Grant Vortex 15/26, Vortex 46/58, Vortex 26/36, Vortex 36/46, Vortex 58/70 User, Installation And Servicing Instructions
USER, INSTALLATION
and
SERVICING INSTRUCTIONS
GRANT VORTEX
Condensing Oil Boiler range
For use with Kerosene only
Part No. DOC 37 Rev. 12 September 2006
Kitchen, Kitchen System,
Utility and Utility System Models
with outputs up to 70 kW
Utility model
Kitchen model
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
2
Grant Vortex Oil Boilers
Subject PageSection
1 Introduction.............................................. 3
2 User instructions ...................................... 4
3 Boiler technical information .................... 7
4 General boiler information....................... 11
5 Boiler installation..................................... 28
6 Commissioning......................................... 34
7 Information for the user ........................... 36
8 Boiler servicing ........................................ 36
9 Wiring diagrams....................................... 40
10 Fault finding ............................................. 43
11 Burner spares ........................................... 45
12 Health and safety information.................. 47
13 EC declaration of conformity .................. 48
Date:..............................
Commissioning engineer:.............................................................................. Tel. No: ....................................
Boiler model/output: ........................................ kW Fuel type: Kerosene
Nozzle size: .................................... Pump pressure: .................... Air setting:...........................
Flue gas % CO2: ............................. Net flue gas temp:................ Smoke No:...........................
It is recommended that the boiler should be regularly serviced, at least once a year, and the details entered in the Boiler
Handbook by the service engineer.
COMMISSIONING REPORT
SERVICE LOG
LIST OF CONTENTS
3
Grant Vortex 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
4
Grant Vortex Oil Boilers
2 - USER INSTRUCTIONS
The boiler will provide domestic hot water and central
heating and is fully automatic once switched on. Kitchen
models have a 'mains on' neon, see Fig. A, which lights
when the boiler is switched on, but does not necessarily
indicate the burner is firing.
If your model has a programmer fitted, it will provide
hot water and central heating during the periods set on
the programmer.
Kitchen and Kitchen System: To access the controls,
open the front door from the right (may be altered to
open from the left if required).
Utility and Utility System: Pull off the front access
panel.
Fig. A Boiler controls (Kitchen 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 in the control panel,
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
5
Grant Vortex 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. On Kitchen
models a neon on the control panel also indicates a
burner lock-out (see Fig. A). 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. On Kitchen models a neon on
the control panel will illuminate to indicate the overheat
thermostat has operated (see Fig. A).
If your boiler goes off and you try to light it but
nothing happens and the 'Lock-out' reset button on the
burner (or the neon on the control panel) are 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.
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
6
Grant Vortex Oil Boilers
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.
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.
2 - USER INSTRUCTIONS
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.
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
7
Grant Vortex Oil Boilers
22 mm (only connect plastic pipe)
28 m
1m
65 to 80° 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 line)
Minimum flue draught - 8.7 N/m² (0.035 in wg)
Maximum flue draught - 37 N/m² (0.15 in wg)
2.5 bar
2.5 bar
Boiler technical data
3.1
3- BOILER TECHNICAL INFORMATION
Model
Water content litre
gal
* Weight (dry) kg
lb
Max. heat output kW
(kerosene) Btu/h
Flow connection
Return connection
Min. flow rate (ΔT=10°C) l/h
Min. flow rate (ΔT=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 required for flexible flue liner (Orange system). For rigid flue system (e.g. Green system) 100 mm
diameter flue required. Refer to Sections 4.1 and 4.7 for further details.
Kitchen System
Utility Utility System
IMPORTANT: On all models except 46/58 and 58/70 Return connections are stainless steel pipe (see above for size).
Compression fitting MUST be used. Brass push-fit connectors are not suitable for use on stainless steel pipe.
Kitchen
90
2.6
0.85
90
4.2
0.85
90
2.6
0.85
150
6.4
1.2
15/26
19
4.2
119
262
26
88 700
22 mm
22 mm
2 200
1 100
15/26
19
4.2
127
280
26
88 700
22 mm
22 mm
2 200
1 100
15/26
19
4.2
112
246
26
88 700
22 mm
22 mm
2 200
1 100
26/36
21
4.7
134
295
36
122 840
28 mm
28 mm
3 000
1 500
36/46
21
4.7
134
295
46
157 000
28 mm
28 mm
4 000
2 000
46/58
50
11
295
649
58
197 896
1¼" BSP
1¼" BSP
5 200
2 600
58/70
50
11
299
658
70
238 840
1¼" BSP
1¼" BSP
6 000
3 000
90
4.2
0.85
26.0 mbar
9.5 mbar
28.5 mbar
10.0 mbar
100 mm (4 in) 100 mm (4 in)
26.0 mbar
9.5 mbar
125 mm (5 in)**
15/26
19
4.2
126.5
278
26
88 700
22 mm
22 mm
2 200
1 100
28.5mbar
10.0mbar
26/36
21
4.7
142
312
36
122 840
28 mm
28 mm
3 000
1 500
36/46
21
4.7
142
312
46
157 000
28 mm
28 mm
4 000
2 000
8
Grant Vortex Oil Boilers
Notes:
1 The data given above is approximate only and is based on the boiler being used with a low level balanced flue.
2 The above settings may have to be adjusted on site for the correct operation of the burner.
3 Gas Oil is not suitable for use with the Grant Vortex boiler range.
4 When commissioning the air damper must be adjusted to obtain the correct CO
2
level.
5 * Factory settings.
6 The combustion door test point may be used for CO2 and smoke readings only. Do not use this test point for temperature
or efficiency readings.
Flue gas analysis
To allow the boiler to be commissioned and serviced, the boiler is 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 CO
2
and smoke readings only.
2. The boiler efficiency and temperature must be taken from the flue test point on high level, vertical and conventional
flue adaptors.
3. Concentric low level flues do not contain a test point. The temperature and efficiency readings must be taken from the
flue terminal.
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
20.0
23.0
26.0
26.0
31.5
36.0
36.0
41.5
46.0
46.0
52.0
58.0
58.0
64.0
70.0
(Btu/h)
51 180
68 240
78 475
88 700
88 700
107 500
123 000
123 000
142 000
157 000
156 952
177 424
197 896
197 896
218 368
238 840
Nozzle
0.50/80°EH
0.60/80°EH
0.65/80°EH
0.75/80°EH
0.75/80°EH
0.85/80°EH
1.00/80°EH
1.00/80°EH
1.20/80°S
1.25/80°S
1.25/80°S
1.35/80°S
1.65/80°S
1.65/80°S
1.65/80°S
1.75/80°S
Oil
press.
(bar)
7.0
8.0
8.5
8.0
8.0
9.0
9.1
9.0
8.0
8.0
8.0
9.5
8.0
8.0
9.5
9.5
Smoke
No.
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
Fuel flow
rate
(kg/h)
1.25
1.67
1.94
2.16
2.18
2.57
3.01
3.01
3.56
3.90
4.01
4.47
5.05
5.05
5.58
6.01
Flue gas
temp.
(° C)
60 - 65
65 - 70
70 - 75
75 - 80
65 - 70
70 - 75
75 - 80
75 - 80
80 - 85
85 - 90
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
CO
2
(%)
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
Burner
head type
T1
T1
T2
T2
T3
T3
T3
T5
T5
T5
GIB
GIB
GIB
GIB
GIB
GIB
Heat Output
15/26
Riello RDB1
26/36
Riello RDB2
36/46
Riello RDB2.2
46/58
Riello RDB3.2
58/70
Riello RDB3.2
Model and
burner type
*
*
Sealed system data - System models (not 46/58 and 58/70)
3.2
*
Heating system pressure (cold)
Operating pressure of pressure relief valve
Expansion vessel size (15/26)
Expansion vessel size (26/36)
Expansion vessel size (36/46)
Max heating system volume (including boiler) (15/26)*
Max heating system volume (including boiler) (26/36)*
Max heating system volume (including boiler) (36/46)*
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
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
Burner
head setting
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
0
0
0
0
0
4
9
Grant Vortex Oil Boilers
FRONT VIEW
470
860
LEFT SIDE VIEW
813
759
709
487
587
352
18
17
110
30
Flue centre line
RIGHT SIDE VIEW
631
59
PLAN VIEW
470
603
110
22mm condensate drain
Safety valve
Cold fill
Flow - 22mm push-fit
22mm stainless
return
170
Flue
spigot
3 - BOILER TECHNICAL INFORMATION
Boiler dimensions
3.4
Fig 1a - Kitchen and Kitchen System 15/26 dimensions
Fig. 1b - Utility and Utility System 15/26 dimensions
10
Grant Vortex Oil Boilers
3 - BOILER TECHNICAL INFORMATION
Fig. 1c - Utility and Utility System 26/36 and 36/46 dimensions
Fig. 1d - Utility 46/58 and 58/70 dimensions
Safety valve
Flow - 28mm push-fit
Cold fill
61
170
61
LEFT SIDE VIEW
455
555
599
311
24
115
63
63
Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
470
603
150
22mm condensate drain
FRONT VIEW
470
900
28mm stainless
return
205
Flue
spigot
170
LEFT SIDE VIEW
731
831
1024
25
30
44 Dia.
44 Dia.
109
250
Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
563
786
109
22mm condensate drain
FRONT VIEW
563
1234
225
Flue
spigot
Note: Cover plate on
each side slides
forwards to provide
opening for pipes.
11
Grant Vortex Oil Boilers
4 - GENERAL BOILER INFORMATION
Boiler description
4.1
Green system......Standard external high level/
vertical flue starter kit (room sealed) - components
available:
External high level/vertical flue starter kit short
(room sealed)
Extensions 150 mm, 250 mm, 450 mm, 950 mm
and adjustable 195 to 270 mm
45° elbow
High level terminal
Vertical terminal
White system ...... High level concentric balanced flue
kit - components available:
Extensions 225 mm, 450 mm, 950 mm and
adjustable 275 to 450 mm
45° elbow
Vertical concentric balanced flue kit
Extensions 225 mm, 450 mm, 950 mm and
adjustable 275 to 450 mm
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
3
/8" to 1/4" BSP male adaptor are available to purchase
from Grant Engineering (UK) Limited, for two-pipe oil
supply systems, Part No. RBS104.
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. An optional plug-in
programmer is available to purchase from Grant
Engineering (UK) Limited for Kitchen models which
allows the User to set the operating times for central
heating and hot water, Part No. EPKIT.
Kitchen and Kitchen System: The boiler casing door is
factory fitted with the hinges on the left hand side. If
required, the door may be hinged on the right hand
side as follows:Remove the hinge pin from the top of the door and the
bottom hinge bracket. Refit them to the other side of
the door and boiler casing. Adjust the bottom bracket
until the door is correctly aligned.
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 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.
Where a rigid conventional flue - either internal or
external - is required, Grant recommends the use of the
Grant 'Green' and 'Orange' flue system components. As
no flue adaptor is supplied with the boiler it will be
necessary to purchase the Grant CF adaptor kit in
order to correctly connect the 'Green' and 'Orange
system flue components to the boiler.
Flue adaptor kit - Ref. CFA15/70 - is used for all Vortex
models from 15 to 70 kW as they all can use the 100 mm
'Green' and 'Orange' system components to construct a
flue of maximum vertical height 8 metres.
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 Grant UK.
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
12
Grant Vortex 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 12 on page 47.
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 Building Regulations for England and Wales,
and the Building Standards for Scotland issued
by the Department of the Environment and any
local Byelaws etc.
b Model and local Water Undertaking Byelaws.
c Applicable Control of Pollution Regulations.
d The following OFTEC requirements:-
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 - Kitchen System model
13
Grant Vortex 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 pipes 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 line, adaptor and 1/4" BSP isolation
valve are supplied loose with the boiler for the final
connection to the burner. If a two pipe system or
'Tiger Loop' type de-aerator is used, an additional
flexible fuel line (600 mm) and 3/8" to 1/4" BSP male
adaptor are available to purchase from Grant
Engineering (UK) Limited, Part No. RBS104.
6 Metal braided flexible pipes should be replaced
annually when the boiler is serviced. Long life
flexible pipes 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 line
(a flexible fuel line (600 mm) and 3/8" to 1/4" BSP
male adaptor are available to purchase from Grant
Engineering (UK) Limited), Part No. RBS104. 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
Shut-off
valve
A
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
14
Grant Vortex 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 deaerator. 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.
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 line (a
flexible fuel line (600 mm) and 3/8" to 1/4" BSP
male adaptor are available to purchase from Grant
Engineering (UK) Limited), Part No. RBS104. See
Section 4.4.6.
Filter
Fire
valve
Shut-off
valve
Shut-off valve
Shut-off
valve
See
section 4.4.6
A
Return
Supply
Head A
(m)
Maximum pipe run (m)
0
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
15
Grant Vortex 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 46/58 and 58/78:
Remove the plastic burner cover (secured by two
screws). To gain access, it may be necessary to
remove the plinth - loosen the screw securing the right
hand side of the plinth, then withdraw the plinth
forward from the right and away from the case.
On 46/58 and 58/70 models only:
Remove the plastic burner cover (secured by three
screws). It may be necessary to remove the burner
from the boiler to access the cover screws - see below.
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 line to the pump.
6 Connect the 3/8" to 1/4" BSP adaptor to the flexible
fuel line.
7 Flexible fuel lines and adaptors are available to
purchase from Grant Engineering (UK) Ltd.
1/4" BSP female
connections
Tiger Loop
SUPPLY
TO PUMP
RETURN
FROM PUMP
SUPPLY
FROM TANK
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
2
3
4
5
6
7
8
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
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