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

USER, INSTALLATION

and

SERVICING INSTRUCTIONS

Vortex Outdoor Condensing Oil Boilers

For use with Kerosene only

Part No. IRL 007 Rev. 03 April 2010

Vortex External Modules

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

2

Grant Vortex External Module

Subject PageSection

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

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

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

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

5 Condensate disposal ................................. 20

6 Boiler installation ..................................... 21

7 Commissioning and Boiler passport ........ 31

8 Information for the user ........................... 33

9 Boiler servicing ........................................ 34

10 Wiring diagram ........................................ 37

11 Fault finding ............................................. 38

12 Burner heads ............................................ 40

13 Burner spares ........................................... 41

14 Health and safety information .................. 43

15 EC declaration of conformity .................. 44

LIST OF CONTENTS

3

Grant Vortex External Module

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.

1 - INTRODUCTION

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.

4

Grant Vortex External Module

2 - USER INSTRUCTIONS

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

An illuminated On/Off switch, see Fig. A, is fitted to the
External modules, which lights when the boiler is switched
on, but does not necessarily indicate the burner is firing.

To access the External module controls, remove the front
panel by turning the handle and withdrawing it forwards
at the bottom.

Controls for External modules - Fig. A

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 neon in the switch is not alight). The Test
switch is set to Off. The room thermostat (if fitted) is
at the desired setting. The boiler thermostat is set to
the required setting.

2 Switch on the electricity supply to the boiler.

3 Set the Boiler On/Off switch to on. A neon in the

switch lights when it is in the on position.

The boiler will now light automatically.

About your boiler

2.1

Boiler controls (see Fig. A)

2.2

Lighting your boiler (see Fig. A)

2.3

BOILER ON/OFF SWITCH
ISOLATES PUMP(IF WIRED
INTO BOILER CONTROL
PANEL) & BURNER ONLY.
THIS COVER ISTO BE
REMOVED BYQUALIFIED
PERSONNELONLY
DO NOTREMOVE COVER
WITHOUTISOLATING
SWITCHED LIVEAND
FROST'STAT
PERMANENTLIVE
TESTSWITCH
OVERIDES SYSTEM
CONTROLSTO
OPERATE BOILER

‘Lock-out’ reset button

Boiler front

panel removed

Control Panel

DANGER

THERE IS MORE THAN ONE LIVE SUPPLY TO
THIS CONTROL PANEL

BOILER

OFF

OVERHEAT

RESET

TEST

SWITCH

OFF

HEATING

THERMOSTAT

ON ON

REFER TO WIRING DIAGRAM IN MANUAL

Overheat thermostat

reset button

(under screw cover)

Boiler

thermostat

Boiler

On/Off switch

Test

switch

DANGER

THERE IS MORE THAN ONE LIVE SUPPLY TO
THIS CONTROL PANEL

BOILER

OFF

OVERHEAT

RESET

TEST

SWITCH

OFF

HEATING

THERMOSTAT

ON ON

REFER TO WIRING DIAGRAM IN MANUAL

5

Grant Vortex External Module

For short periods - Set the boiler switch to OFF.
To restart, set the switch to ON.

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

Note: If the electricity, fuel and water supplies are
turned off, the built-in frost thermostat will not
operate.

1 Check that the boiler switch is ON.

2 Check that any remote 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 External modules operate on Class C2
Kerosene only. 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.

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 Ventilation - Always ensure that the boiler has

adequate ventilation. Any ventilation openings
must not be obstructed. Periodically check that
they are clear.

Do not attempt to 'box in' the boiler or build a
compartment around.

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

Do not place anything against the door of the
External modules that might obstruct the
ventilation openings.

5 Flue terminal - The flue terminal must not be

obstructed or damaged.

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

2 - USER INSTRUCTIONS

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 External Module

6 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.

The control panel of the External modules includes
a built-in frost thermostat factory set to 5°C.

Note: For Vortex External modules we recommend
that a combined antifreeze and corrosion inhibitor
be used in the primary water system.

7 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.

Warning note - External equipment operated at

230 volts should not be serviced or repaired
under adverse weather conditions.

8 Failure of electricity supply - If the electricity

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

An automatic filling system should not be used on a
sealed central heating system.

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. Re­pressurise 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.

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.

2 - USER INSTRUCTIONS

Electricity supply

2.8

Sealed central heating system

2.9

Sealed system filling loop arrangement - Fig. B

7

Grant Vortex External Module

120/155

21

4.7

174

46

157,000

28 mm

28 mm

26.0 mbar

9.5 mbar

4.2 Amp

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

Condensate connection

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

Starting current

Running current

Oil connection

Max operating press - sealed sys

Max operating press - open sys

* Weight includes burner but excludes flue.

Vortex External Module

50/90

19

4.2

157

26

88,700

22 mm

22 mm

28.5 mbar

10.0 mbar

2.6 Amp

50/70

16.5

3.6

99

21

71,650

22 mm

22 mm

28.5 mbar

10.0 mbar

4.2 Amp

200/240

50

11

339

70

238,840

1¼" BSP

1¼" BSP

26.0 mbar

9.5 mbar

150 W max.

6.4 Amp

155/200

50

11

335

58

197,876

1¼" BSP

1¼" BSP

26.0 mbar

9.5 mbar

150 W max.

6.4 Amp

90/120

21

4.7

174

36

122,840

28 mm

28 mm

26.0 mbar

9.5 mbar

2.6 Amp

90 W max.

21.5 mm plastic overflow pipe

28 m

1m

65 to 75°C

111°C ± 3°C

Less than 50°C

230/240 V ~ 50 Hz Fused at 5 Amp

0.85 Amp

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

2.5 bar

2.5 bar

8

Grant Vortex External Module

3 - BOILER TECHNICAL INFORMATION

Note: Grant Vortex External modules are only for use with kerosene.

Grant Vortex External modules using Class C2 kerosene

3.3

Sealed system data - none available for 155/200, 200/240

3.2

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 50/90 to 51,200 or 68,240 Btu/h output or the 120/155 to 123,000 Btu/h output the combustion head must be changed. Refer to Section

7 Commissioning.
When setting the 50/70 to 51,200 Btu/h output the burner air adjuster disc requires repositioning. 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.

(kW)

15.0

18.3

21.0

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)

51,200

62,400

71,650

51,200

68,240

78,500

88,700

88,700

107,500

123,000

123,000

141,600

157,000

156,952

177,424

197,896

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

0.75/80°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

7.5

9.0

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

0 - 1

0 - 1

0 - 1

Fuel flow

rate

(kg/h)

1.29

1.56

1.83

1.25

1.67

1.94

2.18

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)

66

73

80

60 - 65

65 - 70

70 - 75

68

68

70

78

78

80

88

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

12.0

12.0

12.0

Burner

head type

T1

T1

T1

T1

T1

T2

T2

T3

T3

T3

T3

T5

T5

GIB

GIB

GIB

GIB

GIB

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

*

*

*

HARP/SEDBUK

efficiency

(%)

93

94 - 95

97

92.62

94.1

93.6

*

Air disc
position

B

C

C

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

*

*

Maximum 1.0 bar, Minimum 0.5 bar

2.5 bar

15 mm copper pipe

15 mm copper pipe

Model

Heating system pressure (cold)

Operating pressure of pressure relief valve

Expansion vessel size (approximately)

Max heating system volume (including boiler)

Cold water mains connection

Pressure relief valve discharge connection

Circulating pump head

50/70

10 litres

106 litres

6 m

50/90

12 litres

128 litres

6 m

90/120 and 120/155

16 litres

170 litres

7 m

Burner

head setting

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

0

0

0

0

0

4

9

Grant Vortex External Module

3 - BOILER TECHNICAL INFORMATION

Boiler dimensions

3.4

Fig 1b - 50/90, 90/120 and

120/155dimensions

Fig 1c - 155/200 and 200/240

dimensions

Fig 1a - 50/70

dimensions

4 holes
50mm dia.
in sides
covered with
movable plates

both

879

=

244

=

637

768

517

307

187

99
112

Side flue exit
if required

385

943

734

248

3 holes 50 mm dia.in base of boiler

enclosure covered with movable plates

4 holes
50mm dia.
in sides
covered with
movable plates

both

1154

587

945

233

68

50

1000

1154

816

418

179

1240

=

382

=

Side flue exit
if required

3 holes 50 mm dia.in base of boiler

enclosure covered with movable plates

4 holes
50mm dia.
in sides
covered with
movable plates

both

1005

505

800

269

908

=

320

=

117

132

50

756

A

698

417

192

Side flue exit
if required

3 holes 50 mm dia.in base of boiler

enclosure covered with movable plates

50/90 A = 815
90/120, 120/155 A = 825

10

Grant Vortex External Module

Grant Vortex External Modules have an insulated
weatherproof enclosure made of galvanised steel, and
are designed for external installation, either against a
wall or free standing some distance away from the
property, as required. For flue clearances see page 15.

The Vortex External modules are part of the Grant 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.

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

The factory fitted low level discharge flue system can
be adjusted on site for either rear, left hand or right
hand flue outlet position, as required.

An external Plume Diverter kit (Fig. 16) is also available
from your local stockist. Refer to Section 6.4 for further
details.

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 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 description

4.1

Boiler components

4.2

4 - GENERAL BOILER INFORMATION

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

a Local Building Regulations, and 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).

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 43.

Regulations to comply with

4.3

11

Grant Vortex External Module

4 - GENERAL BOILER INFORMATION

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. If a 'Tiger Loop' is fitted it should not be
fitted indoors or within a boiler casing.

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. 2)

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.

4.4.1 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 OFST 200.

A galvanised tank must not be used.

A plastic tank may be used and must comply with
OFST 100.

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

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 (not a fusible head type)

must be installed in the fuel supply line, with the
sensing head located above the burner.
Recommendations are given in BS 5410:1:1997.

Fuel supply

4.4

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 - Single pipe system

Filter

Fire
valve

Shut-off
valve

Shut-off
valve

A

Sludge
valve

Fill
pipe

Vent
pipe

Level
gauge

Fuel
storage
tank

Head A

(m)

Maximum pipe run (m)

0.5

1.0

1.5

2.0

10 mm OD pipe

10
20
40
60

12 mm 0D pipe

20
40
80

100

Fire
valve
sensor

Pump

1m

12

Grant Vortex External Module

4.4.5 Tiger Loop system - (See Figs. 4 and 5)

1 When the storage tank is below the burner, an

alternative to a two pipe system can be achieved
using the '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. 4. Refer to the manufacturers
instructions supplied with the de-aerator.
The de-aerator must be mounted vertically and
externally.

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 your local stockist. See
Section 4.4.6.

4.4.4 Two pipe system - (See Fig. 3)

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. 3. 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.

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

4 - GENERAL BOILER INFORMATION

Fig. 3 - Two pipe system

Filter

Fire
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

10 mm OD pipe

35
30
25
20
15

8
6

12 mm 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

1m

13

Grant Vortex External Module

4 - GENERAL BOILER INFORMATION

4.4.6 Two pipe oil supplies

Riello RDB burner - See Fig. 6

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. 6) into the tapping in the return port.

2 The By-pass screw is supplied in the boiler

accessory pack.

3 Remove the plastic burner cover (two screws).

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.

Fig. 4 - De-aeration device system

Fig. 5 - Tiger loop 'de-aeration' device

Fig. 6 - 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

1/4" BSP female

connections

Tiger Loop

SUPPLY

TO PUMP

RETURN

FROM PUMP

SUPPLY

FROM 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. 5

Fire
valve
sensor

Supply

1m

Return

14

Grant Vortex External Module

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 The boiler requires a permanent mains supply, do

not interrupt it with any external time control.

8 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.

1 External Modules are supplied with a factory fitted

frost protection thermostat, located inside the
boiler control panel. This is pre-wired to the boiler
electrical system and factory set to 5°C.

2 For total system protection against freezing,

particularly during extended periods without
electrical power, Grant recommend the use of a
combined heating system antifreeze and corrosion
inhibitor, used in accordance with the
manufacturer's instructions.

4 - GENERAL BOILER INFORMATION

1 The External Module must stand on a solid, level

surface capable of supporting the weight of the boiler
when full of water, e.g. a prepared concrete standing,
paving slabs bedded down on sand/cement, or similar.

2 The Module can be installed either against the building

or 'free standing' some distance away from the building.

3 The Module must be positioned such that the

required clearances from the low level flue outlet,
as shown in Fig. 7, are achieved.

4 Adequate clearance must be left around the Module

for servicing. In particular, a minimum clearance of
600 mm above the Module for removal of the top
panel and 600 mm at the opposite end to the flue outlet
for access to the burner.

Sufficient clearance is required at the rear of the
boiler to allow the rear panel to be removed for
access to the condensate trap.

5 The flue terminal must be a minimum distance of

1.8 m from an oil storage tank.

The flue terminal should be positioned so as to
avoid products of combustion accumulating in
stagnant pockets around the building or entering
into buildings.

Electricity supply

4.5

Frost protection

4.6

Boiler location

4.7