Grant 50/70, 200/240, 50/90, 90/120, 120/155 User, Installation And Servicing Instructions

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Page 1

USER, INSTALLATION

and

SERVICING INSTRUCTIONS

Vortex Condensing Oil Boilers

For use with Kerosene only

Part No. IRL 003 Rev. 02 May 2010

Indoor/Utility, System and Boiler House Models

with outputs up to 240,000 Btu/h

This appliance is deemed a controlled service and specific regional statutory

requirements may be applicable.

After installing the boiler leave these instructions with the User

IMPORTANT NOTICE

This appliance must be commissioned upon installation, the information recorded and returned to

Grant Engineering (Ireland) Ltd., using the form contained within the boiler passport provided.

Failure to do so may invalidate the warranty.

EFFIC IENT HEATIN G SO LUTION S

GRANT

Page 2

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Subject PageSection

1 Introduction .............................................. 3

2 User instructions ...................................... 4

3 Boiler technical information .................... 7

4 General boiler information....................... 11

5 Condensate disposa; ................................. 27

6 Boiler installation ..................................... 30

7 Commissioning and Boiler passport ........ 35

8 Information for the user ........................... 38

9 Boiler servicing ........................................ 38

10 Wiring diagrams ....................................... 42

11 Fault finding ............................................. 46

12 Boiler spares ............................................ 48

13 Burner spares ........................................... 49

14 Health and safety information .................. 51

15 EC declaration of conformity .................. 52

LIST OF CONTENTS

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

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.

The Grant Vortex condensing boiler contains 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 nett thermal efficiencies of 100%.

To achieve maximum performance from the Grant Vortex boiler, it is recommended that the heating system is designed so that a temperature differential of 20° C between the flow and return is maintained. The use of modulating circulating pumps (now widely available) and effective control systems should be considered.

The Grant Vortex boiler will however still operate at extremely high efficiencies even when it is not in condensing mode and therefore is suitable for fitting to an existing heating system without alteration to the radiator sizes. The boiler is capable of a maximum flow temperature of 75° C.

How a condensing boiler works

1.1

Heating system design considerations

1.2

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

Radiators:-

Flow temperature 70° C

Return temperature 50° C

Differential 20° C

Underfloor:-

Flow temperature 50° C

Return temperature 40° C

Differential 10° C

1 Size radiators with a mean water temperature of

60° C.

2 Design system controls with programmable room

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

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

3 The use of a pipe stat is recommended to control

the return temperature when using weather compensating controls.

1 - INTRODUCTION

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

2 - USER INSTRUCTIONS

The boiler is fully automatic once switched on, providing central heating (and also heating your domestic hot water if you have a hot water cylinder fitted).

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

To gain acces to the controls, pull the front panel forward at the top to disengage the fixing clips then lift it up and off the boiler. To replace locate the bottom of the panel over the fixing tags then push it towards the boiler to engage the fixing clips.

Fig. A Boiler controls (Indoor/Utility model shown)

About your boiler

2.1

Boiler controls (see Fig. A)

2.2

1 Ensure that - There is sufficient fuel, of the correct

type, in the supply tank and all fuel supply valves are open. The water supply is on. The electricity supply to the boiler is off. The boiler On/Off switch is set to OFF. The room thermostat (if fitted) is at the desired setting. The boiler thermostat is set to the required setting (see Section 2.7).

2 Switch on the electricity supply to the boiler.

3 Set the On/Off switch to ON and, if fitted, the

programmer (CH or HW) to ON.

The boiler will now light automatically.

4 If you have a programmer fitted, refer to the

instructions supplied with the programmer and set the programmer. Set the HW and CH functions to TIMED. The boiler will now operate during the 'on' periods set on the programmer.

Lighting your boiler (see Fig. A)

2.3

Pressure gauge

(System models only)

Boiler

thermostat

Overheat

thermostat

reset button

(under cover)

On/Off switch

OVERHEAT

RESET

SYSTEM PRESSURE

HEATING

TEMPERATURE

OVERHEAT

RESET

BOILER

OFF

HEATING

TEMPERATURE

BOILER

OFF

Lock-out

button

Front panel removed

(pull forward at top, then lift off)

Front panel

fixing clips

Front panel bottom locating tags

Mains On

neon

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

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

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

To restart, refer to the full lighting instructions given in Section 2.3.

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

2 Check that the programmer (if fitted) is working

and is in an 'on' period.

3 Check that all thermostats are set to the desired

setting and are calling for heat.

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

burner) is lit. If it is, press it to start the burner. If the burner fails to light and goes to 'Lock-out' again, check that you have sufficient fuel in the storage tank and that the fuel supply valve is open. Check that the fire valve in the oil supply line has not tripped

5 Ensure that a fuse has not blown or that the

electricity supply has not failed.

6 Check to see if the safety thermostat has operated

(see Section 2.7).

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.

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

You should always quote this type of fuel when ordering from your supplier.

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

2 - USER INSTRUCTIONS

1 Boiler thermostat - This control allows the

temperature of the water leaving the boiler to heat the radiators and domestic hot water to be adjusted.

Note: If you have a cylinder thermostat on your hot water cylinder, this will control the temperature of your domestic hot water. The boiler thermostat setting must be equal to or above the cylinder thermostat setting to enable the cylinder thermostat to control the domestic hot water system.

2 Burner Lock-out reset button - If there is a

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

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

3 Safety thermostat - Your boiler is fitted with a safety

overheat thermostat which will automatically switch off the boiler in the case of a control malfunction causing overheating.

If your boiler goes off and you try to light it but nothing happens and the 'Lock-out' reset button on the burner is not lit, the overheat thermostat has probably operated. The boiler will not light until the thermostat is reset. To reset, unscrew the small plastic cap (see Fig. A), press the button then replace the cap.

If this condition continually repeats, contact your Service engineer.

4 Programmer (if fitted) - Refer to the instructions

supplied with the Programmer.

5 Ventilation - Always ensure that the boiler has

adequate ventilation. Any ventilation openings provided by the Installer must not be obstructed. Periodically check that they are clear.

Do not attempt to 'box in' the boiler or build a compartment around it before consulting your Installer.

Do not place any combustible material around or on the boiler or flue pipe.

6 Flue terminal - The flue terminal on the outside

wall must not be obstructed or damaged.

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

Turning off your boiler (see Fig. A)

2.4

Points to check if burner fails to light

2.5

About your fuel

2.6

General notes and care of your system

2.7

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

7 Frost protection - Your Installer may have fitted a

frost thermostat. If not, and you are likely to be away for a short time, leave the boiler on with the boiler thermostat set at a low setting. For longer periods the boiler and system should be drained. Contact your Service engineer for draining and filling the system.

8 Cleaning and servicing - Lightly wipe over the

case with a damp cloth and a little detergent. Do not use abrasive pads or cleaners.

You must have your boiler serviced at least once a year to ensure safe and efficient operation. Contact your Service engineer for further details.

9 Failure of electricity supply - If the electricity

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

If a programmer is fitted it will retain the time settings for up to 24 hours and will not have to be reset to the correct time of day when the supply is restored (the display remains for up to 1 hour, but will re-appear when the supply is restored).

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

Warning: This appliance must be earthed.

If your boiler is operating on a sealed heating system, the installer will have pressurised the system and should have told you (or set it on the pressure gauge) the system pressure when cold (this is normally between 0.5 and 1.0 bar, which will increase slightly when hot). If the pressure (when cold) is below the set pressure mentioned above, you can re-pressurise the system. If the system requires frequent re-pressurising, ask your Installer or Service engineer to check the heating system for leaks and to check the expansion vessel air charge.

The boiler or system will be fitted with an automatic air vent to remove air from the system. Any air trapped in the radiators should be removed by venting the radiators using the vent screw at the top of each radiator. Only vent a radiator if the top is cool and the bottom is hot. Excessive venting will reduce the system pressure, so only vent when necessary and check the system pressure as mentioned above. Re-pressurise the system if necessary.

2 - USER INSTRUCTIONS

The boiler or system may be fitted with a safety valve to release excess pressure from the system. If water or steam is emitted from the end of the safety valve discharge pipe, switch off the boiler and contact your Installer or Service engineer.

The expansion vessel air charge must be checked annually. Failure to maintain an adequate air charge in the vessel may invalidate the warranty.

To re-pressurise the system by adding water:

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

the boiler is off. Do not overfill.

2 Ensure the flexible filling loop (see Fig. B) is

connected and that the shut off valve connecting it to the boiler is open and the double check valve at the front is closed. A valve is open when the operating lever is in line with the valve, and closed when it is at right angles to it.

3 Gradually open the double check valve on the front

of the filling loop until water is heard to flow. When the black needle of the pressure gauge is between 0.5 and 1 bar, close the valve.

4 Vent each radiator in turn, starting with the lowest

one in the system, to remove air.

5 Continue to fill the system until the pressure gauge

indicates between 0.5 and 1.0 bar. Close the fill point valve.

6 Repeat steps 4 and 5 as required.

7 Close the valves either side of the filling loop and

disconnect the loop.

Electricity supply

2.8

Sealed central heating system

2.9

Sealed system filling loop arrangement - Fig. B

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

125 mm (5 in)**

150

6.4

1.2

22 mm (only connect plastic pipe)

26.0 mbar

9.5 mbar

28 m

65 to 75° C

111° C ± 3° C

Less than 50° C

230/240 V ~ 50 Hz Fused at 5 Amp

¼" BSP Male (on end of flexible fuel hose)

Minimum flue draught - 8.7 N/m² (0.035 in wg)

Maximum flue draught - 37 N/m² (0.15 in wg)

2.5 bar

2.6

0.85

125 mm (5 in)**100 mm (4 in) 100 mm (4 in)

Boiler technical data

3.1

3- BOILER TECHNICAL INFORMATION

Model

Water content litre

gal

* Weight (dry) kg

Max. heat output kW

(kerosene) Btu/h

Flow connection

Return connection

Min. flow rate (∆T=10°C) l/h

Min. flow rate (∆T=20°C) l/h

Condensate connection

Flue diameter (conventional)

Waterside resistance

Flow/Return temp. diff. of 10°C

Flow/Return temp. diff. of 20°C

Maximum static head

Minimum circulating head

Boiler thermostat range

Limit (safety) stat shut off temp

Max. hearth temperature

Electricity supply

Motor power Watts

Starting current Amps

Running current Amps

Oil connection

Conventional flue

Max operating press - sealed sys

Max operating press - open sys

* Weight includes burner but excludes flue. ** 125 mm diameter flue required for flexible flue liner (Orange system). Refer to Sections 4.1 and 4.7 for further details.

Indoor/Utility

System

2.6

0.85

2.6

0.85

150

6.4

1.2

4.2

0.85

50/90

4.2

126.5

88,700

22 mm

2,200

1,100

90/120

4.7

142

122,840

28 mm

3,000

1,500

120/155

4.7

142

157,000

28 mm

4,000

2,000

50/70

16.5

3.6

71,650

22 mm

4.2

0.85

200/240

299

238,840

1¼"BSP

6,000

3,000

155/200

295

197,896

1¼"BSP

5,200

2,600

120/155

4.7

134

157,000

28 mm

4,000

2,000

4.2

0.85

90/120

4.7

134

122,840

28 mm

3,000

1,500

50/90

4.2

112

88,700

22 mm

2,200

1,100

50/90

4.2

116

88,710

1"BSP

2,200

1,100

90/120

4.7

133

122,840

1"BSP

3,000

1,500

120/155

4.7

157,000

1"BSP

4,000

2,000

155/200

249

197,896

1¼"BSP

5,200

2,600

200/240

253

238,840

1¼"BSP

6,000

3,000

Boiler House

133

4.2

0.85

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

3 - BOILER TECHNICAL INFORMATION

Note: Grant Vortex boilers are only for use with kerosene.

Grant Vortex oil boilers using Class C2 kerosene

3.3

(kW)

15.0

18.3

21.0

15.0

20.0

23.0

26.0

31.5

36.0

41.5

46.0

52.0

58.0

64.0

70.0

(Btu/h)

51 200

62 400

71 650

51 180

68 240

78 475

88 700

107 500

123 000

142 000

157 000

156 952

177 424

197 896

218 368

238 840

Nozzle

0.50/80°EH

0.55/80°EH

0.60/80°EH

0.50/80°EH

0.60/80°EH

0.65/80°EH

0.75/80°EH

0.85/80°EH

1.00/80°EH

1.20/80°S

1.25/80°S

1.35/80°S

1.65/80°S

1.75/80°S

Oil

press.

(bar)

7.0

7.5

9.0

7.0

8.0

8.5

8.0

9.0

9.1

9.0

8.0

9.5

8.0

9.5

Smoke

No.

0 - 1

Fuel flow

rate

(kg/h)

1.29

1.56

1.83

1.25

1.67

1.94

2.16

2.18

2.57

3.01

3.56

3.90

4.01

4.47

5.05

5.58

6.01

Flue gas

temp.

(° C)

60 - 65

65 - 70

70 - 75

75 - 80

65 - 70

70 - 75

75 - 80

80 - 85

85 - 90

75 - 80

(%)

12.0

Burner

head type

GIB

Heat Output

50/70

Riello RDB2.2

50/90

Riello RDB1

90/120

Riello RDB2

120/155

Riello RDB2.2

155/200

Riello RDB3.2

200/240

Riello RDB3.2

Model and

burner type

Sealed system data - System models (not 50/70, 155/200 and 200/240)

3.2

Heating system pressure (cold)

Operating pressure of pressure relief valve

Expansion vessel size (50/90)

Expansion vessel size (90/120)

Expansion vessel size (120/155)

Max heating system volume (including boiler) (50/90)*

Max heating system volume (including boiler) (90/120)*

Max heating system volume (including boiler) (120/155)*

Cold water mains connection

Pressure relief valve discharge connection

Maximum 1.0 bar, Minimum 0.5 bar

2.5 bar

10 litres (pre-charged at 1 bar)

12 litres (pre-charged at 1 bar)

16 litres (pre-charged at 1 bar)

106 litres (approximately)

128 litres (approximately)

170 litres (approximately)

15 mm copper pipe

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

SEDBUK efficiency

(%)

95.0

97.0

92.6

94.1

93.6

Disc setting B

Disc setting C

Fixed

Head setting 0

Head setting 4

Burner

head/disc

setting

Notes:

1 The data given above is approximate only. 2 The above settings may have to be adjusted on site for the correct operation of the burner. 3 Gas Oil is not suitable for use with the Grant Vortex boiler range. 4 The net flue gas temperatures given above are ± 10%. 5 When commissioning the air damper must be adjusted to obtain the correct CO2 level. 6 * = Factory settings 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. 8 When setting the 50/70 to 15 kW output the burner air adjuster disc requires repositioning. Refer to Section 7 Commissioning.

When setting the 50/90 to 15 or 20 kW output the combustion head must be changed. Refer to Section 9.4 Cleaning the burner. When setting the 200/240 to 70 kW output the combustion head setting must be changed. Refer to Section 9.4 Cleaning the burner.

9 The installer must amend the boiler data label if the output is changed.

Flue gas analysis

To allow the boiler to be commissioned and serviced, the boiler is supplied with a combustion test point on the front cleaning door. When this test point is used please note the following:

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

2. The boiler efficiency and temperature must be taken from the flue test point on high level and vertical flue adaptors.

3. Low level flues do not contain a test point. The temperature and efficiency readings must be taken from the flue terminal.

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

REAR

VIEW

348

21070

140

855

688

760

RIGHT SIDE

VIEW

200

47 25

125

594

766

805

704

R/H flow

R/H return

L/H flow L/H return

LEFT SIDE

VIEW

111

566

Flue centre line

Alternative condensate drain outlets

3 - BOILER TECHNICAL INFORMATION

Fig. 1b - 50/90 Indoor/Utility and System dimensions

Fig. 1a - 50/70 Indoor/Utility dimensions

Boiler dimensions

3.4

Fig. 1c - 50/90 Boiler House dimensions

Alternative condensate drain outlets

FRONT VIEW

470

860

LEFT SIDE

VIEW

814

760

710

587

352

115

Flue centre line

RIGHT SIDE

VIEW

PLAN VIEW

603

110

Safety valve (System) Cold fill (System) Flow

170

Flue spigot

Condensate drain outlet

FRONT VIEW

PLAN VIEW

Return

RIGHT SIDE

VIEW

431

600

632

690

714

327

195

LEFT SIDE

VIEW

Condensate drain

Flow

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

3 - BOILER TECHNICAL INFORMATION

FRONT VIEW

PLAN VIEW

Return

LEFT SIDE

VIEW

Flow

RIGHT SIDE

VIEW

Condensate drain

Dimension

A B C D E F

H J

90/120, 120/155

705 460 600 560 605 191

330

155/200, 200/240

1022

540 868 835 938 285

30 415 115

Boiler House model

Fig. 1d - 90/120, 120/155, 155/200, 200/240 Boiler House dimensions

Fig. 1e - 90/120, 120/155 Indoor/Utility and System dimensions

Fig. 1f - 155/200, 200/240 Indoor/Utility dimensions

Safety valve (System) Flow (System) Cold fill

170

LEFT SIDE

VIEW

455

555

455

115

Flue centre line

RIGHT SIDE

VIEW

PLAN VIEW

603

150

FRONT VIEW

470

900

205 Flue spigot

Alternative condensate drain outlets

Condensate drain outlet

170

LEFT SIDE

VIEW

731

831

1024

109

250

Flue centre line

RIGHT SIDE

VIEW

PLAN VIEW

786

109

FRONT VIEW

563

1234

225 Flue spigot

Alternative condensate drain outlets

Condensate drain outlet

Page 11

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

Boiler description

4.1

White system ...... High level and vertical concentric

balanced flue kit - components available:

Extensions 225 mm, 450 mm, 950 mm, adjustable 275 to 450 mm and 45° elbow Vertical concentric balanced flue kit Extensions 225 mm, 450 mm, 950 mm, adjustable 275 to 450 mm and 45° elbow

All burners are pre-set for use with kerosene and are supplied ready to connect to a single pipe fuel supply system with a loose flexible fuel line and 3/8" to 1/4" BSP male adaptor supplied with the boiler.

If required, an additional flexible fuel line (600 mm) and

/8" to 1/4" BSP male adaptor are available to purchase

from your local stockist, for two-pipe oil supply systems.

The temperature of the water leaving the boiler to heat the radiators and hot water cylinder is User adjustable.

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

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

Boiler components

4.2

The Grant Vortex range of automatic pressure jet oil boilers have been designed for use with a fully pumped central heating system with indirect domestic hot water cylinder. They are not suitable for use with either a direct cylinder or a 'primatic' cylinder or gravity hot water..

The boilers are suitable for use on open vented or sealed central heating systems. System models are supplied with the necessary components factory fitted. See Section 4.13.

All models are supplied with the control panel and burner factory fitted.

The boilers can be connected to either a conventional flue system or a balanced flue system, as required.

For Conventional flue applications where a chimney is to be lined - Grant recommends the use of the Grant ‘Orange’ flue system, specifically designed for the Vortex range of condensing boilers. Refer to Section

4.7 for further details.

Important: The flue system materials and construction MUST be suitable for use with oil-fired condensing

boilers. Failure to fit a suitable conventional flue may invalidate the warranty on the boiler.

Fitting instructions for the Low level concentric, High level and Vertical balanced flue kits are supplied with the kits. Where a balanced flue system is required, the following flue kits are available from your local stockist. Refer to Section 4.8 for further details.

Yellow system..... Standard low level concentric

balanced flue - components available:

Low level concentric balanced flue short Extensions 225 mm, 450 mm and 675 mm 90° extension elbow 45° extension elbow 45° elbow

Where it is not possible to terminate the low level flue at low level, a plume diverter kit is available for fitting to the low level flue. The plume diverter kit diverts the flue gases up and terminates at a higher level. When fitting the plume diverter kit, follow the instructions supplied with the kit. See Fig. 10b.

Page 12

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

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

BS 715 Metal flue pipes, fittings, terminals

and accessories. BS 799:5 Oil storage tanks. BS 1181 Clay flue linings and flue terminals. BS 4543:3 Factory made insulated chimneys for

oil fired appliances. BS 4876 Performance requirements for oil

burning appliances. BS 5410:1 Code of Practice for oil firing appliances. BS 5449 Forced circulation hot water systems. BS 7593 Code of Practice for treatment of

water in heating systems. BS 7671 Requirements for electrical

installations, IEE Wiring Regulations.

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

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 14 on page 51.

4.4.1 Fuel storage

The tank should be positioned in accordance with the recommendations given in BS 5410:1:1997, which gives details of filling, maintenance and protection from fire.

A 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.

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

Fuel supply

4.4

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

a Local Building Regulations and the Building

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

b Model and local Water Undertaking Byelaws.

c Applicable Control of Pollution Regulations.

d The following OFTEC requirements:-

OFST 100 Polythene oil storage tanks for

distillate fuels.

OFST 200 Fuel oil storage tanks and tank

bunds for use with distillate fuels, lubrication oils and waste oils.

Further information may be obtained from the OFTEC Technical Information Book 3 (Installation requirements for oil fired boilers and oil storage tanks).

4 - GENERAL BOILER INFORMATION

Regulations to comply with

4.3

Regional statutory requirements may deem this appliance to be a 'controlled service'.

Where this is the case, it is a legal requirement that the appliance is installed and

commissioned either under the remit of building control or by a 'Competent person' such

as a suitably qualified Oftec registered technician.

Fig. 2 - System model (Also refer to Fig. 15)

SYSTEM PRESSURE

10508

HEATING

TEMPERATURE

OVERHEAT

RESET

BOILER

OFF

Expansion vessel

Air supply tube

Lock-out button

Burner

Pump

Pump isolating valves

Condensate trap

Drain tap

Page 13

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

4.4.2 Fuel pipes

1 Fuel supply pipes should be of copper tubing with

an external diameter of at least 10 mm. Galvanised pipe must not be used. All pipe connections should preferably use flared fittings. Soldered connections must not be used on oil pipes.

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

3 A remote sensing fire valve must be installed in the

fuel supply line (outside) where it enters the building, with the sensing head located above the burner. Recommendations are given in BS 5410:1:1997.

4 A metal bowl type filter with a replaceable micronic

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

5 A flexible fuel hose, adaptor and 1/4" BSP isolation

valve are supplied loose with the boiler for the final connection to the burner. If a two pipe system or 'Tiger Loop' type de-aerator is used, an additional flexible fuel hose (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from your local stockist.

6 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.

4.4.3 Single pipe system - (See Fig. 3)

1 Where the storage tank outlet is above the burner

the single pipe system should be used. The height of the tank above the burner limits the length of pipe run from the tank to the burner.

2 As supplied the burner is suitable for a single pipe

system.

4.4.4 Two pipe system - (See Fig. 4)

1 When the storage tank outlet is below the burner,

the two pipe system should be used. The pipe runs should be as shown in Fig. 4. The return pipe should be at the same level in the tank as the supply pipe, both being 75 to 100 mm above the base of the tank. The pipe ends should be a sufficient distance apart so as to prevent any sediment disturbed by the return entering the supply pipe.

2 Avoid the bottom of the tank being more than 3 m

below the burner.

3 A non-return valve should be fitted in the supply

pipe together with the filter and fire valve. A nonreturn valve should be fitted in the return pipe if the top of the tank is above the burner.

4 To be used with a two-pipe system, the burner

must be fitted with an additional flexible fuel hose (a flexible fuel hose (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from your local stockist. See Section 4.4.6.

5 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 booklet T1/139. Available at www.oftec.org.uk.

Fig. 3 - Single pipe system

Filter

Fire valve

Shut-off valve

Sludge valve

Fill pipe

Vent pipe

Level gauge

Fuel storage tank

Fire valve sensor

Pump

Head A

(m)

Maximum pipe run (m)

0.5

1.0

1.5

2.0

10mm OD pipe

10 20 40 60

12mm OD pipe

20 40 80

100

Page 14

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Fig. 5 - De-aeration device system

4.4.5 Tiger Loop system - (See Figs. 5 and 6)

1 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.

2 The de-aerator is connected close to the boiler as a

two pipe system (omitting the non-return valve) as shown in Fig. 5. Refer to the manufacturers instructions supplied with the de-aerator. The de-aerator must be mounted vertically and external.

4 - GENERAL BOILER INFORMATION

Fig. 4 - Two pipe system

Note: To prevent any possibility of fuel fumes entering the building, the de-aerator must be fitted outside.

3 To be used with a de-aerator, the burner must be

fitted with an additional flexible fuel hose (a flexible fuel hose (600 mm) and 3/8" to 1/4" BSP male adaptor are available to purchase from yor local stockist. See Section 4.4.6.

Filter

Fire valve

Shut-off valve

See

section 4.4.6

Return

Supply

Head A

(m)

Maximum pipe run (m)

0.5

1.0

1.5

2.0

3.0

3.5

10mm OD pipe

35 30 25 20 15

8 6

12mm OD pipe

100 100 100

90 70 30 20

Non return valve

Fire valve sensor

Sludge valve

Fill pipe

Vent

pipe Level gauge

Fuel storage tank

Fire valve

Tankmaster

See

section 4.4.6

Sludge valve

Fill pipe

Vent pipe

Fuel storage tank

De-aeration device

e.g. Tiger Loop

See Fig. 6

Fire valve sensor

Return

Supply

Page 15

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4.4.6 Two pipe oil supplies

Riello RDB burner - See Fig. 7

1 The fuel pump is supplied for use with a single

pipe fuel supply system. For use on a two pipe system, it is necessary to fit the By-pass screw (see Fig. 7) into the tapping in the return port.

2 The By-pass screw is supplied in the boiler

accessory pack.

3 On all models except 155/200 and 200/240:

Remove the plastic burner cover (secured by two screws).

On 155/200 and 200/240 models only:

Remove the plastic burner cover (secured by three screws). For ease of access to the fuel pump, to fit the by-pass screw and connect the oil lines, the burner can be removed from the boiler. To do this, unscrew the single nut at the top of the burner (using a 13 mm spanner) and withdraw the burner from the boiler.

4 Remove and discard the blanking plug from the

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

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

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

fuel hose.

7 Flexible fuel hoses and adaptors are available to

purchase from your local stockist.

Fig. 6 - Tiger loop 'de-aeration' device

4 - GENERAL BOILER INFORMATION

Fig. 7 - Riello RDB pump

1 Oil inlet connection 2 Return connection 3 By-pass screw 4 Pressure gauge connection 5 Pressure adjuster 6 Vacuum gauge connection 7 Solenoid 8 Supply to nozzle

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

The boiler must be earthed.

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

only be one common isolator for the boiler and control system, providing complete electrical isolation.

3 A fused double pole switch or a fused three pin

plug and shuttered outlet socket should be used for the connection.

4 The power supply cable should be at least 0.75 mm²

PVC as specified in BS 6500, Table 16.

5 All the wiring and supplementary earth bonding

external to the boiler must be in accordance with the current I.E.E. Wiring Regulations.

6 Any room thermostat or frost thermostat used must

be suitable for use on mains voltage.

7 In the event of an electrical fault after installation

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

Electricity supply

4.5

1/4" BSP female

connections

Tiger Loop

SUPPLY

TO PUMP

RETURN

FROM PUMP

SUPPLY

FROM TANK

Page 16

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

BOILER IN ROOM

Conventional open flue

BOILER IN COMPARTMENT

Conventional open flue

compartment ventilated from room

Conventional open flue

compartment ventilated from outside

BOILER IN ROOM

Room sealed balanced flue

no ventilation required to room

BOILER IN COMPARTMENT

Room sealed balanced flue

compartment ventilated from room

Room sealed balanced flue

compartment ventilated from outside

Fig. 8 - Air supply for room sealed balanced flue boilers

4 - GENERAL BOILER INFORMATION

Fig. 9 - Air supply for conventional flue boilers

155/200

319 cm² (50 in²)

638 cm² (100 in²)

200/240

385 cm² (60 in²)

770 cm² (120 in²)

Model

Vent A

Vent B

50/70

116 cm² (18 in²)

232 cm² (36 in²)

90/120

198 cm² (31 in²)

396 cm² (62 in²)

Model

Vent A

Vent B

120/155

253 cm² (40 in²)

506 cm² (80 in²)

155/200

319 cm² (50 in²)

638 cm² (100 in²)

957 cm² (150 in²)

200/240

385 cm² (60 in²)

770 cm² (120 in²)

1155 cm² (180 in²)

Model

Vent C

Vent D

Vent E

50/70

116 cm² (18 in²)

232 cm² (36 in²)

348 cm² (54 in²)

90/120

198 cm² (31 in²)

396 cm² (62 in²)

594 cm² (93 in²)

Model

Vent C

Vent D

Vent E

120/155

253 cm² (40 in²)

506 cm² (80 in²)

759 cm² (120 in²)

Air supply

4.6

See Figs. 8 and 9

A sufficient permanent air supply to the boiler should be provided:

a For proper combustion of fuel and effective

discharge of combustion products to the open air.

b For the ventilation of any confined space in

which the boiler is installed to prevent overheating of the boiler any equipment in and near the boiler.

50/90

143 cm² (23 in²)

286 cm² (46 in²)

429 cm² (69 in²)

50/90

143 cm² (23 in²)

286 cm² (46 in²)

Page 17

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

It should be both the designer's and installer's concern that the air required for these functions be introduced so as to cause as little discomfort as possible to the building occupants and thus to offer them the least temptation to obstruct the ventilators. Further details may be obtained from BS 5410:1:1997.

Notes:

For a boiler fitted in a compartment, which is ventilated as shown, no additional allowance is necessary. Open flue - Extract fans, where needed, should be in accordance with Section 4.4.7 in BS 5410 Part 1 1997. All ventilation areas given are for domestic applications. For all other cases refer to BS 5410 Part 2 1978.

Under no circumstances can Grant Vortex boilers be installed with existing flue systems. Only flue systems and components suitable for wet flues should be used. Failure to install the correct type of flue system will invalidate the warranty.

See Fig. 10a

General

Grant condensing boilers have high operating efficiencies and low flue gas temperatures. Care must be taken to ensure the flue system is suitable for the very low flue gas temperatures and condensate in the flue gases.

Suitable conventional flue systems (Orange system) are available to purchase from your local stockist - see Fig. 10a.

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 condensate may be allowed to run back into

the boiler. A condensate drain at the base of the flue system is not required.

3 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. See Fig. 11.

4 If an existing chimney is to be used, it must be lined

with a smooth bore stainless steel liner suitable for use with oil fired condensing boilers. The top and bottom of the annular space must be sealed. The internal flue and liner diameter for all models up to and including 120/155 must be 100 mm (4 in), for the 155/200 and 200/240 models 125 mm (5 in).

Conventional flue system

4.7

Grant recommends the use of the Grant 'Orange' flue system, specifically designed for the Vortex range of condensing boilers. Refer to Section 4.7 for further details. The maximum vertical height (from the top of the boiler to the terminal) for the 'Orange' system is 19 metres.

Fig. 10a - Grant Orange flue system in a typical

brick chimney

Brick chimney

Flaunching

Locking band

Rigid to flexi flue connector (bottom)

This component must be installed vertically

Note:

Extension

Boiler flue connector

Boiler

Flexi pack

Terminal

Adjustable section 235/300mm

WXA250/100 WXA250/125

100mm dia. 125mm dia.

Locking band

45 elbow

Top plate

Clamp

Page 18

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

5 Twin-wall flues are recommended for externally

run flues to reduce the possibility of the condensate freezing in the flue.

6 No part of any flue system should be made of an

asbestos material; aluminium must not be used in any part of the flue. Only stainless steel flue components should be used.

7 If the draught conditions are satisfactory, the flue

should terminate with a standard cowl.

8 Refer to the locally applicable Building

Regulations, BS 5410:1 and OFTEC Installation Requirements (Books 2 and 3) for further guidance on conventional flue systems.

It is important to ensure that the flue system is sealed and that condensate cannot escape. Up to 1.5 l/h of condensate can be produced in a conventional flue system.

Only use flue systems suitable for oil fired condensing boilers.

Do not use fire cement. The use of high temperature silicone sealants is recommended.

Grant EZ-Fit Flexi Pack conventional flue system (Orange System) - See Fig. 10a

A range of Flexi pack conventional flue lining kits are available to purchase from your local stockist . The packs have been specifically produced for Grant Vortex oil fired condensing boilers.

Contents of Grant EZ-Fit Flexi Pack

The pack includes a terminal/top plate/flexi flue adaptor, stainless steel smooth bore flexible flue liner, a rigid to flexi adaptor and a boiler flue connector. Two diameters are available, a 100 mm for models up to and including 120/155 and 125 mm for the 155/200 and 200/240 models.

4 - GENERAL BOILER INFORMATION

Part No.

WX 150/100

WX 150/125

WX 250/100

WX 250/125

WX 450/100

WX 450/125

WX 950/100

WX 950/125

Extensions (Orange System)

100 mm dia. x 150 mm

125 mm dia. x 150 mm

100 mm dia. x 250 mm

125 mm dia. x 250 mm

100 mm dia. x 450 mm

125 mm dia. x 450 mm

100 mm dia. x 950 mm

125 mm dia. x 950 mm

Part No.

GFKIT 6/100

GFKIT 6/125

GFKIT 8/100

GFKIT 8/125

GFKIT 10/100

GFKIT 10/125

GFKIT 11/100

Flexi Pack (Orange System)

100 mm dia. x 6 metre

125 mm dia. x 6 metre

100 mm dia. x 8 metre

125 mm dia. x 8 metre

100 mm dia. x 10 metre

125 mm dia. x 10 metre

100 mm dia. x 11 metre

Extensions

A range of white powder coated single wall extensions are available to connect the boiler to the flexible liner. The external diameter of the extensions is 100 mm or 125 mm (see Table below). Extensions are supplied with locking bands.

Flue extensions cannot be cut.

An adjustable extension and 45° elbow are also available. See Fig. 10a.

The rigid flue between the boiler and flexible flue liner should incorporate an adjustable section to allow inspection and cleaning of the flue system.

Page 19

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

Apart from a conventional flue, several balanced flue options are available for use with the Grant Vortex boilers. All are suitable for use with Class C2 kerosene.

Note: None of the flue sections in the following system can be cut.

1 Low level horizontal balanced flue (Yellow system)

Available in Standard kits.

Extensions are available which extend the flue by 225 mm, 450 mm or 675 mm. 90° and 45° elbows are also available.

The maximum flue length - from the centre of the boiler flue outlet to the outer face of the wall - is 4 metres (with or without elbows included). No more than 2 x 45° or 1 x 90° elbow should be fitted per system.

2 High level (horizontal) balanced flue (White

system)

Allows the flue to rise vertically within the building before exiting through the wall horizontally.

The maximum flue length - from the top of the boiler flue outlet to the outer face of the wall - is 10 metres for all Vortex boilers.

Extensions are available which extend the flue by 225 mm, 450 mm or 950 mm. An adjustable extension of 275 to 450 mm is also available.

A 45° elbow is also available. No more than 6 x 45° elbows should be fitted per system. Each elbow reduces the overall maximum length of the system by 1 metre.

3 Vertical balanced flue (White system)

Allows the flue to rise vertically from the boiler to exit through the roof.

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

Extensions are available which extend the flue by 225 mm, 450 mm or 950 mm. An adjustable extension of 275 to 450 mm is also available.

A 45° elbow is also available. No more than 6 x 45° elbows should be fitted per system. Each elbow reduces the overall maximum length of the system by 1 metre.

Balanced flue options

4.8

The minimum dimensions for locating the terminal from building features (windows, doors, etc.) are shown in Fig. 11.

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

The low level balanced flue (Yellow system) is supplied with a stainless steel guard. This must be fitted in all circumstances to prevent objects from entering the flue outlet.

The terminal must be positioned so as to avoid products of combustion accumulating in stagnant pockets around the buildings or entering into buildings. Care should be taken that the plume from condensed flue gases does not cause a nuisance.

Page 20

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

Fig. 10b- Plume diverter

GPDA90 = 1240 - 2080 mm

GPDA200 = 1290 - 2140 mm

Self tapping screw 3mm (x2)

Locking band (x2)

Telescopic locking band (x1)

Locking band (x2)

Adjustable wall bracket (x2)

Terminal elbow (x1)

Telescopic flue pipe 1000mm long (x2)

Starter elbow (x1)

Plume diverter kit components

50/70, Indoor/Utility, 50/90 Indoor/Utility, System and Boiler House models

90/120, 120/155 Indoor/Utility, System and Boiler House models

155/200, 200/240 Indoor/Utility and Boiler House models

A = 768 mm

A = 780 mm

A = 1102 mm

Page 21

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Frost protection

4.9

4 - GENERAL BOILER INFORMATION

Fig. 11 - Clearances for Balanced flues

Notes: * 75 mm with protection.

** Only applies if one or both terminals are balanced flues.

Distances measured to rim of terminal.

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

A Below a gutter or sanitary pipework

B Horizontal from an opening, air brick or window

C Above ground or balcony level

D Below eaves or balcony

E From an internal or external corner

F From a terminal facing the terminal

G From a surface facing the terminal

H Vertical from terminals on the same wall

I Horizontal from terminals on the same wall

J Below an opening, air brick, window etc.

K From vertical sanitary pipework

L Vertical flue from a wall

M From an oil storage tank

Min. distance (mm)Terminal position

* 600

600

300

*600

300

1200

600

1500

**750

600

300

750

1800

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 dimensions

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

3 A way of providing protection of

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

Where the frost thermostat is installed outside the house (to protect a boiler installed in an external boiler room or garage) or in an attic, it is recommended that it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property. The pipe thermostat should be located on the boiler return pipe, and set to operate at 25° C. Refer to Section 10 for connection details.

For additional protection of either the entire heating system, or the boiler and localised pipework, it is recommended that a frost thermostat be installed. Refer to Section 9 for connection details.

To protect the heating system, the frost thermostat should be sited within the house in such a place that it can detect any rise and fall in the ambient air temperature, i.e. in a room with a radiator.

The Installer must ensure that the terminal does not cause a nuisance.

Page 22

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

Boiler location

4.10

1 The boiler must stand on a surface that is firm and

level. It does not require a special hearth as the temperature of the boiler base is less than 50° C.

2 Sufficient clearance must be allowed at the front of the

boiler to remove the burner and baffles for servicing.

3 Indoor/Utility models - Once the boiler has been

installed, a permanent worktop may be fitted over it as access to the top of the boiler is no longer required after installation.

System models - A removable section of worktop above the boiler is required to provide access for servicing.

Water connections - System models

4.12

Water connections - all models See Fig. 12

4.11

50/70 Indoor/Utility

50/90 Indoor/Utility

50/90 System

90/120 Indoor/Utility

90/120 System

120/155 Indoor/Utility

120/155 System

155/200 Indoor/Utility

200/240 Indoor/Utility

50/90 Boiler House

90/120 Boiler House

120/155 Boiler House

155/200 Boiler House

200/240 Boiler House

*22 mm pipe

22 mm pipe

*28 mm pipe

28 mm pipe

*28 mm pipe

28 mm pipe

*1¼ " BSP

*1" BSP

*1¼ " BSP

Compression straight

Compression elbow

Compression

Compression straight

Compression

Compression straight

Compression

none

in fittings kit

fitted

in fittings kit

fitted

in fittings kit

fitted

22 mm pipe

28 mm pipe

1¼ " BSP

1" BSP

1¼ " BSP

Compression

none

fitted

Size SizeFitting FittingSupplied Supplied

Boiler model

Flow connection

Return connection

1 A 15 mm discharge pipe must be connected to the

safety valve outlet connection. The pipework between the safety valve and the boiler must be unrestricted, i.e. no valves. The discharge pipe should be run to the outside of the building and terminate so that it cannot cause injury to persons or property.

2 A 15 mm double check valve ballofix type valve is

provided on the flexible filling loop hose for connection of the cold mains supply to the heating system. The cold mains supply should terminate inside the boiler casing.

3 The expansion vessel is connected via a flexible

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

*Ensure the flow pipe is vented at its highest point of the boiler.

All models

To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly flushed out - before the boiler is connected and then again after the system has been heated and is still hot. This is especially important where the boiler is used on an old system.

For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 7593:1992 'Treatment of water in domestic hot water central heating systems'.

This must involve the use of a proprietary cleaner, such as BetzDearborn's Sentinel X300 or X400, or Fernox Restorer.

For Long term protection against corrosion and scale, after flushing, it is recommended that an inhibitor such as Betzdearborn's Sentinel X100 or Fernox MB-1 is dosed in accordance with the guidelines given in BS 7593:1992.

Failure to implement the guidelines will invalidate the warranty.

A drain cock is fitted at the bottom on the front of the boiler to allow the heating system to be drained, on the Boiler House models the drain cock is supplied in the accessories pack and requires to be fitted.

Page 23

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Fig. 12 - Water connections and thermostat phial positions

Heating return

Heating flow

Thermostat phials

Vortex 70/90

Heating return

Heating flow

Thermostat phials

Vortex 90/120, 120/155

Heating return

Heating flow

Thermostat phials

Vortex 155/200, 200/240

Vortex 50/70

Heating flow

Thermostat phials

Heating return

Vortex 90/120, 120/155, 155/200, 200/240 Boiler House

Heating return

Heating flow

Dual stat

(comes fitted)

Vortex 50/90 Boiler House

Dual stat phials

Heating return

Dual stat

Heating flow

(under blanking plate)

Page 24

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Fig. 13 - Sealed system

4 - GENERAL BOILER INFORMATION

50/90 Boiler House Flow connection: A 1" BSP socket is provided on the

boiler for the flow connection. This is located underneath the side blanking plate on the right hand side panel. The flow pipe will need to be vented, as it is the highest point on the primary heat exchanger. Return connection: A 1" BSP socket is located on top of the boiler. This return pipe will also need to be vented at some point, as it is the highest point on the secondary heat exchanger.

90/120, 120/155 Boiler House Flow connection: A 1" BSP socket is provided for the

flow connection. This is located on the right hand side of the boiler. This flow pipe will need to be vented, as it is the highest point on the primary heat exchanger. Return connection: A 1" BSP socket is located on top of the boiler. This return pipe will also need to be vented at some point, as it is the highest point on the secondary heat exchanger.

155/200, 200/240 Boiler House Flow connection: A 1¼" BSP socket is provided for the

flow connection. This is located on the right hand side of the boiler. This flow pipe will need to be vented, as it is the highest point on the primary heat exchanger. Return connection: A 1¼" BSP socket is located on top of the boiler. This return pipe will also need to be vented at some point, as it is the highest point on the secondary heat exchanger.

Sealed systems

4.14

See Fig. 13

1 All Grant Vortex boilers are suitable for use with

sealed systems complying with the requirements of BS 5449. The maximum temperature of the central heating water is 75° C.

2 The system must be provided with the following items:-

a Diaphragm expansion vessel complying with

BS 4814. b Pressure gauge. c Safety valve. d Approved method for filling the system.

Refer to BS 7074:1 for further guidance.

3 The expansion vessel can be fitted in either the

return or flow pipework in any of the recommended positions as shown in Fig. 13. To reduce the operating temperature of the expansion vessel diaphragm, position it below the pipe to which it is connected. The expansion vessel may be positioned away from the system, providing the connecting pipe is not less than 13 mm diameter.

4 The pressure gauge should have an operating range

of 0 to 4 bar.

5 The safety valve, set to operate at 2.5 bar, should

be fitted in the flow pipework near to the boiler. The pipework between the safety valve and boiler must be unrestricted, i.e. no valves. The safety valve should be connected to a discharge pipe which will allow the discharge to be seen, but cannot cause injury to persons or property.

Water connections - Boiler House models

4.13

Page 25

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

4 - GENERAL BOILER INFORMATION

Fig. 14 - Sealed system boilers

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

6 Provision should be made to replace water lost

from the system. This can be done manually (where allowed by the local water undertaking) using an approved filling loop arrangement incorporating a double check valve assembly (as supplied fitted on System models).

7 An automatic air vent should be fitted to the

highest point of the system.

8 The system design pressure (cold) should be between

0.5 and 1.0 bar. This pressure is equivalent to the maximum static head (see Fig. 14) in bar + 0.3 (1 bar = 10.2 metres of water).

9 If thermostatic radiator valves are fitted to all

radiators, a system by-pass must be fitted. The bypass must be an automatic type.

10 Filling of the system must be carried out in a

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

11 All fittings used in the system must be able to

withstand pressures up to 3 bar.

12 Radiator valves must comply with the requirements

of BS 2767(10):1972.

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

to allow the system to be completely drained.

14 The expansion vessel is connected via a flexible

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

All System models have the following sealed system

components factory fitted (refer to Fig. 15):-

a A diaphragm expansion vessel complying with

BS 4814, pre-charged at 1.0 bar. Refer to Section 3.2.

b System pressure gauge, with an operating range

of 1 to 4 bar.

c Pressure relief safety valve complying with

BS 6759 and set to operate at 2.5 bar.

d Automatic air vent, fitted to the flow pipe of the

boiler, ensures the boiler is vented.

e Filling loop. This must be isolated and

disconnected after filling the system.

15 Refer to Section 3.2 for system volume and BS

7074: for further guidance. Refer to Section 5.6 for further details of the expansion vessel.

16 The use of an automatic fill is not permitted.

On underfloor systems it is essential that the return

temperature must be maintained above 40° C to

prevent internal corrosion of the boiler water jacket.

Underfloor heating systems

4.15

Page 26

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Pipework materials

4.16

4 - GENERAL BOILER INFORMATION

Boiler components - System models

4.17

General - Grant boilers are compatible with both copper and plastic pipe. Where plastic pipe is used it must be of the oxygen barrier type and be of the correct class (to BS 7291:Part 1:1990) for the application concerned.

IMPORTANT: The first metre of pipework connected to both the heating flow and return connections of the boiler must be made in copper on all types of system - sealed or open-vented.

Sealed systems - If plastic pipe is to be used, the installer must check with the plastic pipe manufacturer that the pipe to be used is suitable for the temperature and pressures concerned. Pipe must be Class S to BS 7291: Part 1:1990.

Fig. 15 System components

External connection

• into an external soil stack

• into an external drain or gulley

• into a rainwater hopper (that is part of a combined system where sewer carries both rainwater and foul water)

• purpose made soakaway

All condensate disposal pipes MUST be fitted with a trap - whether they are connected internally or externally to a domestic waste system/soil stack or run externally to a gully, hopper or soakaway.

Vortex 50/90

Pressure relief valve

Automatic air vents

Pump

Heating flow

Heating return

Pump isolating valves

Vortex 90/120, 120/155

Pressure relief valve

Automatic air vents

Pump

Heating flow

Heating return

Pump isolating valves

General requirements

5.1

The system should incorporate a low-pressure switch to shut off power to the boiler if the system pressure drops below 0.2 bar. A suitable low pressure switch kit is available from your local stockist.

Underfloor systems - Plastic pipe may be used on Underfloor systems where the plastic pipe is fitted after the thermostatic mixing valve. Copper tube must be used for at least the first metre of flow and return primary pipework between the boiler and the underfloor mixing/blending valves.

When in condensing mode the Grant Vortex boilers produce condensate from the water vapour in the flue gases. This condensate is slightly acidic with a ph value of around 3 (similar to vinegar). Provision must be made for the safe and effective disposal of this condensate.

Condensate can be disposed of using one of the following methods of connection:

Internal connection (preferred option)

• into an internal domestic waste system (from kitchen sink, washing machine, etc.)

• directly into the soil stack

5 - CONDENSATE DISPOSAL

Page 27

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

5 - CONDENSATE DISPOSAL

Connections into a rainwater hopper, external drain or gulley should be terminated inside the hopper/drain/ gulley below the grid level but above the water level.

Condensate disposal pipes should not be connected directly into rainwater downpipes or to waste/soil systems connected to septic tanks.

Condensate should not be discharged into 'grey water' systems that re-use water used in the home (not including water from toilets).

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

Condensate disposal pipework must be plastic (plastic waste or overflow pipe is suitable).

IMPORTANT: Copper or steel pipe is NOT suitable and MUST NOT be used.

Condensate disposal pipes should have a minimum 'nominal' diameter of 22 mm (¾") - e.g. use 21.5 mm OD polypropylene overflow pipe.

Condensate disposal pipes must be fitted with a fall (away from the boiler) of at least 2.5° (~45 mm fall per metre run).

Note: Where it is not possible for the pipe to fall towards the point of discharge - either internally into a waste system or externally to a gulley (e.g. for boilers installed in a basement), it will be necessary to use a condensate pump.

Condensate disposal pipes should be kept as short as possible and the number of bends kept to a minimum.

Pipes should be adequately fixed to prevent sagging, i.e. at no more than 0.5 metre intervals.

External pipework

Ideally, external pipework, or pipework in unheated areas, should be avoided. If unavoidable, external pipework should be kept as short as possible (less than 3 metres) and 32 mm waste pipe used to minimise the risk of ice blocking the pipe in freezing conditions.

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

Note: For boiler installed in an unheated area such as an outhouse or garage, all condensate pipework should be considered as an ‘external’.

To keep external pipework to a minimum, locate the soakaway as close as possible to the boiler but ensure it is at least 1 metre from building foundations and away from other services, e.g. gas, electricity, etc.

The condensate pipe may be run above or below ground level and can enter either the top or side of the soakaway tube. Refer to Fig.16.

Ensure that the drainage holes in the soakaway tube face away from the building.

Connections

5.2

Pipework

5.3

Condensate soakaway

5.4

Fig. 16 - Purpose made condensate soakaway

Ground level

32 mm waste pipe external to the building

2.5 fall

25 mm

300 mm

400 mm

min.

Two rows of3x12mm holes at 25 mm centres and 50 mm from the bottom of the tube. Holes facing away from the property.

Cement seal

100 mm

plastic

tube

Sealed

end

Backfill with 10 mm limestone chippings

Page 28

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

5 - CONDENSATE DISPOSAL

Backfill both the soakaway tube, and the hole around it, with 10 mm limestone chippings.

Only use a soakaway where the soil is porous and drains easily. Do not use in clay soils or where the

soil is poorly drained.

Condensate trap

5.5

Fig. 17a - Condensate trap (Boiler House models)

If connecting the condensate discharge (either internally or externally) into a waste system or soil stack - the sealing cap MUST be fitted in the trap outlet.

On external discharge systems to a hopper, gully or soakaway, the sealing cap should be removed from the trap outlet.

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

Care should be taken when siting the trap such that the overflow outlet is readily visible and that any condensate overflowing from the outlet cannot cause either a hazard to persons or damage to surrounding property or equipment.

The condensate trap outlet is at an angle of 48° below the horizontal. This is to automatically give a 3° fall on any 'horizontal' runs of condensate disposal pipe. Refer to Fig.17.

The outlet of the trap will accept 21.5 mm to 23 mm OD Polypropylene overflow pipe for the condensate discharge pipe.

Condensate drain from boiler

Minimum 2° fall

Overflow warning

outlet (with cap)

Condensate trap

Condensate

outlet to drain

Wall bracket

Fig. 17 - Condensate trap (Indoor/Utility)

Condensate trap

Condensate outlet to drain

Overflow warning outlet (with cap)

Condensate drain pipe from boiler

Condensate disposal pipework

5.6

WARNING: Any damage due to condensate backing up into the boiler due to a high water table, in the case of a soakaway, or flooded drains when the condensate disposal is via a gulley or soil stack, is not covered by the Grant product warranty.

Grant Vortex 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.

The condensate trap for the Boiler House models is supplied loose in the burner box and needs to be fitted as shown in Fig. 17a.

This trap incorporates a float (which will create a seal when the trap is empty) and an overflow warning outlet (fitted with a plastic sealing cap), See Fig. 17.

The trap is factory-fitted inside the boiler casing (mounted on the inside of the left side panel) in an accessible position to allow for routine maintenance.

Note: If required, this condensate trap may be relocated outside the boiler casing. Refer to procedure given in Section 5.8. This procedure MUST be carried out before the boiler is installed.

A flexible hose connects the outlet of the condensing heat exchanger to the trap inlet. Ensure the straight connector on the hose is fully pushed onto the 'top hat' inlet connector of the trap.

With the trap fitted inside the boiler casing, the sealing cap MUST be fitted. If the trap is re-located outside the boiler then the following applies:

Page 29

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

5 - CONDENSATE DISPOSAL

This discharge pipe can exit through the left side of the boiler through one of two pre-cut 'knock-outs' in the lower part of the left casing panel (see to Fig. 1). Push out the 'knock-out' from the required hole taking care not to distort the side panel.

The trap MUST be checked at regular intervals (e.g. on every annual service) and cleaned as necessary to ensure that it is clear and able to operate.

Note: The bottom bowl is sealed to the trap body and cannot be removed.

To inspect and clean the trap:

1 Disconnect flexible condensate hose from inlet

connector.

2 Unscrew the inlet connection nut.

3 Remove the inlet connector and nut from trap.

4 Remove trap from bracket.

5 Remove float from trap – clean if necessary.

6 Inspect inside of trap and clean as necessary.

7 Re-assemble trap, re-fit to boiler and re-connect

flexible hose. Ensure that hose is fully pushed onto the trap inlet connector.

IMPORTANT: Failure to regularly check and clean the condensate trap may result in damage to the boiler and will not be covered by the Product Warranty.

Indoor/Utility - To re-locate the factory-fitted trap outside the boiler casing, use the following procedure:

Note: This procedure must be carried out before the boiler is installed.

1 Remove the top casing panel(s) from the boiler.

2 Unscrew and remove the screws fastening the left

side panel to the rear casing panel of the boiler.

3 Carefully separate the left side and rear panels just

enough to gain access to the condensate outlet on the left rear of the condensing heat exchanger (see Fig.18).

4 Push out pre-cut 'knock-out' from the condensate

outlet hole in the rear of left side casing panel.

5 Remove the right angle end of the flexible

condensate discharge hose from the outlet connection on the condensing heat exchanger.

6 From the front of boiler, remove the straight

connector end of the flexible hose from the top of the condensate trap.

7 Reverse the flexible hose and pass the straight

connector end through the new hole in the left hand casing panel. Push the straight connector firmly onto the condensate outlet connection of the condensing heat exchanger - push on at least 20 mm.

8 Refit the left hand casing panel to the rear panel

using the reverse procedure, ensuring all fixing screws are used.

9 Remove the trap from the mounting bracket.

10 Unscrew and remove the trap mounting bracket

from the left side panel.

11 Fix the trap mounting bracket to the wall adjacent

to the boiler in the required position.

Note: The top of the trap must be below the condensate connection on the boiler.

12 Re-fit the trap to the mounting bracket.

The mounting bracket supplied with the trap MUST be used - the trap should NOT be supported by the condensate pipework only.

13 Connect the flexible condensate hose to the trap,

pushing the right angle hose connector onto the trap inlet connection.

IMPORTANT: The flexible hose must fall continuously from the outlet to the top of the trap.

Inspection and cleaning of trap

5.7

Fig. 18 - Remove the condensate trap

Left hand side panel

Rear panel

External condensate trap fitting

5.8

Page 30

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Indoor/Utility and System models:

1 Carefully remove the packaging from the boiler

and remove it from the transit pallet.

2 Pull the front panel forward at the top to disengage

the fixing clips then lift it up and off the boiler. Remove the literature packs.

3 Lift off the case top panel(s) and remove the water

connecting fittngs.

Boiler House models:

1 The Boiler House boiler comes in two separate

cartons, one containing the boiler and the other containing the burner and drain trap. (50/90 - the dual thermostat is also included).

2 Carefully remove the packaging from the boiler

and unpack the carton containing the remaining items.

3 Remove the literature pack from the combustion

chamber of the boiler through the front burner opening.

Unpack the boiler

6.1

Prepare the wall

6.2

6 - BOILER INSTALLATION

See Fig. 19 and 19a

If the boiler is to be used with a low level balanced flue (Yellow system) make the hole in the wall for the flue as shown in Fig. 19.

Note: Dimension B given in Fig. 19a includes an extra 10 mm over the size of the terminal to provide clearance for fitting.

Fig. 19a - Low level balanced flue (Yellow System)

Fig. 19 - Low level balanced flue

Side wall

Rear wall

Note: This dimension is given with

the boiler pushed back against the rear wall. Any clearances must be added to it.

Hole to be cut in wall

Boiler centre line

Outline of boiler

Rear exit

Side exit

50/70 Indoor/Utility, 50/90 Indoor/Utility, System and Boiler House

90/120, 120/155 Indoor/Utility, System and Boiler House

155/200, 200/240 Indoor/Utility and Boiler House

768

780

1102

Dimension (mm)

Model

A dia

127

162

115

112

Page 31

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

6 - BOILER INSTALLATION

Fig. 20a - High level balanced flue (White system)

Fig. 20 - High level balanced flue

High level and vertical balanced flue

6.3

See Fig. 20 and 20a

If the boiler is to be used with the high level balanced flue (White system) make the hole in the wall as shown in Fig. 20a.

Note: Dimension B given in Fig. 20a includes an extra 10 mm over the size of the terminal to provide clearance for fitting.

Fitting instructions for the high level balanced flue and vertical balanced flue are supplied with the flue kits.

Adjustable sections: The adjustable extensions are telescopic. The wall terminal section is adjustable and is suitable for a wall thickness of 215 mm to 450 mm. Simply adjust to the required length using a twisting motion. The outer pipes must overlap by a minimum of 25 mm.

Side wall

Rear wall

Note: This dimension is given with

the boiler pushed back against the rear wall. Any clearances must be added to it.

Hole to be cut in wall

Boiler centre line

Outline of boiler

Rear exit

Side exit

Standard kit with no extensions

*Dimension C for Starter section and elbow/terminal only

50/70 Indoor/Utility, 50/90 Indoor/Utility, System and Boiler House

90/120, 120/155 Indoor/Utility, System and Boiler House

155/200, 200/240 Indoor/Utility and Boiler House

1715 - 2115

1700 - 2020

2015 - 2335

Dimension (mm)

Model

A dia

175

200

115

112

1215*

1280*

1595*

Page 32

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Fig. 21 - Boiler flue connector

Refer to Section 4.11 and 4.12 and Fig. 12. for the size, type and position of the connections.

The Flow and Return pipework can be routed to either side of the boiler, dependant on the type and direction of the flue system used.

For condensate disposal pipework refer to Section 5.

Pipe entry/exit holes in case (Indoor/Utility, System)

All models except the 155/200 and 200/240 have holes to enable the pipework to exit the boiler casing. On the 50/70 and 50/90 models these holes are pre-cut knockouts located at the rear of both side panels and on the 90/120 and 120/155 models these pre-cut holes are in the removable flue outlet cover plates.

Push out the 'knock-out' from the required holes, taking care not to distort the side panel.

If access will be restricted, make any connections to the boiler before placing it in its final position.

If using a balanced flue system - Install the balanced flue system before connecting the heating system pipework to the boiler. Once the flue system is fitted then complete the water connections and fill the heating system.

If using a conventional flue system - Complete the water connections and fill the heating system.

Check all connections for leaks and rectify as necessary.

1. Lift off upper rear casing panel.

2. Remove the insulation from the underside of the panel (do not discard it). Carefully press out the pre-cut flue opening in the top panel.

3. The flue dress panel supplied in the literature pack. Place the dress panel in position on the rear casing top panel and secure in place.

4. Re-fit the insulation to the panel with the foil surface facing outwards. With a sharp knife cut around the edge of the round opening in the dress plate to leave a round hole through the insulation for the flue.

5. If the Grant ‘Orange’ flue system is being used – follow the instructions supplied with the flue kit.

6. Fully screw the length of threaded studding (provided in the kit) into the nut located in the centre of the boiler flue outlet.

Make the water connections

6.4

6 - BOILER INSTALLATION

7. Fit the boiler connector (from the CF adaptor kit) over the threaded studding. Position flange on to the neoprene gasket around the boiler flue outlet, ensuring that small spigot on the base of the connector is located in the hole in the centre of the neoprene gasket and that end of studding passes through the hole in the of the spacer bracket. Fit washer and wing nut provided onto end of threaded studding and secure connector in position by tightening down on wing nut – as shown in Fig. 21.

8. Re-fit the rear top casing panel to the boiler – fitting it over the boiler connector.

9. Fit the flue adaptor (from the adaptor kit) into the boiler connector. Note lubricate the seal on the adaptor using the lubricant provided before attempting to fit the flue adaptor.

10. Fit the first section of flue into the flue adaptor and secure using the clamp band provided.

11. Assemble the remainder of the flue system as required, lubricating the seal on each component before fitting.

Connect a conventional flue

6.5

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Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Expansion vessel pressure - System models

6.6

6 - BOILER INSTALLATION

The expansion vessel fitted, is supplied with a charge pressure of 1.0 bar (equivalent to a max. static head of

10.2 metres). The charge pressure must not be less than the actual static head at the point of connection. Do not pressurise the vessel above 1.5 bar.

The air pressure in the vessel must be checked annually.

The central heating system volume, using the expansion vessel as supplied, must not exceed the recommended volumes. If the system volume is greater, an extra expansion vessel (complying with BS 4841) must be fitted as close as possible to the central heating return connection on the boiler. The charge pressure of the extra vessel must be the same as the vessel fitted in the boiler. Refer to BS 7074:1 for further guidance.

The air charge pressure may be checked using a tyre pressure gauge on the expansion vessel Schraeder valve. The vessel may be re-pressurised using a suitable pump. When checking the air pressure the water in the heating system must be cold and the system pressure reduced to zero.

(90/120, 120/155, 155/200, 200/240 Boiler House models come with the dual thermostat factory fitted)

1 Unpack the dual thermostat which comes supplied

in the burner box.

2 Undo the two screws fitted in the top panel (front

centre).

3 Fit the dual thermostat complete with bracket using

the screws supplied as shown in Fig. 12.

4 Remove the side blanking plate from the boiler.

5 Fit the dual thermostat phials in the thermostat

saddle on the side of the boiler.

6 Replace the side blanking plate after

commissioning is complete, ensuring that the phials are inserted fully and are not pinched by the blanking plate.

7 Refer to Section 10.7 for wiring of the dual thermostat.

It is recommend that the boiler should be connected to a switched mains power supply from a programmer or control system. A three core cable is required to connect the boiler terminal block to the live supply. Refer to Sections 10.3 to 10.6 for typical control system wiring diagrams.

White cased models:

1 Lift off the boiler case top panel, if it has not

already been removed.

2 Remove the top of the control panel and open the

cable clamp. Route the supply cable through the hole in the rear panel (using the grommet supplied) up to the control panel, pass it through the cable clamp and connect to the boiler terminal block (refer to Section 10) as follows:-

Brown to live (terminal 1) Blue to mains neutral (terminal 2) Green/Yellow to mains earth (terminal 3)

Note: Ensure that the route and length of the cable is such that the boiler front cover plate can be easily removed without disconnecting the supply cable from the terminal block.

3 Secure the cable in the cable clamp.

4 Place the wiring cover in position over the terminal

block, taking care not to trap any wires and secure in position with the two M4 screws provided.

5 Ensure that all external wiring is adequately supported.

Do not switch on the electricity supply at this stage.

Boiler House models:

It is recommended that the boiler should be connected to a switched mains power supply from an external timer or control system.

1 Check the thermostat phials are pushed fully into

the thermostat pocket on the side of the boiler.

2 Remove the overheat thermostat reset cap and undo

the three screws securing the combined boiler/overheat thermostat cover and lift off the cover.

3 Withdraw the cable support bushes from the cover.

Pass the burner supply cable through one of the bushes and connect it to the boiler (control) thermostat (refer to Fig. 23) as follows:-

Brown to terminal 1 of the control thermostat. Green/yellow and earth fly lead from the boiler casing to the earth terminal, marked

on the

control thermostat.

4 Pass a switched mains power supply through the other

cable support bush and connect it to the overheat thermostat as follows:-

Switched live (brown) to terminal C on the overheat thermostat. Earth (green/yellow) and remaining earth fly lead from casing to the earth terminal, marked on the overheat thermostat.

Connect the power supply

6.8

Fit the dual thermostat - 50/90 Boiler House

6.7

Page 34

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

2 Connect the flexible fuel hose to the rigid supply

using the adaptor supplied. The supply enters through one of the holes in the casing plinth.

1 Automatic air vent(s) are fitted to the top of the boiler (see

Fig. 15). Check that the small cap on the top of each air vent is screwed on fully, then unscrew it one complete turn - the cap remains in this position from now on.

2 If the flexible filling loop is used to fill the system, ensure

it is connected and that the valve connecting it to the boiler is open and the valve at the front is closed. A valve is open when the operating lever is in line with the valve, and closed when it is at right angles to it.

3 Ensure that the mains cold water supply valve is open

(operating lever in line with the valve), then turn on the mains cold water supply and gradually open the front valve on the filling loop until water is heard to flow.

4 Vent each radiator in turn, starting with the lowest

one in the system, to remove air.

5 It is important that the pump is properly vented to

avoid it running dry and damaging its bearings. To gain access to the pump for venting it is necessary to remove the control panel. Loosen the four fixing screws securing the panel to the casing, push the panel towards the rear of the boiler and lower the control panel to expose the pump. Remove the cap, then unscrew and remove the plug from the centre of the pump. Using a suitable screwdriver rotate the exposed spindle about one turn. Replace the plug and cap.

6 Check the operation of the safety valve by turning

the head anticlockwise until it clicks. The click is the safety valve head lifting off its seat allowing water to escape from the system. Check that this is actually happening.

7 Continue to fill the system until the pressure gauge

indicates between 0.5 and 1.0 bar. Close the fill point valve and check the system for water soundness, rectifying where necessary. Water may be released from the system by manually operating the safety valve until the system design pressure is obtained.

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

bar and 1.0 bar. The pressure is equivalent to the maximum static head in bar + 0.3 (1 bar = 10.2 metres of water), where the static head is the vertical height from the centre of the expansion vessel to the highest point of the system.

9 Close the valves either side of the filling loop and

disconnect the loop.

Fill the sealed system

6.11

6 - BOILER INSTALLATION

The neutral (blue) wire from the burner supply must be linked to the incoming neutral of the switched mains supply using a single connector (not supplied).

Do not connect the neutral wires to either of the two thermostats.

5 Connect a link between terminal 2 on the overheat

thermostat and terminal C on the control thermostat.

6 There is no connection to terminal 1 on the

overheat thermostat or terminal 2 on the control thermostat.

7 Position the support bushes so as not to strain the

connections when the cover is replaced.

Place the cover in position locating the bushes at the same time.

Note: It may be necessary to rotate the thermostat knob to engage it on the operating spindle as the cover is replaced.

8 Secure the cover in position by tightening the three

screws. Refit the overheat thermostat reset cap. Tighten the cable support bush nuts to secure the cables.

9 Ensure all external wiring is adequately supported.

Do not switch on the electricity supply at this stage.

Indoor/Utility and System models are supplied with the burner fitted. Fit the burner to a Boiler House model as follows:

1 Remove and retain the burner fixing nut from the stud

on the burner mounting flange on the front of the boiler, see Fig. 22. Leave the small nut in position (ensure it is located up against the mounting flange).

Note: Do not remove the mounting flange from the boiler.

2 Check that the 'O' ring is in position (around the collar

of the burner combustion head). Position the burner on the boiler by sliding the combustion head into the mounting flange on the boiler. With the burner level and correctly located over the fixing stud, secure it in position using the nut previously removed.

3 Balanced flue - Fit the air tube over the air tube spigot

and secure in position using the clamp supplied.

See Fig. 7

If a two pipe system is to be used refer to Section 4.4.6.

1 Remove the oil inlet plug from the fuel pump and

connect the elbow of the flexible fuel hose supplied with the boiler.

Fit the burner

6.9

Connect the fuel supply

6.10

Page 35

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

6 - BOILER INSTALLATION

7 - COMMISSIONING

Pressure gauge

(System models only)

Boiler

thermostat

Overheat

thermostat

reset button

(under cover)

On/Off switch

OVERHEAT

RESET

SYSTEM PRESSURE

HEATING

TEMPERATURE

OVERHEAT

RESET

BOILER

OFF

HEATING TEMPERATURE

BOILER

OFF

Lock-out

button

Front panel removed

(pull forward at top, then lift off)

Front panel

fixing clips

Front panel bottom locating tags

Mains On

neon

Boiler Passport - The Installer is responsible for completing the boiler passport supplied with this boiler and

returning the paperwork to Grant Engineering (IRL) Ltd.. This appliance must be correctly commissioned in

accordance with the appliance instructions and the details returned to Grant Engineering (IRL) Ltd. using the

address shown on the back of this manual.

Refer to Fig. 23 for boiler controls

Fig. 23 - (Indoor/Utility model shown)

1 Pump 2 Control box 3 Reset button with lock-out lamp 4 Mounting flange with gasket (do not remove from boiler) 5 Air damper adjustment screw

Fig. 22 - Riello RDB burner components

6 Air supply tube connection (balanced flue) 7 Pump pressure adjustment screw 8 Pressure gauge connection 9 Burner fixing nut

Burner components

6.12

Page 36

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

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

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

IMPORTANT: Check that the turbulators are in position and that the ends are vertical (see Fig. 26).

Notes: 1. If the 50/70 model is down rated to 15 kW,

the burner air adjuster disc must also be adjusted to setting B as described overleaf. See Section 3.3.

2. If the 50/90 models are down rated to 20 or 15 kW, the burner head must also be changed to a T1 head. See Section 3.3.

1 Check that the water system has been vented (and

pressurised if sealed system) and there are no leaks.

Ensure the flow pipe has been vented.

2 Check that all fuel line valves are open.

3 Remove the plastic burner cover if it was not

previously removed.

4 Connect a combined vent manifold and pressure

gauge to the pressure gauge connection port on the oil pump. See Fig. 7. Open the vent screw on your vent manifold to vent the supply while the pump is running.

5 Set the boiler On/Off switch to Off. Check that all

system controls are calling for heat and turn the boiler thermostat to maximum. Switch on the electricity supply.

6 Set the boiler On/Off switch to On. The burner fan

should start and the burner should light within about 12 seconds. If the burner does not light and the 'Lock-out' reset button lights, wait for about 45 seconds then press the reset button to restart the ignition process. This procedure may have to be repeated several times during first lighting.

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

to the Technical Information, Section 3.3. Adjust the pressure if necessary - see Fig. 7. Note that the 'Mains On' neon lights when the boiler is switched on, but does not necessarily indicate the burner is firing.

8 Operate the boiler until it reaches normal operating

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

9 Check the operation of the boiler thermostat.

Ensure that by turning it anticlockwise it switches the burner off.

10 With the burner alight, re-check the fuel pressure and

re-adjust if necessary. Turn the boiler off, remove the pressure gauge and replace the plug in the pump.

11 Having ensured that there are no oil leaks, replace the

burner cover. Ensure the flexible air tube is connected to the burner (balanced flue models).

12 Relight the boiler and allow it to run for at least 20

minutes.

13 Check the smoke number, if satisfactory check the

CO2. Set the CO2 to the value given in Section 3.3 for the boiler concerned.

Use the hexagonal key supplied to adjust the burner air damper (see Fig. 22) as required. Turning the screw anti-clockwise closes the damper and increases CO2 level, turning the screw clockwise opens the damper and reduces CO2 level.

Re-check the smoke number if the damper has been moved. Under no circumstances must the smoke number be above 1.

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

14 Check the flue gas temperature.

15 Check that both the boiler overheat and boiler control

thermostat bulbs are correctly located in their respective pockets. For location of thermostat pockets, refer to Fig. 12. Also check the condition of both thermostat capillaries, i.e. that they are not damaged, broken or kinked, and that they are not trapped or crushed between any internal boiler components.

16 Replace the case top.

17 When the boiler has been adjusted and is running

satisfactorily, balance the central heating system by adjusting the radiator lock shield valves. Start with the radiator nearest the boiler and adjust the valves to achieve the required temperature drop across each radiator. If thermostatic radiator valves have been installed, check the system by-pass.

18 Switch off the boiler.

19 With the system hot, check again for leaks,

rectifying where necessary. Drain the system while it is hot to complete the flushing process. Refill and vent (and pressurise if a sealed system) the system.

20 A suitable central heating system inhibitor must be

added to protect the system against the effect of corrosion.

21 Replace the front panel - Locate the bottom of the

panel over the fixing tags then push it towards the boiler to engage the fixing clips.

7 - COMMISSIONING

Page 37

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

7 - COMMISSIONING

Note: After commissioning the boiler complete the boiler passport that comes supplied with this boiler and return the commissioning details to Grant Engineering (IRL) Ltd.

If the boiler is to be left in service with the User, set the controls, timer (If optional programmer is fitted, see instructions supplied in kit) and room thermostat (if fitted) to the User's requirements.

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

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

IMPORTANT NOTE:

To allow the boiler to be commissioned and serviced correctly a combustion test point is provided on the front cleaning door.

The CO2 and smoke test may all be carried out using this test point. The test point is not suitable for measuring boiler efficiency or conventional flue draught.

When using the test point on the cleaning cover note that the flue gas temperature reading will be higher than that measured in the flue thus resulting in an inaccurate efficiency reading. To obtain an accurate flue gas temperature and efficiency, the reading can only be measured outside through the low level flue terminal. For high level and vertical balanced flues the reading may be taken from the flue kit test point provided . Refer to Section 3.3.

For Conventional flue draught measurement and efficiency a test point is provided in the conventional flue adaptor.

To adjust the 50/70 air adjuster disc when downrating - See Fig. 24

1. Ensure the boiler is isolated from the electrical supply.

2. Disconnect the air supply tube.

3. Remove the burner from the boiler.

4. Undo the two screws and remove the air inlet cover from the side of the burner.

5. The secondary air shutter disc is factory set in position ‘C’ – i.e. with the cut-out marked C located against the die-cast boss on the fan housing - suitable for outputs of 18.3 and 21 kW only. See Fig 24.

6. Remove the screw from the centre of the air shutter disc, and re-position the disc such that the cut-out ‘B’ (corresponding to 15 kW output setting – See Section 3.3) is located against the cast boss on the fan housing. Replace the screw in the centre of the air shutter disc and tighten.

7. Re-fit the air inlet cover to the side of the burner and reassemble in reverse order.

Fig. 24 - 50/70 air adjuster disc at position 'C'

Page 38

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

The User must be advised (and demonstrated if necessary) of the following important points:-

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

operate the system controls.

2 The precautions necessary to prevent damage to

the central heating system and to the building, in the event of the boiler not being in operation during frost conditions.

3 The importance of servicing the boiler to ensure

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

4 The type of fuel used.

5 That any servicing or replacement of parts must

only be carried out by a suitably qualified engineer.

6 Ensure that the boiler controls and room thermostat

(if fitted) are set to the User's requirements.

8 - INFORMATION FOR THE USER

9 - BOILER SERVICING

7 If the boiler is used on a sealed heating system, tell

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

8 Show the User how to reset the overheat thermostat

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

Leave this Instruction manual with the User.

To ensure your continued Boiler Warranty, the annual service must be carried out by an OFTEC Registered Technician or an otherwise competent person.

Use of non-competent persons may invalidate this warranty. A list of OFTEC Registered Technicians is available at www.oftec.org or alternatively telephone OFTEC on 0845 658 5080 (UK) or 01 864 5771 (ROI).

If there is any doubt as to the suitability of your technician, please check with the manufacturer prior to the work being carried out.

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

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

Important: Details of every service should be entered in the boiler passport. This information may be required to validate the Grant extended warranty.

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 14 on page 51.

1 Check the flue terminal and ensure it is not blocked

or damaged.

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

Important notes prior to servicing

9.1

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.

If the boiler is used on a sealed central heating system, check the system pressure, check the operation of the pressure relief valve and check the expansion vessel air charge. See Section 6.6. Refill, vent and re-pressurise the system as necessary. See Section 6.11

4 Check that any ventilation openings are adequate

and are clear. See Section 4.7.

5 Remove any sludge/water from the fuel tank by

opening the sludge valve at the lower end of the tank.

6 With the fuel supply valve closed, clean/replace the

filter element and clean the filter bowl.

7 Flexible fuel supply hoses should be inspected annually

when the boiler is serviced and braided hoses replaced every year. If in doubt replace the hoses

Warning: Before servicing, set the boiler On/Off switch to Off, isolate the electricity supply and close the fuel supply valve. Allow the boiler to cool. The data label on the inside of the case side panel will indicate the fuel used and the nozzle fitted.

Page 39

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

9 - BOILER SERVICING

1 Pull the front panel forward at the top to disengage

the fixing clips then lift it up and off the boiler.

2 On System models, carefully lift up and remove the

expansion vessel from the front of the boiler. Place the vessel on the floor taking care not to strain the flexible pipe.

3 Disconnect the flexible air tube from the burner.

4 Remove the burner fixing nut (top of mounting

flange) and withdraw the burner. If required, disconnect the flexible oil hose(s), use a suitable container to prevent any oil spillage.

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

1 Remove the nuts and washers securing the front

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

2 Remove the baffles as shown in Fig. 25, 26, 27 or 28.

3 Remove all deposits from the baffle plates and all

the boiler internal surfaces using a stiff brush and scraper if necessary.

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

5 Check the condition of the front cleaning door seal,

replace if necessary.

6 Replace the baffles, ensuring they are correctly

fitted. See Fig. 25, 26, 27 or 28.

7 Pull out the spiral turbulators from the heat

exchanger tubes. See Fig. 28. Clean the turbulators using a stiff brush Test the heat exchanger condensate drain by pouring water into one of the lower tubes and observe whether the water discharges from the 22 mm condensate outlet. Replace the turbulators.

8 Replace the front cleaning door, ensuring the seal

is in good condition and secure it in position with the nuts and washers previously removed. Tighten to form a seal.

Fig. 25 - 50/70 baffles

Fig. 26 - 50/90 baffles

Dismantling prior to servicing

9.2

Cleaning the boiler

9.3

9 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.

10 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.

Page 40

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

9 - BOILER SERVICING

Fig. 27 - 155/200 and 200/240 baffles and turbulators (all models)

200/240 shown

Top baffle

Bottom baffle

IMPORTANT:

The ends of the turbulators must be vertical

Position in vertical plane

Cleaning the burner

9.4

Fig. 28 - 90/120 and 120/155 baffles

Top set

Bottom set

Fig. 29

4 ± 0.3 mm

3 to 3.5 mm

Clamp screw

IMPORTANT: The electrode settings given above MUST be observed

Check the electrode settings

Electrode tips approximately 4 mm apart and 3 to

3.5 mm in front of the nozzle, see Fig 29.

3 Nozzle - The nozzle should be replaced on an

annual service - Check that the nozzle size and type are correct, refer to table in Section 3.3 and boiler data label.

With the combustion head removed, loosen the electrode assembly clamp screw and slide the electrodes away from the nozzle.

Do NOT attempt to clean the nozzle.

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

50/70, 50/90, 90/120, 120/155 models - See Section 13.1

1 Combustion head - Loosen the two screws

securing the combustion head and withdraw the head. Clean and refit the combustion head.

2 Inspect the ignition electrodes - Remove the

combustion head.

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

Page 41

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

9 - BOILER SERVICING

Fig. 30

Combustion head

fixing screw Electrode clamp screw

Electrode leads

Nozzle holder

Diffuser clamp screw

Burner flange

Fig. 31

Fig. 32

Screw

Slotted ring

Screw Combustion

head

Combustion head fixing screw

Electrode clamp screw

5.75

-0.2

+0.5

Diffuser clamp screw

4.0

+0.5

7.5

+0.7

- 0.5

Diffuser disc

155/200 or 200/240 models - See Section 13.2 and Fig. 30

1 Combustion head - Loosen the two screws

securing the combustion head (NOT the screws in the slotted ring, Fig. 32) and withdraw the head. Clean and refit the combustion head.

2 Inspect the ignition electrodes - Remove the

combustion head. Loosen the electrode clamp screw, disconnect the leads and withdraw the electrode assembly. Wipe clean and check for any cracks in the ceramic insulation. Replace if necessary.

3 Check the electrode and diffuser settings - Fig. 31

To adjust the diffuser disc: Loosen the diffuser clamp screw and slide the disc along the nozzle holder to achieve the gap 'A' in Fig. 31, tighten the screw.

To adjust the electrodes: Loosen the electrode clamp screw and move the electrode unit to achieve the gap 'B' in Fig. 31, tighten the screw.

4 The combustion head position is adjustable on the

155/200 and 200/240 burners. Check that it is fully closed (position 0), or the 4th line if the 200/240 has been set to maximum output (70 kW).

To adjust the head setting, refer to Fig. 32 and proceed as follows: Loosen the two screws in the slotted ring - NOT the two fixing screws, and turn the blast tube until '0' lines up with the edge of the slotted ring. Tighten the two screws.

All models

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

body. Carefully pull out the photocell to clean.

2 Burner fan - With the air intake grille or spigot

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.

3 Pump filter - With the burner cover removed,

remove the four screws securing the pump end cover. Remove the filter and wash in kerosene. Replace the filter and end cover, ensure the 'O' ring is in position. Check for the presence of sludge or water.

Re-assemble in reverse order.

To ensure safe and efficient operation of the boiler it is important that re-commissioning is carried out, especially combustion checks (CO2 level, flue gas temperature and smoke number) after the boiler has been serviced.

Refer to the Commissioning instructions starting on page 35.

Page 42

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

10 - WIRING DIAGRAMS

Control panel wiring diagram - Utility models

10.1

Control panel wiring diagram - System models

10.2

Limit

Thermostat

Control

Thermostat

G/Y

Boiler On/Off

LLENE

101112

PUMP

BURNER

G/Y

123 546

CENTRAL HEATING

DHW -ON

BOILER FEED

DHW -OFF

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

Boiler

Terminal

Blocks

N L

G/Y

CH OFF

HW OFF

CH ON

HW ON

Bl G/YBr

G/Y

BlBr

Programmer/Timer

Mains Supply:

Use 2 pole isolator with power ‘ON’ indicator

Note:

MUST

The factory fitted link between terminals 1 & 4 be removed when the plug-in programmer is fitted to the control panel.

G/Y

Control

Thermostat

CH OFF

HW OFF

CH ON

HW ON

Boiler

On/Off

Limit

Thermostat

G/Y

BOILER FEED

4321

DHW -ON

CENTRAL HEATING

65 978

G/Y

BURNER

DHW -OFF

N L

G/Y

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

G/Y

Boiler Terminal Block

Programmer/Timer

Mains Supply:

Use 2 pole isolator with power ‘ON’ indicator

Note:

MUST

The factory fitted link between terminals 1 & 4 be removed when the plug-in programmer is fitted to the control panel.

Page 43

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Utility models with CH and HW controlled by two 2-port zone valves

Typical control system wiring diagram - Utility models

10.3

Utility models with CH and HW controlled by 3-port mid position valve

Typical control system wiring diagram - Utility models

10.4

10 - WIRING DIAGRAMS

LN E

240 V 50 HZ

Frost

Thermostat

Pipe

Thermostat

(if fitted)

Wiring Centre

45 6 7 8 9 10

134NL

Cylinder

Stat

Room Stat

Pump

E N

2-port

Zone Valve

Motor

HTG

2-port

Zone Valve

Motor

DHW

Grey

Blue Blue

Brown

Green/Yellow

Orange

Grey

123456

LNE

78910

ENL

Boiler

Terminal Block

Remove link 1 to 4 when

plug-in programmer is fitted

Programmer/Timer

123456

LNE

78910

ENL

Supply to burner

Cylinder

Stat

LN E

240 V 50 Hz

Room

Stat

213

3-Port

Mid Position

Zone Valve

Pump

Blue

Green/Yellow

White

Grey

Orange

Frost

Thermostat

Pipe

Thermostat

(if fitted)

Wiring Centre

12345678910

134NL

Boiler Terminal Block

Remove link 1 to 4 when

plug-in programmer is fitted

Programmer/Timer

Page 44

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

10 - WIRING DIAGRAMS

System models with CH and HW controlled by two 2-port zone valves

Typical control system wiring diagram - System models

10.5

System models with CH and HW controlled by 3-port mid position valve

Typical control system wiring diagram - System models

10.6

LN E

240 V 50 HZ

Frost

Thermostat

Pipe

Thermostat

(if fitted)

Wiring Centre

45 6 7 8 9 10

134NL

Cylinder

Stat

Room Stat

Pump

Burner

2-port

Zone Valve

Motor

HTG

2-port

Zone Valve

Motor

DHW

Grey

Blue Blue

Brown

Green/Yellow

Orange

Grey

123456

LNE

8910

11 12

LNELNE

Boiler

Terminal Blocks

Remove link 1 to 4 when

plug-in programmer is fitted

Programmer/Timer

Cylinder

Stat

LN E

240 V 50 Hz

Room

Stat

213

3-Port

Mid Position

Zone Valve

Blue

Green/Yellow

White

Grey

Orange

Frost

Thermostat

Pipe

Thermostat

(if fitted)

Wiring Centre

12345678910

134NL

Pump

Burner

123456

LNE

8910

11 12

LNELNE

Boiler

Terminal Blocks

Remove link 1 to 4 when

plug-in programmer is fitted

Programmer/Timer

Page 45

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

10 - WIRING DIAGRAMS

Dual thermostat wiring diagram - Boiler House models

10.7

Overheat

Thermostat

Supply to

Burner

Mains

Supply

Control

Thermostat

Boiler Casing Earth

Connector to link Neutral wires (not supplied)

Note: No connection

to terminal 1

Note: No connection to terminal 2

Page 46

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

11 - FAULT FINDING

Burner fault finding

11.1

Motor/pump

seized

or tight

Replace

motor

capacitor

Burner

motor runs

Check L & N

to control

box

Check

boiler

controls

Motor gives

50 Volts

to white wire

Replace

burner

motor

Repair

or replace

motor/pump

Lockout

after 12 sec

purge

Lockout

within

1 second

Replace

solenoid

coil

Coil of

solenoid

sound **

Repair or

replace

oil pump

Washing

pressure

1to2bar

Photocell

sound ***

If balanced flue,

remove air tube

and retest

Reseal

balanced flue

or reposition flue

Replace

photocell

Drive

coupling

broken

Pump

produces

pressure

Replace

nozzle

Contaminated

fuel or

filter

Combustion

air set

Flame off

and

relights

Boiler or

flue

blocked

Combustion

head set

YES

Check and

set the

electrodes

Replace

the

control box

Ignition

spark

proved

Solenoid

valve

operating

Replace

control

box

Check oil

pressure

regulator

Replace coil

and/or

stem valve

Nozzle

atomising

fuel

YES

Notes

***

Motor white wire returns 50 - 53 V AC

to control box.

Test solenoid coil for continuity or 100

ohms.

Test photocell by disconnecting it in

control box. If burner fires and then

goes to lockout, photocell should be

replaced.

It is best to replace the photocell if it is

suspect.

Burners on balanced flue systems can

recirculate flue products causing

burner recycling. If this happens,

check flue position and sealing.

Page 47

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

11 - FAULT FINDING

Warning: Always isolate the electricity supply to the boiler before working on the boiler.

Ensure that an adequate supply of fuel is available and that the fuel supply valve is open. Check the condition of the fuel filter, clean if necessary. Ensure fuel supply is reaching burner and vent pump.

Ensure electricity supply to the boiler is switched on and that all controls are calling for heat. Ensure that the overheat thermostat has not tripped, reset if necessary. Check that a mains supply is present at the burner terminal block. If not, check the boiler and overheat thermostat.

Press the reset button on the burner control box if it is lit. Refer to burner fault finding flow diagram.

If the flame is unstable, check the combustion settings. Refer to burner fault finding flow diagram.

Insufficient air supply - check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 4.6. Check the nozzle size and type. Fuel pressure may be too high - check and adjust.

Insufficient air supply - check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 4.6. Check the nozzle size and type.

Undersize nozzle and/or low fuel pressure. Check condition of boiler heat exchanger and clean if necessary. Check the boiler thermostat. Check the combustion settings. Check the condition of the fuel filter.

Faulty boiler thermostat.

Check the condition of the chimney, ensure it is not blocked and is high enough to produce the required draught. Check that there is an adequate air supply near the burner and that a kitchen fan is not drawing products out of the burner.

Check all fuel line connections, remake as necessary.

Check boiler cleaning cover and seal are correctly fitted. Check burner is correctly fitted onto flange. Check flue is correctly sealed into flue outlet of boiler. Check the condensate pipe and trap are operating correctly.

Faults Remedies

Boiler will not start

1 No fuel supply.

2 No electricity supply.

3 Burner not starting - fuel and

electricity supplies present.

4 Burner lights but goes to 'lock-out'.

Boiler works but:-

5 Visible smoke from flue or high

smoke number.

6 Burner pulsates.

7 Flame slow to stabilise during start up.

8 Water temperature low.

9 Boiler operating on overheat

thermostat.

10 Fumes and puffing during starting

(conventional flue).

11 Oil odours.

12 Combustion fumes smell.

Boiler fault finding

11.2

Page 48

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

Description Part No.

Cleaning door nut and washer set ..................................................... EFBS14

Double pole switch ........................................................................... EFBS19

Baffle set - 50/70 .............................................................................. UBS93

Baffle set - 50/90 .............................................................................. VBS12

Baffle set - 90/120 and 120/155 ........................................................ VBS13

Sealed system - Expansion vessel 10 litre - 50/70 ............................. MPCBS27

Sealed system - Expansion vessel 12 litre - 50/90 ............................. MPSS01

Sealed system - Expansion vessel 16 litre - 90/120 and 120/155 ...... MPSS07

Sealed system - Water pressure gauge .............................................. MPSS02

Sealed system pressure relief valve ................................................... MPSS03

Sealed system - Expansion vessel flexible hose ................................ MPSS04

Cleaning cover seal - 50/70 .............................................................. UBS15

Cleaning cover seal - 50/90 .............................................................. VBS15

Cleaning cover seal - 90/120 and 120/155 ........................................ VBS16

Overheat thermostat .......................................................................... TPBS33

Boiler thermostat .............................................................................. TPBS34

Circulating pump - 6 m head ............................................................ MPCBS23

Circulating pump - 7 m head ............................................................ VBS54

Vortex Indoor/Utility - Spare Parts

12.1

Burner Heads

12 - BOILER SPARE PARTS

20 dia.

15 x 4.5dia.

5 x R5

T2 - 50/90

20dia.

15 x 5.5dia.

5 x R5

T3 - 90/120

23dia.

15 x 5.5dia.

5 x R5

T5 - 120/155

18dia.

15 x 4dia.

5 x R3

T1 - 50/70, 50/90

GIB - 155/200, 200/240

Page 49

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

13 - BURNER SPARE PARTS

Riello RDB1, 2, 2.2 burner - exploded view

13.1

1 Not applicable ........................................... -

2 Flange ....................................................... 3005786

3 Combustion head T1 - 50/70 ..................... 3002507

3 Combustion head T2 - 50/90 ..................... 3002423

3 Combustion head T3 - 90/120 ................... 3002447

3 Combustion head T5 - 120/155 ................. 3002533

4 Electrode assembly .................................... 3007513

5 Electrode bracket ...................................... 3006552

6 Nozzle holder ............................................ 3008642

7 Collar ........................................................ 3008643

8 High voltage lead ...................................... 3008794

9 Air damper assembly ................................. 3008647

10 Fan - 50/70 ................................................ 3005708

10 Fan - 90/120 .............................................. 3008645

10 Fan - 50/90, 120/155 ................................. 3005788

11 Photocell ................................................... 3008646

12 Capacitor 4.5 µF ....................................... 3002837

13 Seal kit ...................................................... 3008878

Key No. Description Part No.

14 Needle valve ............................................. 3007582

15 Regulator .................................................. 3008651

16 Pump seal .................................................. 3000439

17 Pump ........................................................ 3008654

18 'O' ring ...................................................... 3007162

19 Filter - 'O' ring ........................................... 3008653

20 Connector ................................................. 3003602

21 Flexible pipe ............................................. 3007672

22 Tube .......................................................... 3008644

23 Pressure gauge connector .......................... 3008876

24 Drive coupling .......................................... 3000443

25 Solenoid .................................................... 3008648

26 Motor RBS102 .......................................... 3002836

27 Cover ........................................................ 3008649

28 Control box assembly ................................ 3008652

29 Solenoid lead ............................................ 3008851

30 Cover ........................................................ 3008879

31 Air tube spigot .......................................... 3062774

Key No. Description Part No.

Page 50

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

13 - BURNER SPARE PARTS

Riello RDB3.2 burner - exploded view

13.2

1 Flange ....................................................... 3008637

2 Combustion head ...................................... 3002572

3 Diffuser disc assembly .............................. 3020180

4 Nozzle holder ............................................ 3002570

5 High voltage lead ...................................... 3008794

6 Collar ........................................................ 3008957

7 Seal kit ...................................................... 3008963

8 Air damper assembly ................................. 3008839

9 Insulation .................................................. 3008958

10 Fan ............................................................ 3005799

11 Photocell ................................................... 3008646

12 Cover ........................................................ 3008962

13 Electrode ................................................... 3020121

14 Capacitor 5 µF .......................................... 3008960

15 Connector ................................................. 3003602

16 Flexible pipe ............................................. 3007621

17 Motor ........................................................ 3008964

18 Pressure gauge connector .......................... 3008876

19 Tube .......................................................... 3008961

20 Drive coupling .......................................... 3000443

21 Solenoid .................................................... 3008648

22 Solenoid lead ............................................ 3008851

23 Pump ........................................................ 3008654

24 Pump seal .................................................. 3000439

25 Filter - 'O' ring ........................................... 3008653

26 Regulator .................................................. 3008651

27 Needle valve ............................................. 3007582

28 Control box assembly ................................ 3008652

29 Cover ........................................................ 3008649

Key No. Description Part No. Key No. Description Part No.

Page 51

Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers

14 - HEALTH AND SAFETY INFORMATION

Under the Consumer Protection Act 1987 and Section 6 of the Health & Safety at Work Act 1974, we are required to provide information on substances hazardous to health (COSHH Regulations 1988). Adhesives, sealants and paints used in the manufacture of the product are cured and present no known hazards when used in the manner for which they are intended. The following other materials are present in the product:

Insulation materials

Material Types: Ceramic fibre board, mineral wool.

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

Known Hazards: May cause temporary irritation or rash to skin. High dust levels may irritate eyes and upper

respiratory system.

Precautions: Avoid unnecessary or rough handling, or harsh abrasion of boards. Normal handling and use of

material should not produce high dust levels. Avoid inhalation, and contact with skin and eyes. After handling always follow normal good hygiene practices.

Protection: Use disposable gloves, face mask and eye protection.

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

immediate medical advice. Skin - If irritation occurs, wash under running water before washing with soap and water. Inhalation - Remove to fresh air, drink water to clear throat and blow nose to remove dust/fibres. Ingestion - Drink plenty of water.

Sealants

Material Types: Silicone elastomer.

Description: Sealant and adhesive.

Known Hazards: Irritation to eyes.

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

After handling always follow normal good hygiene practices.

Protection: Use eye protection. Rubber or plastic gloves should be worn where repeated contact occurs and a

face mask worn when working in confined spaces.

First Aid: Eyes - Flush eyes with water for 15 minutes. Seek immediate medical attention.

Skin - Wipe off and wash with soap and water. Inhalation - Remove to fresh air.

Kerosene and Gas oil fuels (Mineral oils)

Known Hazards: The effect of mineral oils on the skin vary according to the duration of exposure and the type of oil.

The lighter fractions remove the protective grease naturally present on the skin, leaving it dry, liable to crack and more prone to damage by cuts, abrasions and irritant chemicals. Skin rashes (Oil acne) most often on arms, but also on any part of the body in contact with oil or oily clothing. Contact with fuel oils can cause dermatitis.

Precautions: Avoid as far as possible any skin contact with mineral oil or with clothing contaminated with

mineral oil. The use of a lanolin-based barrier cream is recommended, in conjunction with regular washing with soap and rinsing with water to ensure all oil is removed from the skin. Take care to prevent clothing, especially underwear, from becoming contaminated with oil. Do not put oily rags or tools in pockets, especially trouser pockets. Have first-aid treatment at once for an injury, however slight. Do not inhale any vapours from mineral oils.

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D244

GRANT ENGINEERING (IRELAND) LTD.,

CRINKLE, BIRR, CO. OFFALY.

Telephone: (057) 9120089 / 9120352

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.

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

TERMS OF GUARANTEE

1. The Company shall mean Grant Engineering (Ireland) Limited.

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

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

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

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

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

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

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

15 - EC DECLARATION OF CONFORMITY

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

1. 89/336/EEC - Electromagnetic Compatibility Directive Referred to the generic standards EN 55014: 1993, EN 50082: 1: 1992

2. 73/23/EEC - Electrical Equipment Safety Regulations Directive Referred to the generic standard NO: 3260: The Electrical Equipment (Safety) Regulations: 1994

3. 92/42/EEC - Hot Water Boiler Efficiency Directive Referred to the generic standard The Boiler (Efficiency) (Amendment) Regulations 1994 (SI 1994/3083)

EFFICIENT HEATING SOLUTIONS