hot water flow ...

Page 10: ...t Input Net eff Head Nozzle Oil press Smoke Fuel Flow Net flue gas Flue gas mass CO2 kW Btu h kW Btu h type size bar No rate kg h temp C flow rate kg h 26 4 90 000 28 5 97 402 92 4 LD3 0 60 60 S 12 0 0 1 1 97 200 38 7 12 0 Combi MAX Riello RDB2 2 burner Heat Output Net Heat Input Net eff Head Nozzle Oil press Smoke Fuel Flow Net flue gas Flue gas mass CO2 kW Btu h kW Btu h type size bar No rate kg...

Page 11: ...mbi boiler 4 Net thermal efficiency 5 The net flue gas temperatures given above are 10 6 When commissioning the air damper must be adjusted to obtain the correct CO2 level 7 The combustion door test point may be used for CO2 and smoke readings only Do not use this test point for temperature or efficiency readings Flue gas analysis To allow the boiler to be commissioned and serviced the boiler is s...

Page 12: ...ll activate and an amber neon on the control panel see Fig A or B will light The system must be recharged to between 0 5 and 1 bar If the heating system loses pressure on a regular basis then contact your Installer to investigate the cause 4 7 Boiler dimensions Outdoor Combi 90 V3 and Combi Max Fig 1 Fig 2 4 8 Water schematic of boiler Outdoor Combi 90 V3 and Outdoor Combi Max 12 Outdoor Combi 90 ...

Page 13: ...4 9 Boiler dimension Outdoor Condensing Combi Fig 3 Fig 4 4 10 Water schematic of boiler Outdoor Condensing Combi Outdoor Combi 90 V3 Combi Max and Condensing Combi 13 4 BOILER TECHNICAL INFORMATION ...

Page 14: ...perature of the domestic hot water leaving the boiler is controlled by a thermostatic mixing valve located in the rear compartment of the boiler on the Outdoor Combi 90 V3 and Combi Max and in the front burner compartment on the Outdoor Condensing Combi 26 and 36 boilers Refer to Section 5 13 for boiler operating details To achieve the optimum hot water performance from the Outdoor Combi 90 V3 and...

Page 15: ...ion from fire A galvanised tank must not be used A plastic tank may be used and must comply with OFS T100 Note Plastic tanks should be adequately and uniformly supported on a smooth level surface across their entire base area 5 4 2 Fuel pipes 1 Fuel supply pipes should be of copper tubing of a suitable internal diameter Galvanised pipe must not be used 2 Flexible pipes must not be used outside the...

Page 16: ...n entering the supply pipe 2 Avoid the bottom of the tank being more than 3 m below the burner 3 A non return valve should befitted in the supply pipe 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 5 The pump vacuum should not exceed 0 4 bar Beyond this limit gas is released from the oil A vacuum gauge must ...

Page 17: ...anufacturers instructions supplied with the Tiger Loop The Tiger Loop must be mounted vertically 3 To be used with a Tiger Loop system the burner must be fitted with an additional flexible fuel line a flexible fuel line 600 mm and 3 8 to 1 4 BSP male adaptor are available to purchase from your local stockist See Section 5 3 6 Fig 6 Two pipe system Fig 7 Tiger loop system Head A Maximum pipe run m ...

Page 18: ...e pump and fit the By pass screw using an hexagonal key 5 Connect the return oil flexible fuel line to the pump 6 Connect the 3 8 to 1 4 BSP adaptor to the flexible fuel line 7 Flexible fuel lines and adaptors are available to purchase from your local stockist 8 The burner cover may be left off until the boiler is commissioned Fig 8 Tiger loop Fig 9 RDB pump 1 Oil inlet connection 5 Pressure adjus...

Page 19: ...sion inhibitor used in accordance with the manufacturer s instructions See Fig 17 On underfloor systems it is essential that the return is pre heated by mixing flow water into the return before it enters the boiler To prevent internal corrosion of the boiler water jacket the return water temperature must be maintained above 55 C for the Combi 90 V3 and Combi Max and 40 C for the Condensing Combi F...

Page 20: ...nal Note 75 mm with protection Clearances recommended by Grant Engineering Irl Limited in accordance with relevant Standards and Building Regulations Notes 1 An opening means an openable element such as an openable window or a permanent opening such as a permanently open air vent 2 Notwithstanding the dimen sions given a terminal should be at least 300 mm from combustible material e g a window fra...

Page 21: ...r with a sample of water from the mains cold water supply to the boiler Immerse the test strip in the water for approximately one second ensuring that all the test zones on the strip are fully wetted Shake off the surplus water and wait for one minute Assess the hardness of the water by the colouration of the test zones on the strip using the following chart Note 1 mg l 1 ppm part per million Shou...

Page 22: ... Sections 4 1 or 4 2 for maximum heating system volume and BS 7074 for further guidance If the system volume exceeds the maximum value given for the boiler an additional vessel will be required This should be connected to the system on the return Refer to Fig 12 Refer to Section 6 5 for further details of the expansion vessel 4 The system design pressure cold should be between 0 5 and 1 0 bar This...

Page 23: ...ondensing Combi boilers are supplied with a factory fitted condensate trap to provide the required 75 mm water seal in the condensate discharge pipe from the boiler This trap incorporates a float which will create a seal when the trap is empty and an overflow warning outlet fitted with a rubber bung See Fig 13 A short length of flexible pipe is supplied connected to the outlet of the trap The end ...

Page 24: ...he system for as long as both the timer programmer and room thermostat if fitted are calling for heat As the heating system water cools the temperature drop is detected by the boiler thermostat and the burner is automatically restarted for the cycle to continue until either the timer or room thermostat stops calling for heat The burner and pump are then turned off Domestic Hot Water Mode Combi 90 ...

Page 25: ...er This superheated steam contains sensible heat available heat and latent heat heat locked up in the flue gas Aconventional boiler cannot recover any of the latent heat and this energy is lost to the atmosphere through the flue The Condensing Combi condensing boilers contain an extra heat exchanger which is designed to recover the latent heat normally lost by conventional boilers This is done by ...

Page 26: ...seal in the casing The terminal has been factory lubricated Take care not to dislodge or damage the red seals 7 Carefully insert the terminal into the flue elbow until the bend of the terminal contacts the outer casing then pull the terminal forward approximately 25 mm and rotate the bend so that the outlet is horizontal 8 Tighten the wing nuts holding the flue elbow and fit the stainless steel fl...

Page 27: ...l or vertically as required See Fig 16 1 The flue must terminate in a down draught free area i e at least 600 mm above the point of exit through the roof or preferably above the ridge level 2 The flue terminal must be at least 600 mm from any opening into the building and 600 mm above any vertical structure or wall less than a horizontal distance of 750 mm from the terminal 3 Condensing Combi only...

Page 28: ...Fig 16 Outdoor high level flue Green system 28 Outdoor Combi 90 V3 Combi Max and Condensing Combi 6 BOILER INSTALLATION ...

Page 29: ...r connection of the heating flow and return pipes allowing either left or right hand pipe entry as required 3 Hot water connections Both models are supplied with compression elbows for the connection of the cold water mains inlet and domestic hot water pipes allowing either left or right hand pipe entry as required 4 Safety valve A 15 mm discharge pipe is factory fitted to the safety valve outlet ...

Page 30: ...ovided at the bottom on the front of the boiler A second drain tap is fitted on the primary store of the Condensing Combi boilers 2 Carefully manoeuvre the boiler into position Complete the water connections 3 If the boiler is installed against a wall fit the wall flashing strip Position the strip with the bottom edge of the wider flange 30 mm above the enclosure top panel with the narrow flange w...

Page 31: ...witch thermostat or programmer Terminal 2 Hot water on from programmer Terminal Earth Terminal N Neutral Terminal 3 Mains live including permanent live for frost thermostat 6 BOILER INSTALLATION 31 Outdoor Combi 90 V3 Combi Max and Condensing Combi 6 6 Connect the power supply 6 5 Expansion vessel pressure To avoid the danger of dirt and foreign matter entering the boiler the complete heating syst...

Page 32: ...boiler and set to 25 C For Outdoor Combi 90V3 and Max boilers Remove link from terminals P1 and P2 on the boiler terminal block Connect the pipe thermostat via common and on connections between these terminals For Outdoor Condensing Combi 26 and 36 boilers Remove link from terminals 4 and 5 on the boiler terminal block Connect the pipe thermostat via common and on connections between these fixing ...

Page 33: ...et grille in its place 1 Pump 2 Control box 3 Reset button with lock out lamp 4 Flange with gasket do not remove from boiler 5 Air damper adjustment screw 6 Air supply tube connection balanced flue 7 Pump pressure adjustment screw 8 Pressure gauge connection Fig 20 RDB burner components Outdoor Combi 90 V3 Combi Max and Condensing Combi 33 6 BOILER INSTALLATION ...

Page 34: ...maged Outdoor Combi 90 V3 and Combi Max Remove the rear casing panel to access the single circulating pump Outdoor Condensing Combi boilers Remove the front casing panel for access to the Hot Water pump and the top casing panel for access to the Heating pump Unscrew and remove the plug from the centre of the pump Using a suitable screwdriver rotate the exposed spindle about one turn When water sta...

Page 35: ...ove the plastic burner cover two screws if it was not previously removed Note Check that the baffles are in position and that the cleaning cover is correctly fitted and a good seal made Check that the Condensing Combi turbulators are in position and that the ends are vertical see Fig 28 Fig 22 Boiler controls Outdoor Condensing Combi Fig 21 Boiler controls Outdoor Combi 90 V3 and Combi MAX Outdoor...

Page 36: ...nected to the burner 12 After allowing the burner to run for 20 minutes Check the smoke number if satisfactory check the CO2 level Set the CO2 to the value given in Section 4 3 4 4 or 4 6 for the boiler and fuel used Adjust the burner air regulator see Fig 24 turning the screw anti clockwise closes the damper and increases CO2 level turning the screw clockwise opens the damper and reduces CO2 leve...

Page 37: ...of parts must only be carried out by a suitably qualified engineer 1 Check the flue terminal and ensure it is not blocked or damaged 2 Run the boiler and check the operation of its controls 3 Ensure that all water fuel system connections and fittings are sound Remake any joints and check the tightness of any fittings that may be leaking Check the expansion vessel air charge See Section 6 5 Check t...

Page 38: ... the boiler internal surfaces using a stiff brush and scraper if necessary 4 Check the condition of the flue clean as necessary 5 Check the condition of the front cleaning door seal Replace if necessary 6 Replace the baffles ensuring they are correctly fitted See Fig 24 25 26 or 27 10 2 Dismantling prior to servicing Note The top panel has been designed to provide a slight fall away from the side ...

Page 39: ...nuts and washers previously removed 9 Condensing Combi Remove the condensate trap and check that it is not blocked and is operating correctly i e the float is free to move Clean the trap and float as required Check that the boiler condensate outlet is unobstructed Clean if necessary IMPORTANT The condensate trap and condensate outlet must be checked on every service and cleaned as necessary Fig 24...

Page 40: ... check the electrode settings after replacing the nozzle see Fig 29 4 Photocell The photocell is a push fit in the burner body Carefully pull out the photocell to clean 5 Fan With the plastic air intake grille removed remove the screws securing the fan housing cover R H side of burner and remove the cover Inspect the fan and housing and clean as necessary Replace the cover and re fit the plastic g...

Page 41: ...Flow restrictor Q Heating flow isolating valve R Heating return isolating valve S Pressure switch Connections 1 Diverter valve cold water inlet 2 Diverter valve primary inlet 3 Diverter valve primary outlet 4 Plate heat exchanger hot water outlet 5 Cold water inlet isolating valve outlet 6 Plate heat exchanger primary outlet 7 Plate heat exchanger cold water inlet 8 Plate heat exchanger primary in...

Page 42: ...elbow C Cold water inlet push fit elbow D Hot water outlet push fit elbow E Pump isolating valves heating pump F Pump isolating valves hot water store pump G Primary inlet to store H Primary outlet from store I Primary inlet to condensing heat exchanger J Primary outlet from condensing heat exchanger K Primary return to main heat exchanger L Primary flow manifold M Primary return manifold N Primar...

Page 43: ...diagram Outdoor Combi 90 V3 and Combi Max Note If a single channel timer is used a link must be fitted between terminals 2 and 3 If a room thermostat is fitted it must be wired in series with the time control and the boiler terminal S L 1 Colour code Br Brown R Red Bl Blue Y Yellow G Y Green Yellow Blk Black Or Orange ...

Page 44: ...l connection of external timer Outdoor Combi 90 V3 and Combi Max only Functional flow wiring diagram Outdoor Combi 90 V3 and Combi Max 12 2 44 Outdoor Combi 90 V3 Combi Max and Condensing Combi 12 WIRING DIAGRAMS ...

Page 45: ... Yellow G Y Green Yellow Blk Black Or Orange 12 4 Control panel wiring diagram Outdoor Condensing Combi 12 5 Functional flow wiring diagram Outdoor Condensing Combi Outdoor Combi 90 V3 Combi Max and Condensing Combi 45 12 WIRING DIAGRAMS ...

Page 46: ...AGRAMS Outdoor Combi 90 V3 Combi Max and Condensing Combi 46 12 6 Typical connections of external timer Outdoor Condensing Combi only 12 7 Connection of typical two channel programmer Outdoor Condensing Combi only ...

Page 47: ...burner Contaminated combustion air balanced flue Insufficient oil flow to burner due to restriction in supply line Excessive combustion air ACTION Refill system to 0 5 1 0 bar Check for 230 V at boiler terminal block Check boiler On Off switch is set to ON Set boiler thermostat to maximum Check and reset thermostat as necessary Check for 230 V output from BURNER LIVE terminal of PCB Check continui...

Page 48: ... and type and replace if necessary Fuel pressure too low Check fuel pressure and adjust as necessary Oil smells Oil leak in supply line or burner Check all joints and flexible hose for leaks and rectify as necessary Combustion fume smells Leak around boiler cleaning door Check gasket re tighten nuts or replace gasket as necessary Burner not correctly fitted on mounting flange Remove and re fit bur...

Page 49: ...CTION Check and rectify as necessary Open all valves in pipework to and from boiler Open valve situated above pump in front of boiler Check and rectify as necessary Check and rectify as necessary Check flow is at least 3 litres min rectify as necessary Check and rectify as necessary Check hot and cold inlets are connected correctly Check operation of diverter valve Check pump is free to rotate and...

Page 50: ...iler is underfired Combustion setting of burner incorrect Boiler heat exchanger is sooted up ACTION Check setting and set to Constant to test Check power supply to timeswitch Check and replace if necessary Check continuity of switch replace if necessary Check continuity of wiring to timeswitch Check and set switch to ON to test Set thermostat to call and check boiler operates Check continuity of t...

Page 51: ...er pump should start Primary store hot water pump is not operating Check for 230 V supply to pump with water on Faulty Hot Water PCB sensor Replace sensor and check operation Faulty Hot Water PCB Check for 230 V output from B Burner terminal on PCB If no output replace Hot Water PCB and check operation Relay No 1 faulty not switching Check for 230 V to Flow switch terminal of Heating PCB Low water...

Page 52: ...inal If no 230 V output replace PCB Faulty relay No 2 Check for 230 V supply to burner between terminals 6 10 Check for 230 V supply to heating pump between terminals 5 9 Flow temperature low Boiler temperature control set too low Check and set as necessary Little or no heating flow Heating pump speed too low Check pump speed and set as required Heating pump not operating Check for 230 V supply to...

Page 53: ...13 FAULT FINDING 13 7 Riello RDB burner fault finding Outdoor Combi 90 V3 Combi Max and Condensing Combi 53 13 FAULT FINDING ...

Page 54: ...lexible pipe 3007672 6 Nozzle holder 3008642 22 Tube 3008644 7 Collar 3008643 23 Pressure gauge connector 3008876 8 High voltage lead 3008794 24 Drive coupling 3000443 9 Air damper assembly 3008647 25 Solenoid 3008648 10 Fan 90V3 Condensing 26 3005708 26 Motor 3002836 10 Fan Max Condensing 36 3005788 27 Cover 3008649 11 Photocell 3008646 28 Control box assembly 3008652 12 Capacitor 4 5 gF 3002837 ...

Page 55: ...14 BURNER SPARE PARTS Burner Heads Outdoor Combi 90 V3 Combi Max and Condensing Combi 55 14 BURNER SPARE PARTS ...

Page 56: ...d contact with skin After handling always follow normal good hygiene practices Protection Use eye protection Rubber or plastic gloves should be worn where repeated contact occurs and a face mask worn when working in confined spaces First Aid Eyes Flush eyes with water for 15 minutes Seek immediate medical attention Skin Wipe off and wash with soap and water Inhalation Remove to fresh air Kerosene ...

Page 57: ...Safety Regulations Directive Referred to the generic standard NO 3260 The Electrical Equipment Safety Regulations 1994 3 92 42 EEC Hot Water Boiler Efficiency Directive Referred to the generic standard The Boiler Efficiency Amendment Regulations 1994 SI 1994 3083 Signed ________________________________________________ Managing Director Grant Engineering Ireland Ltd Crinkle Birr Co Offaly Ireland 1...

Page 58: ...58 Outdoor Combi 90 V3 Combi Max and Condensing Combi ...

Page 59: ...Outdoor Combi 90 V3 Combi Max and Condensing Combi 59 ...

Page 60: ...s sanctioned by the Company 6 The Company will endeavour to provide prompt service in the unlikely event of a problem occurring but cannot be held responsible for any consequence of delay however caused 7 This guarantee does not cover labour handling or shipping 8 This guarantee applies to boilers installed on the island of Ireland both North and South Provision for warranty cover elsewhere is sub...

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