Grant Vortex Eco Series, Vortex Eco 26/35, Vortex Eco 15/21, Vortex Eco 21/26 Installation And Servicing Instructions
Grant Vortex Eco
External and System Floor Standing Condensing Oil Boiler Range
Installation and Servicing Instructions
UK | DOC 0081 | Rev 3.1 | June 2015
Important Note
For use with Kerosene* only.
After installing the boiler leave these
instructions with the User.
This appliance is deemed a controlled
service and specific regional statutory
requirements may be applicable.
*Operation on Bio-fuel
All Grant Vortex Eco condensing boilers,
manufactured since May 2011, are
suitable for operation on both standard
kerosene (Class C2 to BS2869) and also
bio-kerosene – up to a 30% blend (B30K).
All burner settings and nozzle sizes (as
detailed in Section 2.3 of this manual) are
correct for both standard kerosene and
bio-kerosene (B30K).
In order to operate this boiler on biokerosene it will be necessary to take
the following actions:
• Use a bio-kerosene (B30K
compatible flexible oil line in place of
the oil line supplied with this boiler.
• Have your oil storage tank and oil
supply line (including all pipework,
sight gauges, filters, isolating valves,
fire valves, ed-aeration devices, etc.)
checked for their compatibility with
bio-kerosene (B30K).
Where necessary some, or all, of
these items may have to be replaced
with a bio-kerosene compatible
alternative.
• Check the suitability of the flue
system with Grant UK.
• Use only bio-kerosene (B30K) that
conforms to OPS24.
IMPORTANT
Under no circumstances should the boiler
be used with bio-kerosene without the
above actions being taken first.
Date:______________________________
Commissioning Engineer:_____________________________________________________
Tel. No:____________________________
Boiler model:_______________________ Boiler output:________________ kW
Fuel type: Kerosene / Bio-Kerosene
Nozzle size:________________________ Pump pressure:_____________________
Air setting:_________________________ Flue gas % CO2:____________________
Net flue gas temp:___________________ Smoke No:_________________________
System flushed: yes / no Corrosion inhibitor added: yes / no
Antifreeze added: yes / no
For Sealed systems only:
Expansion vessel size:______________________ litres
Expansion vessel charge pressure:___________ bar
Sealed system fill pressure (cold):____________ bar
Service Log
It is recommended that the boiler should be regularly serviced, at least once a year, and
the details entered in the Boiler Handbook by the service engineer.
Declaration of Conformity
We declare that the Grant VORTEX range of Oil Boilers equipped with Riello RDB
burners approved to EN 267: 1999 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)
GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes
???????
Wiltshire SN10 2EU
Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991
Email: info@grantuk.com www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are
changed in the interests of continued product improvement.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
2
2
© Grant Engineering (UK) Limited 2015. No part of this manual may be reproduced by any means without prior written consent.
Contents
1 Introduction 4
1.1 How a condensing boiler 4
works
1.2 Boiler description 4
1.3 Boiler components 5
2 Technical Data 6
2.1 Boiler technical data 6
2.2 Sealed system data - sealed 7
system models
2.3 Vortex boilers using Class 7
C2 kerosene
2.4 Flue gas analysis 7
2.5 Water connections 7
2.6 Boiler dimensions 8
3 Oil Storage and Supply 9
System
3.1 Fuel supply 9
3.2 Burner oil connection 11
4 Boiler Installation 13
Information
4.1 Introduction 13
4.2 Boiler location 13
4.3 Preparation for installation 13
4.4 Installing the boiler 14
4.5 Regulations compliance 14
4.6 Completion 14
4.7 Before you commission 14
4.8 Heating system design 15
considerations
4.9 Underfloor heating systems 15
4.10 Pipework materials 15
4.11 Sealed systems 15
4.12 Underfloor pipework 15
6 Condensate Disposal 17
6.1 General requirements 17
6.2 Connections 17
6.3 Pipework 17
6.4 External pipework 17
6.5 Condensate soakaway 17
6.6 Condensate trap 18
6.7 Condensate disposal 18
pipework
6.8 Inspection and cleaning of 18
trap
7 Sealed Systems 19
7.1 Sealed system installation 19
7.2 System models 20
7.3 Fill the sealed system 20
7.4 Pressure relief safety valve 20
7.5 Circulating pump 21
8 Electrical 23
8.1 Connecting the power 23
supply
8.2 Frost protection 23
8.3 Control system wiring 24
diagrams
8.4 Boiler control panel wiring 25
diagram
9 Flue and Air Supply 26
9.1 Air supply 27
9.2 Low level discharge flue 27
9.3 Horizontal system 27
9.4 Green system 28
9.5 Hybrid system 29
9.6 Coventional flue systems 29
10 Commissioning 30
10.1 Before switching on 30
10.2 Switching on 30
10.3 Running the boiler 31
10.4 Balancing the system 31
10.5 Completion 31
10.6 Air adjuster disc - 15/21 only 31
11 Boiler Servicing 32
11.1 Checking before servicing 32
11.2 Dismantling prior to servicing 32
11.3 Cleaning the boiler 34
11.4 Cleaning the burner 34
12 Fault finding 35
12.1 Boiler fault finding 35
12.2 Burner fault finding 36
12.3 Circulating pump fault 37
diagnosis
13 Spare Parts 38
13.1 Boiler parts list 38
13.2 Burner heads 38
13.3 Riello RDB2.2 burner 39
14 Health and Safety 41
Information
14.1 Insulation materials 41
14.2 Sealant materials 41
14.3 Kerosene and gas oil fuels 41
(mineral oils)
15 Recycling and disposal 42
16 Guarantee 43
5 Pipe Connections 16
5.1 Water connections 16
18 Notes 45
3
1 Introduction
This manual is intended to guide
Installers who have completed the
Grant Wood Pellet Boiler Installer
training course on the installation,
commissioning and servicing of the
Grant Spira Condensing Wood Pellet
Boiler.
A separate manual is available to guide
users in the operation of the boiler.
The following special text formats are
used in this manual for the purposes
listed below:
WARNING
!
Warning of possible human injury
as a consequence of not following
the instructions in the “warning”.
CAUTION
!
Caution concerning likely damage
to equipment or tools as a
consequence of not following the
instructions in the “Caution”.
NOTE
!
Used for emphasis or information
not directly concerned with the
surrounding text but of importance
to the reader.
1.1 How a Condensing Boiler
Works
During the combustion process,
hydrogen and oxygen combine to
produce heat and water vapour. The
water vapour produced is in the form
of superheated steam in the heat
exchanger. This superheated steam
contains sensible heat (available heat)
and latent heat (heat locked up in the
flue gas). A conventional boiler cannot
recover any of the latent heat and
this energy is lost to the atmosphere
through the flue.
The Grant Vortex Eco 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
4
the flue gases to their dew point
(approximately 55°C).
To ensure maximum efficiency, the
boiler return temperature should be
55°C or less, this will enable the latent
heat to be condensed out of the flue
gases.
• The boiler will achieve net thermal
efficiencies of 100%.
To achieve maximum performance
from the Grant Vortex Eco 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 Eco 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.
1.2 Boiler Description
Grant Vortex Eco External modules have
an insulated weatherproof enclosure
made of galvanised steel with a powder
coated finish, and are designed for
external installation, either against a wall
or free standing some distance away
from the property, as required.
The External modules are part of the
Grant range of automatic pressure jet
oil boilers which 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 conventional flue (Green
system (Figure 9-2) is also available
from Grant UK. Refer to Section 9.2 for
further details.
A Hybrid flue (Green/Orange) system
(Figure 9-3) is also available which
allows the External module to utilise an
existing chimney stack. Refer to Section
9.3 for further details.
Where an existing 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 9.3 for further details.
Where a rigid conventional flue 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 correct Grant
Starter Elbow in order to connect this
system to the boiler. Refer to Section 9
for further details.
The ‘Green’ and ‘Orange’ system
components can be used to construct
a flue of maximum vertical height 19
metres.
NOTE
!
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
guarantee on the boiler.
A horizontal system - see Figure
9-4, is also available up to 4 metres components available:
• Straight starter
• Extensions 150 mm, 250 mm, 450
mm and 950 mm
• Adjustable extension 195 to 270
mm
• 45° elbow
• Straight terminal
Green system
Standard external high level/vertical
flue starter kit - components available:
• External starter kit, straight or
elbow
• Extensions 150 mm, 250 mm, 450
mm, 950 mm
• Adjustable extension 195 to 270
mm
• 45° elbow
• High level terminal
• Vertical terminal
1.3 Boiler Components
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 UK, for two-pipe oil supply
systems (product code: RBS35 and
RBS36).
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 boiler control panel is fitted with
an ON/OFF switch, boiler thermostat
control knob and the manual reset
button for the overheat thermostat.
An optional indoor programmer is
available to purchase from Grant
UK which allows the User to set the
operating times for central heating and
hot water (product code: EPKIT).
To access the controls remove the
front panel by turning the handle at
the bottom and withdrawing the cover
forwards at the bottom.
Figure 1-1: Boiler controls for external modules
5
2 Technical Data
2.1 Boiler Technical Data - Vortex Eco
Model Unit 15/21 21/26 26/35
Water content litre 13 13 19
gal 2.9 2.9 4.2
Weight (dry) *
External modules
kg 113 (ex ternal module)
136 ( external system)
113 (external module)
136 ( external system)
142 (external module)
152 ( external system)
lb 249 (ex ternal module)
300 ( external system)
Flow connection 22 mm 22 mm 22 mm
Return connection 22 mm 22 mm 22 mm
Min. flow rate (∆ T=10°C) l/h l/h 1 780 2 200 2 980
Min. flow rate (∆ T=20°C) l/h l/h 890 1 100 1 490
Condensate connection 22 mm (only connect plastic)
Flue diameter (conventional) 100 mm
Waterside resistance ∆T=10°C mbar 28.5
Waterside resistance ∆T=20°C mbar 10
Maximum static head m 28
Minimum circulating head m 1
Boiler thermostat range °C 65 to 75
Limit (safety) stat shut of f temp. °C 111 ± 3
Max. hearth temperature °C Less than 50
Electricity supply 230/240 V ~ 50 Hz fused at 5 Amp
Motor power Watts 90
Starting current Amps 4.2
Running current Amps 0.85
Oil connection ¼ BSP Male (on end of flexible fuel hose)
Conventional flue draught N/m² Minimum 8.7 - Maximum 37
in wg Minimum 0.035 - Maximum 0.15
Maximum operating pressure - sealed system bar 2.0
Maximum operating pressure - open system bar 2.0
Maximum operating pressure - pressure relief
valve
bar 2.5
249 (external module)
300 ( external system)
313 (external module)
335 ( external system)
* Weight includes burner but excludes flue.
6
2.2 Sealed System Data - Sealed System Models
15/21, 21/26, 26/35
Heating system pressure (cold) Maximum 1.0 bar / Minimum 0.5 bar
Operating pressure of pressure relief valve 2.5 bar
Expansion vessel size (pre-charged at 1 bar) 12 litres
Max. heating system volume (including boiler)* 128 litres - approximately
Cold water mains connection 15 mm copper pipe
Pressure relief valve discharge connection 15 mm copper pipe
Circulating pump head 7 m
* Based on vessel charge and system cold fill pressure of 0.5 bar
2.3 Vortex Eco Boiler Using Class C2 Kerosene
Model
and
burner
type
15/21
Riello
RDB2.2
21/26
Riello
RDB2.2
26/35
Riello
RDB2.2
Notes
1 The data given above is approximate only.
2 The above setting 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 Eco 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: 15/21 - 18.1 kW, 21/26 - 22.7 kW, 26/35 - 30.8 kW.
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 15/21 to 15.1 kW output the burner air adjuster disc requires repositioning. Refer to Section 10.
When setting the 21/26 to 20.7kW or the 26/35 to 25.6 kW output the combustion head must be changed. Refer to Section 11.4.
9 The installer must amend the boiler data label if the output is changed.
Heat Output SEDBUK
2009
(kW) (Btu/h)
annual
efficiency
Nozzle Oil
press.
(bar)
Smoke
No.
Burner
head
type
Burner
head/disc
setting
Fuel
flow
rate
(kg/h)
Flue
gas
temp.
(°C)
(%)
15.1 51 500
* 18.1 61 750 0.55/80°EH 7.5 0 - 1 T1 Disc setting C 1.53 75 - 80 11 - 12
20.7 70 600 0.60/80°EH 8.5 0 - 1 T1 Disc setting C 1.78 80 - 85 11 - 12
20.7 70 600
* 22.7 77 500 0.65/80°EH 8.5 0 - 1 T2 Fixed 1.95 85 - 90 11 - 12
25.6 87 350 0.75/80°EH 8.0 0 - 1 T2 Fixed 2.19 90 - 95 11 - 12
25.6 87 350
* 30.8 105 100 0.85/80°EH 9.1 0 - 1 T3 Fixed 2.65 85 - 90 11 - 12
34.7 118 400 1.00/80°EH 8.0 0 - 1 T3 Fixed 2.93 90 - 95 11 - 12
91.9
91.7
91.4
0.50/80°EH 7.0 0 - 1 T1 Disc setting B 1.29 70 - 75 11 - 12
0.60/80°EH 8.5 0 - 1 T1 Fixed 1.78 85 - 90 11 - 12
0.75/80°EH 8.0 0 - 1 T2 Fixed 2.19 75 - 80 11 - 12
CO
(%)
²
2.4 Flue Gas Analysis
To allow the boiler to be commissioned and serviced, the boiler is supplied with a combustion test point on the front cleaning door.
When this test point is used please note the following:
• The test point is for CO2 and smoke readings only.
• The boiler efficiency and temperature must be taken from the flue test point on high level, vertical and conventional flue adaptors.
• Concentric low level flues do not contain a test point. The temperature and efficiency readings must be taken from the flue
terminal.
2.5 Water Connections
Boiler model Flow connection Return connection
Size Fitting Supplied Size Fitting Supplied
15/21 22mm pipe Tectite elbow in fittings kit 22mm pipe Compression fitted
21/26 22mm pipe Tectite elbow in fittings kit 22mm pipe Compression fitted
26/35 22mm pipe Tectite elbow in fittings kit 22mm pipe Compression fitted
7
2.6 Boiler Dimensions
Figure 2-1: 15/21, 21/26 and 26/35 external module dimensions
8
3 Oil Storage and Supply System
3.1 Fuel Supply
Fuel Storage
The tank should be positioned in
accordance with the recommendations
given in BS 5410-1:2014, which gives
details of filling, maintenance and
protection from fire.
A steel tank may be used and must be
constructed to BS 799-5:2010 and OFS
T200.
CAUTION
!
A galavanised 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, that is, the area in
contact with the ground.
Fuel Pipes
Fuel supply pipes should be of copper
tubing with an external diameter of at
least 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.
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
5410-1:2014.
It is recommended that a good quality
metal bowl type fuel filter is fitted at the
tank and a secondary filter in the fuel
supply line adjacent to the boiler (15
µ for Kerosene) to protect the burner
pump and nozzle from contamination.
If the boiler operates on bio kerosene, a
compatible filter should be used.
A flexible fuel line, adaptor and ¼” 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 (900 mm)
and 3/8” to 1/4” BSP male adaptor are
available to purchase from Grant UK
(product codes: RBS35 and RBS36).
Metal braided flexible hoses should be
replaced annually when the boiler is
serviced. Long life flexible hoses should
be inspected annually and replaced at
least every 60 months.
Single pipe system (see Figure 3-1)
With the storage tank outlet above the
burner a 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.
Two pipe system (see Figure 3-2)
With the storage tank outlet below the
burner, a two pipe system should be
used. The pipe runs should be as
shown in Figure 3-2. The return pipe
should be 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.
Avoid the bottom of the tank being
more than 3.5 m below the burner.
A non-return valve should be fitted in
the supply pipe together with the filter
and fire valve. A non-return valve should
be fitted in the return pipe if the top of
the tank is above the burner.
To be used with a two-pipe system, the
burner must be fitted with an additional
flexible fuel pipe - a flexible fuel hose
(900 mm) and 3/8” to 1/4” BSP male
adaptor are available to purchase from
Grant UK (product codes: RBS35 and
RBS36).
The pump vacuum should not exceed
0.4 bar. Beyond this limit gas is
released from the oil.
For guidance on installation of top outlet
fuel tanks and suction oil supply sizing,
see OFTEC Technical Book 3. Available
from OFTEC.
CAUTION
!
Flexible hoses must NOT be used
outside the boiler case of Utility
models.
Figure 3-1: Single pipe system
As supplied the burner is suitable for a
single pipe system
9
Figure 3-2: Two pipe system
Figure 3-3: De-aeration device system
10
Tiger Loop system (See Figures 3-3 and 3-4)
When the storage tank outlet is below
the burner, an alternative to a two
pipe system can be achieved using a
‘Tiger Loop’ type oil de-aerator. This
effectively removes the air from the oil
supply on a single pipe lift.
The de-aerator is connected close
to the boiler as a two pipe system
(omitting the non-return valve) as shown
in Figure 3-3.
Refer to the manufacturers instructions
supplied with the de-aerator.
The de-aerator must be mounted
vertically. See Figure 3-3 and 3-4.
WARNING
!
To prevent any possibility of fuel
fumes entering the building, the
de-aerator must be fitted outside in
accordance with BS 5410-1:2014.
To be used with a de-aerator, the
burner must be fitted with an additional
flexible fuel hose (a flexible fuel hose
(900 mm) and 3/8” to 1/4” BSP male
adaptor are available to purchase from
Grant UK (product codes: RBS35 and
RBS36).
3.2 Burner Oil Connection
The burner 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, as
shown in Figure 3-5, into the tapping in
the return port.
The By-pass screw is supplied in the
boiler accessory pack.
Remove the plastic burner cover
(secured by two 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.
Remove and discard the blanking plug
from the return connection of the pump
and fit the By-pass screw using an
hexagonal key.
Connect the return oil flexible fuel pipe
to the pump.
Connect the 3/8” to 1/4” BSP adaptor to
the flexible fuel pipe.
Flexible fuel pipes and adaptors are
available to purchase from Grant UK.
The blanking plug supplied in the inlet
(suction) port may now be plastic and
will not provide an oil tight seal when
the pump is running.
Figure 3-5: Riello RDB pump
Item Description
1 Inlet (suction) port
2 Return port
3 By-pass screw
4 Pressure gauge port
5 Pressure adjustment
6 Vacuum gauge port
7 Solenoid
8 Nozzle outlet
Figure 3-4: Tiger loop de-aeration device
WARNING
!
Ensure that the supply from the tank
is connected to this port and that
the plastic plug is discarded.
11
Main Burner Components
It may be necessary to remove
theburner from the boiler to
accessconnections in the fuel pump.
Disconnect the flexible air tube from the
burner.
Remove the single nut at the top of the
burner (using a 13 mm spanner) and
withdraw the burner from the boiler.
NOTE
!
Remove the factory fitted air inlet
spigot adaptor (item 6) in Figure 3-6
from the air intake on the top right
hand side of the burner and fit the
grey plastic air inlet grille in its
place.
Burner Connection
If a two pipe system is to be used refer
to Section 3.2.
Remove and discard the blanking
plug from the inlet (suction) port of the
pump. Refer to Figure 3-5.
Connect the elbow of the flexible fuel
pipe supplied with the boiler to the inlet
port.
Connect the other end of the flexible
fuel pipe to the rigid supply line using
the adaptor supplied. The supply enters
through one of the holes in the casing
plinth.
12
Figure 3-6: Riello RDB burner components
Item Description
1 Oil pump
2 Control box
3 Reset button with lock-out lamp
4 Flange with gasket (do not remove from boiler)
5 Air damper adjustment screw
6 Air supply tube connection (balanced flue)
7 Pump pressure adjustment screw
8 Pressure gauge connection
4 Boiler Installation Information
4.1 Introduction
All models are supplied fully assembled
with the flue terminal guard supplied
loose inside the boiler.
4.2 Boiler location
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 Figure 9-4, 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.
4.3 Preparation for Installation
1. Carefully remove the packaging
from the boiler and remove it from
the transit pallet.
2. Remove the case top panel (four
screws) and also the front and rear
panels, as required.
3. The flue may exit the boiler from
the left, right or rear of the casing.
Carefully press out the pre-cut
section on the side or rear casing
panel to provide the opening in
the required position for the flue to
pass through the casing.
Fit the cover panel (with the round
flue exit hole) over the square
flue opening in the casing. Fit the
circular rubber sealing grommet,
provided, into the circular hole in
the cover panel before fitting the
flue terminal section.
4. Slacken the wing nuts holding the
flue elbow and rotate the elbow to
the required direction for the flue to
exit the casing.
5. Push the end of the flue terminal
section (with the red seal) through
the sealing grommet in the casing
panel.
The terminal section has been
factory lubricated. Take care not
to dislodge or damage the red flue
seal.
6. Carefully insert the terminal into
the flue elbow until the bend of
the terminal contacts the outer
casing, then, pull the terminal
forward approximately 25 mm and
rotate the bend so that the outlet is
horizontal.
Rear exit - The flue must
discharge away from the building.
Side exit - The flue should
discharge towards the rear of
the casing to prevent flue gases
re-entering the boiler casing
through the air inlet vents on the
casing front door.
The flue terminal must be fitted
horizontally to prevent dripping
from the end of the terminal.
7. Tighten the wing nuts holding the
flue elbow and fit the stainless
steel flue guard using the two
screws provided.
8. he top panel of the casing has
been designed so that it may be
fitted to create a slight slope away
from the side positioned against
the wall. To tilt the top panel,
loosen the four top panel casing
screws, one at each corner and
push down on the side furthest
from the wall. Tighten the screws.
See Figure 4-1.
Figure 4-1: Standard low level flue
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4.4 Installing the Boiler
1. 1. If the boiler is to be fitted against
the wall, prepare the wall to accept
the heating system pipework. To
mark the wall for drilling, refer
to Section 2.6 for the positions
of the pipework openings in the
enclosure sides.
NOTE
!
Pipework should be insulated
where it passes through the wall
into the boiler enclosure.
If the boiler is to be installed ‘free
standing’ (i.e. away from a wall)
and the pipework run underground,
push out the ‘knock-outs’ to open
the required pipe openings in the
base of the boiler enclosure. Using
a sharp knife, cut through the
polystyrene in the base, around
the edge of the holes, to allow the
flow and return pipes to enter the
enclosure.
2. The electrical supply to the boiler
should be routed through the wall
in a suitable conduit, such that it
enters the boiler enclosure via one
of the unused pipework openings.
The cable can be routed to the
front of the boiler, for connection to
the boiler control panel, either over
the top or beneath the boiler heat
exchanger. Heat resistant PVC
cable, of at least 1.0 mm² cross
section should be used within the
boiler enclosure.
3. The oil supply line should be
installed up to the position of the
boiler. Refer to Section 3.1 for
details. The final connection into
the boiler enclosure can be made
with 10 mm soft copper, routed
along the base of the enclosure
(either between the enclosure and
wall or in front of the enclosure)
to enter through one of the holes
located in the bottom edge side
panel, at the front (burner) end.
4.5 Regulations Compliance
Installation of a Grant VORTEX Eco
boiler must be in accordance with the
following recommendations:
• Building Regulations for England
and Wales, and the Building
Standards for Scotland issued by
the Department of the Environment
and any local Byelaws which you
must check with the local authority
for the area.
• Model and local Water Undertaking
Byelaws.
• Applicable Control of Pollution
Regulations.
• The following OFTEC
requirements:
• OFS T100 Polythene oil
storage tanks for distillate
fuels.
• OFS T200 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 Book 3
(Installation requirements for oil storage
tanks) and OFTEC Technical Book 4
(Installation requirements for oil fired
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 EN 1856-1:2009 Chimneys.
Requirements for metal chimneys.
System chimney products.
• 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, IET Wiring
Regulations.
NOTE
!
Failure to install and commission
appliances correctly may invalidate
the boiler guarantee.
WARNING
!
Before starting any work on the
boiler, or fuel supply please read
the health and safety information
given in Section 14.
4.6 Completion
Please ensure that the OFTEC CD/10
installation completion report (provided
with the boiler) is completed in full.
Leave the top copy with the User.
Retain the carbon copy.
Ensure that the User Information pack
(supplied with the boiler) is handed over
to the Householder.
4.7 Before you Commission
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 heating system must
be flushed in accordance with the
guidelines given in BS 7593:2006
‘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. Full instructions are
supplied with the products, but for more
details of BetzDearborn’s products,
view the website www.sentinelsolutions.net and for more details of
Fernox products view the website www.
fernox.com.
14
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 7593:2006.
Failure to implement these
guidelines will invalidate the
guarantee.
NOTE
!
We recommend that both antifreeze
and corrosion inhibitor be used in
the primary water system.
4.8 Heating System Design
Considerations
To achieve the maximum efficiency
possible from the Grant VORTEX Eco
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
Size radiators with a mean water
temperature of 60°C.
Design system controls with
programmable room thermostats or
use weather compensating controls
to maintain return temperatures below
55°C.
The use of a pipe thermostat is
recommended to control the return
temperature when using weather
compensating controls.
Refer to Section 2.5 for the size and
type of the connections and Section 5
for the position of the connections.
4.9 Underfloor Heating
Systems
In underfloor systems it is essential
that the return temperature must be
maintained above 40°C to prevent
internal corrosion of the boiler water
jacket.
4.10 Pipework Materials
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 7291-1: 2010) for the application
concerned.
WARNING
!
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.
4.11 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.
Plastic pipe must be Class S to BS
7291-1: 2010.
WARNING
!
The system must 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 to
purchase from Grant UK (product
code: MPCBS63).
4.12 Underfloor Pipework
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.
NOTE
!
The boiler should not be allowed to
operate with return temperatures of
less than 40°C when the system is
up to operating temperature.
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