Grant Vortex Eco VTXWH12/16, Vortex Eco Series, Vortex Eco VTXWH16/21, Vortex Eco VTXSWH12/16, Vortex Eco VTXSWH16/21 Installation And Servicing Instructions
Grant Vortex Eco
Internal Wall Hung
Condensing Oil Boiler Range
Installation and Servicing Instructions
UK | DOC 0126 | Rev 1.1 | October 2018
IMPORTANT NOTE FOR INSTALLERS
These instructions are intended to guide installers on the
installation, commissioning and servicing of the Grant Vortex oil
boiler. After installing the boiler, leave these instructions with the
user.
A user handbook is available to guide users in the operation of the
oil boiler.
SPECIAL TEXT FORMATS
The following special text formats are used in these instructions
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.
PRODUCT CODES AND SERIAL
NUMBERS COVERED
The serial numbers used on Grant oil boilers consist of a fteen
digit numerical code with the nal three digits being the product
identier.
For example:
100000200218767
These instructions cover the following product codes and serial
numbers:
Product code Serial number identier
VTXWH12/16 767
VTXWH16/21 769
VTXSWH12/16 768
VTXSWH16/21 770
SERVICING
The boiler should be serviced at least every twelve months and
the details entered in the Service Log in the user handbook.
FUEL TYPE
All Grant Vortex boilers are suitable for use with Class C2
Kerosene. To use Bio-Kerosene (B30K), refer to the information
below:
OPERATION ON BIO-FUEL
All Grant Vortex condensing boilers manufactured since May 2011
are suitable for operation on both standard Kerosene (Class C2 to
BS 2869) and also bio-kerosene - up to a 30% blend (B30K).
All burner settings and nozzle sizes (as detailed in Section 2.2 of
these instructions) are correct for both standard kerosene and biokerosene (B30K).
In order to operate this boiler on bio-kerosene, it will be necessary
to take the following actions:
• Use a bio-kerosene (B30K) compatible exible oil line in
place of the oil line supplied with the boiler.
• Have the oil storage tank and oil supply line (including all
pipework, sight gauges, lters, isolating valves, re valves,
de-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 ue 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 rst.
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.
However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the
author or others involved in its publication.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited. No part of this manual may be reproduced by any means without prior written consent.
Page 2
CONTENTS
1 INTRODUCTION 4
1.1 How a condensing boiler operates 4
1.2 Boiler description 4
1.3 Flue options 4
1.4 Boiler components 5
2 TECHNICAL DATA 6
2.1 Boiler technical data 6
2.2 Sealed system data 6
2.3 Burner settings 7
2.4 Flue gas analysis 7
2.5 Water connections 7
2.6 Boiler dimensions 8
3 OIL STORAGE AND SUPPLY SYSTEM 9
3.1 Fuel supply 9
3.2 Burner oil connection 11
4 INSTALLATION 13
4.1 Introduction 13
4.2 Boiler location 13
4.3 Regulations 13
4.4 Heating system design 13
considerations
4.5 Pipework materials 14
4.6 Connections 14
4.7 Preparation for installation 14
4.8 Dismantling the boiler 14
4.9 Installing the boiler 16
4.10 Before you commission 17
4.11 Completion 17
5 PIPE CONNECTIONS 18
5.1 Water connections 18
5.2 Water connections - system models 18
6 CONDENSATE DISPOSAL 19
6.1 General requirements 19
6.2 Connections 19
6.3 Pipework 19
6.4 External pipework 19
6.5 Condensate soakaway 20
6.6 Condensate trap 20
6.7 Condensate disposal pipework 20
6.8 Inspection and cleaning of trap 20
9 FLUE SYSTEM AND AIR SUPPLY 28
9.1 Air supply 28
9.2 Conventional ue systems 28
9.3 Connecting a conventional ue 31
9.4 Balanced ue systems 31
9.5 Prepare the wall 35
9.6 Flue clearances 36
10 COMMISSIONING 38
10.1 Before switching on 39
10.2 Burner settings: 39
10.3 Switching on 40
10.4 Running the boiler 41
10.5 Balancing the system 41
10.6 Completion 41
11 SERVICING 42
11.1 Checks before servicing 42
11.2 Dismantling prior to servicing 42
11.3 Cleaning the boiler 43
11.4 Cleaning the burner 43
12 FAULT FINDING 45
13 SPARE PARTS 48
14 DECLARATION OF CONFORMITY 50
15 HEALTH AND SAFETY INFORMATION 51
15.1 Insulation materials 51
15.2 Sealant and adhesive 51
15.3 Kerosene and Gas Oil fuels 51
16 END OF LIFE INFORMATION 52
17 PRODUCT FICHE 53
17 GUARANTEE 54
7 SEALED SYSTEMS 21
7.1 Sealed system requirements 21
7.2 Filling the sealed system 22
7.3 Venting the pump 22
7.3 Pressure relief (safety) valve 22
operation
8 ELECTRICAL 23
8.1 General 23
8.2 Connecting the power supply 23
8.3 Frost protection 23
8.4 Control system wiring diagrams 24
8.5 Boiler control panel wiring diagrams 26
Contents Page 3
1 INTRODUCTION
1.1 HOW A CONDENSING BOILER
OPERATES
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 ue gas). A conventional boiler
cannot recover any of the latent heat and this energy is lost to the
atmosphere through the ue.
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 ue gases
to below 90°C, thus extracting more sensible heat and some of
the latent heat. This is achieved by cooling the ue gases to their
dew point (approximately 55°C).
To ensure maximum efciency, the boiler return temperature
should be 55°C or less, this will enable the latent heat to be
condensed out of the ue gases.
• The boiler will achieve net thermal efciencies 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 ow and return is
maintained.
The Grant Vortex boiler will however still operate at extremely
high efciencies even when it is not in condensing mode and
therefore is suitable for tting to an existing heating system
without alteration to the radiator sizes. The boiler is capable of a
maximum ow temperature of 78°C.
1.2 BOILER DESCRIPTION
The Grant Vortex Eco Wall Hung range of automatic pressure jet
oil boilers have been designed for use with a fully pumped central
heating system with indirect domestic hot water cylinder.
They are not suitable for use with either a direct cylinder or a
‘primatic’ cylinder or gravity hot water.
The boilers are suitable for use on open vented or sealed central
heating systems. System models are supplied with the necessary
components factory tted. Refer to Section 7.
All boilers are supplied with the control panel and burner factory
tted.
All the models in the current Grant Vortex Pro range of boilers are
designed to comply with the maximum NOx emissions* under the
Energy-related Products Directive (ErP).
* From the 26th September 2018, the maximum NOx emissions
for all new oil red boilers (up to and including 400kW for both
new build and replacement boiler installations) is 120mg/kWh.
1.3 FLUE OPTIONS
The boilers can be connected to either a conventional ue system
or a balanced ue system, as required.
1.3.1 FOR CONVENTIONAL FLUE APPLICATIONS
Where a chimney is to be lined - Grant recommends the use
of the Grant ‘Orange’ ue system, specically designed for the
Vortex range of condensing boilers. Refer to Section 9.2 for
further details.
Where a rigid conventional ue - either internal or external - is
required, Grant recommends the use of the Grant ‘Green’ and
‘Orange’ ue system components. As no ue adaptor is supplied
with the boiler it will be necessary to purchase the Grant CF
adaptor kit in order to correctly connect this system to the boiler.
Flue adaptor kit (Grant product code: CFA15/70) is used for all
models as they all use the 100 mm ‘Green’ and ‘Orange’ system
components to construct a ue of maximum vertical height of 8
metres.
! NOTE !
The ue system materials and construction MUST be
suitable for use with oil-red condensing boilers. Failure
to t a suitable conventional ue may invalidate the
guarantee on the boiler.
1.3.2 FOR BALANCED FLUE APPLICATIONS
The following ue kits are available from Grant UK. Refer to
Section 9.4.
Yellow system
Standard low level concentric balanced ue - components
available:
• Low level concentric balanced ue short
• Extensions 225 mm, 450 mm and 675 mm
• 90° extension elbow
• 45° extension elbow
• 45° elbow
• Plume diverter kits
Green system
Standard external high level/vertical ue starter kit (room sealed) -
components available:
• External high level/vertical ue starter kit short (room sealed)
• Extensions 150 mm, 250 mm, 450 mm, 950 mm
• Adjustable extension 195 to 270 mm
• 45° elbow
• High level terminal
• Vertical terminal
White system
High level and vertical concentric balanced ue kit- components
available:
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable 275 to 450 mm
• Vertical concentric balanced ue kit
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable extension 275 to 450 mm
• 45° elbow
Red system
A exible vertical balanced ue system designed to be tted inside
an existing masonry chimney.
Consisting of three sections:
• Concentric white painted ue pipe connected to the boiler
• Vertical concentric exible ue (exible stainless steel ue liner
inside a stainless steel air inlet liner)
• Terminal assembly for chimney top mounting
Flue extensions and 45° elbows from the White system may be
used.
Fitting instructions for the Low level, High level and Vertical
balanced ue systems are supplied with the kits.
Section 1: IntroductionPage 4
1.4 BOILER COMPONENTS
All burners are pre-set for use with kerosene and are supplied
ready to connect to a two pipe fuel supply system with a two
exible fuel lines and 3/8ʺ to 1/4ʺ BSP male adaptor supplied with
the boiler.
The temperature of the water leaving the boiler to heat the
radiators and hot water cylinder is user adjustable.
The boiler is tted 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 110°C ± 3°C.
The control panel is tted with an ON/OFF switch, boiler
thermostat control knob and the manual reset button for the
overheat thermostat.
To access the controls, open the lower front panel by pulling it
down as shown in Figure 1-1.
Figure 1-2 shows the details of the control panel.
Figure 1-1: Boiler lower front panel in down position
Figure 1-2: Vortex Pro boiler control panel
Section 1: Introduction Page 5
2 TECHNICAL DATA
2.1 BOILER TECHNICAL DATA
Table 2-1: Boiler technical data
Units
Water content
Weight - complete boiler (dry)
Weight - boiler shell only (dry)*
Maximum heat output (Kerosene)
Minimum ow rate (∆T=10°C) l/h 1,410 1,800 1,410 1,800
Minimum ow rate (∆T=20°C) l/h 730 900 730 900
Condensate connection Accepts 21.5 mm Ø polypropylene overow pipe
Flue diameter (conventional) mm 100
Waterside resistance ∆T=10°C mbar 28.5
Waterside resistance ∆T=20°C mbar 10.0
Maximum static head m 28
Minimum circulating head m 1
Boiler thermostat range °C 65 to 78
Limit (safety) thermostat shut off
temperature
Maximum casing temperature °C Less than 50
Electricity supply ~230 1ph 50Hz 5A fused
Burner motor power Watts 75
Absorbed motor power kW 0.155 0.143
Starting current Amps 2.7
Running current Amps 0.67
Oil connection ¼ʺ BSP male (on end of exible fuel hose)
Conventional ue draught
Maximum operating pressure sealed/open system
Maximum operating pressure pressure relief valve
Boiler type ON/OFF
* Weight of shell - without bafes and clean out door: 45.5kg
litre 11 11 11 11
gal 2.4 2.4 2.4 2.4
kg 91.1 91.1 98.0 98.0
lb 200.8 200.8 216.1 216.1
kg 56.5 56.5 56.5 56.5
lb 124.6 124.6 124.6 124.6
kW 16.5 21.0 16.5 21.0
Btu/h 56,300 71,700 56,300 71,700
°C 110 ± 3
mbar Minimum: 0.087 - Maximum: 0.37
in wg Minimum: 0.035 - Maximum: 0.15
bar 2.0
bar 2.5
Internal Wall Hung Internal System Wall Hung
12/16 16/21 12/16 16/21
2.2 SEALED SYSTEM DATA
Internal System 12/16 and 16/21
Heating system pressure (cold) Minimum 0.5 bar | Maximum 1.0 bar
Operating pressure of pressure relief valve 2.5 bar
Expansion vessel size (pre-charged at 1 bar) 8 litres
Maximum heating system volume (including boiler)* 85 litres
Cold water mains connection 15 mm compression (supplied)
Pressure relief valve discharge connection 15 mm compression (supplied)
* Based on vessel charge and system cold ll pressure of 0.5 bar
Section 2: Technical DataPage 6
2.3 BURNER SETTINGS
Table 2-2: Burner settings
Boiler
models
(burner
type)
Internal and
Internal
System 12/16
(Ecoam
Max 1 LN
Vortex WM
12-16 ERP)
Internal and
Internal
System 16/21
(Ecoam
Max 1 LN
Vortex WM
16-21 ERP)
Notes:
‡ Flue gas VFR: Flue gas volumetric ow rate
1. The data given above is approximate only and is based on the boiler being used with a low level balanced ue.
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 Grant Vortex boiler range
4. The ue gas temperatures given above are ± 10%.
5. When commissioning, the air damper must be adjusted to obtain the correct CO2 level.
6. * Factory settings: 12/16 - 14kW, 16/21 - 18.7kW.
7. The combustion door test point may be used for CO2 and smoke readings only. Do not use this test point for temperature or efciency readings.
8. The installer must amend the boiler data label if the output is changed.
Heat output
(kW) (Btu/h)
12.7 40,900 0.40/80°S 7 0 - 1 EK 12-16 30.5 1.06 60 - 65 12.5 13.0
14.0 * 47,80 0 0.40/80°EH 9 0 - 1 EK 12-16 31.5 1.17 65 - 69 12.5 15.0
16.5 56,300 0.50/80°EH 8 0 - 1 EK 12-16 32.5 1.38 65 - 69 12.5 17.0
16.5 56,300 0.50/80°EH 7 0 - 1 EK 16-21 29.5 1.38 65 - 69 12.5 17.0
18.7 * 63,800 0.50/80°EH 10 0 - 1 EK 16-21 31.0 1.56 70 - 75 12.5 20.0
21.0 71,700 0.60/80°EH 8 0 - 1 EK 16 - 21 31.0 1.76 75 - 79 12.5 23.0
Nozzle
Oil
pressure
(bar)
Smoke
No.
Burner
head type
Distance
between
nozzle and
burner head
Fuel
ow rate
(kg/h)
Flue gas
temp.
(°C)
CO
(%)
2
Flue gas
VFR ‡
(m³/hr)
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 CO
• The boiler efciency and temperature must be taken from the ue test point on high level, vertical and conventional ue adaptors.
• Concentric low level ues do not contain a test point. The temperature and efciency readings must be taken from the ue terminal.
and smoke readings only.
2
2.5 WATER CONNECTIONS
Table 2-3: Water connections
Boiler model
All models 22 mm Push-t Tectite Fitted 22 mm Push-t Tectite Fitted
Size Fitting Supplied Size Fitting Supplied
Flow connection Return connection
Section 2: Technical Data Page 7
2.6 BOILER DIMENSIONS
FRONT VIEW
TOP VIEW
BOTTOM VIEW
RIGHT SIDE VIEW
113
81
842
630,5
22
75
109
144
179
214
249
284
Oil
Flow
Return
Cold Mains
PRV
Condensate
Electricity
221
110
Flow
Return
Cold Mains
Electricity
23
109
179
144
214
BACK PANEL
221
87
128 375
102
419
BACK PANEL
221
87
128 375
102
630,5
73
100 100 290
842
419
*
Figure 2-4: Vortex Eco Internal and Internal System 12/16 and 16/21
Section 2: Technical DataPage 8
3 OIL STORAGE AND SUPPLY SYSTEM
3.1 FUEL SUPPLY
3.1.1 FUEL STORAGE
The tank should be positioned in accordance with the
recommendations given in BS 5410-1 (Code of Practice for
Oil Firing - Installations up to 45kW output capacity for space
heating and hot water supply purposes). This gives details of the
requirements for suitable oil tank construction, tank installation,
tank bases, re protection and secondary containment.
For installations of greater than 45kW output capacity, the tank
should be installed accordance with BS 5410-2.
Oil storage tanks should comply with the following standards:
• Plastic tanks OFT T100
• Steel tanks OFT T200
! CAUTION !
A galvanised tank must not be used.
! NOTE !
Plastic tanks should be stood on a rm non-combustible
base that adequately and uniformly supports the weight of
the tank over its entire base area.
The tank capacity should be selected to suit the appliance rated
output. Refer to BS5410-1 for guidance.
3.1.2 FUEL PIPES
Fuel supply pipes should be either copper or steel. Galvanised
pipes or ttings should not be used.
Plastic oil supply pipe conforming to BS EN 14125 can be used
for underground pipe runs, but must not be used above ground.
All soft copper pipe connections should preferably be made using
ared ttings. If compression ttings are to be used, a suitable
pipe insert must be tted into the pipe end.
Soft soldered connections must NOT be used on oil supply
pipework.
Fuel supply pipework should be of a suitable diameter, depending
on the type of oil supply system being used. Refer to information
given in sections 3.1.3, 3.1.4 or 3.1.5.
Run pipes as level as possible to prevent air being trapped. Take
the most direct route possible from tank to burner whilst locating
the pipe where it will be protected from damage.
Pipes should be supported to prevent sagging and sleeved where
they pass through a wall.
A metal body fuel lter of no better than 70 μm (micron) must be
tted in the oil supply pipe close to the tank. This should be tted
with sufcient clearance around and below it to allow easy access
for maintenance.
An isolating valve should also be tted at the tank, before the lter,
to allow the oil supply to be shut off for the lter to be serviced.
A second lter (15 μm for Kerosene) must be located closer to the
burner to protect the burner pump and nozzle from contamination.
Refer to Figures 3-1 to 3-3.
A remote sensing re valve must be installed in the fuel supply
line in accordance with BS540-1.
A fusible wheelhead type combined isolating/re valve MUST
NOT be used in place of a remote sensing re valve.
The re valve must be located outside; just before the oil line
enters the building, with the re valve sensor located above the
burner.
A spring clip for mounting the sensor is provided with the boiler.
This should be xed with the screw provided, using the small hole
in the front panel of the boiler.
The re valve should be located after the second (15 micron) lter,
i.e. between the lter and the point at which the oil line enters the
building. Refer to Figures 3-1 to 3-3.
The re valve must have an operating temperature of between
90 and 95°C to avoid unnecessary nuisance shut-offs to the oil
supply.
Two exible fuel hoses, adaptors and ¼ʺ isolating valves are
supplied loose with the boiler, to make the final connection to the
burner with a two pipe or ‘Tiger Loop’ type de-aerator.
Metal braided flexible fuel hoses should be replaced ANNUALLY
when the boiler is serviced.
Long life flexible fuel hoses should be inspected annually and
replaced, if necessary, or after a maximum five years service life.
3.1.3 SINGLE PIPE (GRAVITY) SYSTEM (REFER TO FIGURE 3-1)
Head
(metres)
0.5 19 60 100
1 21 66 100
1.5 23 72 100
2 25 79 100
2.5 27 85 100
3 29 91 100
3.5 31 98 100
If the storage tank outlet is at least 300 mm above the level of the
level of the burner oil pump, a single pipe (gravity) system should
be used.
The maximum height of the oil level above the burner oil pump
when the tank is full, must not exceed four metres. If this height
is exceeded, a pressure reducing valve must be tted in the oil
supply pipe between the tank and the burner oil pump.
The maximum length of pipe run from the tank to the burner is
limited by the minimum head of oil (the height of the tank outlet
above the burner oil pump).
Ø 6 mm Ø 8 mm Ø 10 mm
Maximum pipe run (m)
3.1.4 TWO PIPE SYSTEM (REFER TO FIGURE 3-2)
Head
(metres)
0.5 15 47 100
1 13 41 99
1.5 11 34 84
2 9 28 68
2.5 7 22 53
3 5 15 37
3.5 - 9 22
If the storage tank outlet is below the level of the burner oil pump,
a two pipe (sub gravity) system can be used.
The return pipe should be at the same level as the tank outlet,
between 75 to 100 mm above the base of the tank. The return
pipe should be a sufcient distance from the tank outlet so as to
prevent any sediment disturbed by the return entering the supply
pipe from the tank.
A non-return valve should be tted in the supply pipe, along with
a re valve and lters (refer to section 3.1.2 - fuel pipes). A nonreturn valve should also be tted in the return pipe if the top of the
tank is above the burner oil pump.
The maximum suction height (from the tank outlet to the level of
the burner oil pump), must not exceed 3.5 metres.
The pump vacuum should not exceed 0.4 bar. Beyond this limit,
gas is released from the oil.
For guidance on the installation of top outlet fuel tanks and suction
oil supply pipe sizing, refer to OFTEC Technical Book 3: Storage
and Supply, available for purchase from OFTEC.
Ø 6 mm Ø 8 mm Ø 10 mm
Maximum pipe run (m)
Section 3: Oil Storage and Supply System Page 9
123
2
6
12
9
7
4
8 5
4m Max
300mm
Min
7
123
2
6
12
9
7
4
8 5
4m Max
300mm
Min
123
2
6
12
9
7
4
11
3.5m Max
10
8 5
9
123
4m Max
12
8 5
Figure 3-1: Single pipe (gravity) system
7
9
12
8 5
Figure 3-2: Two pipe system
4
2
6
300mm
Min
11
4
2
6
10
123
3.5m Max
7
9
12 4
2
10
6
8 5
10
Figure 3-3: De-aeration device system
Key to oil supply diagrams
1 Oil tank 5 Heating ow and return 9 Burner
2 Isolating valve 6 Oil lter (15μm max. ltration size) 10 Non-return valve
3 Oil strainer 7 Fire valve sensor 11 De-aerator*
4 Fire valve to BS 5410 8 Oil pump 12 Appliance isolation valves
* Position of de-aeration device must be level with or above the oil pump
123
150mm
Section 3: Oil Storage and Supply SystemPage 10
3.5m Max
3.1.5 SINGLE PIPE (SUCTION) SYSTEM WITH
DEAERATOR - (REFER TO FIGURE 3-3)
If the storage tank outlet is below the level of the burner oil pump,
an alternative to the two pipe (sub gravity) system is the single
pipe (suction) system using a deaerator, e.g. a ‘Tiger Loop’
device.
The deaerator creates a loop with the burner oil pump, with the oil
being circulated through the pump out to the deaerator and back
to the pump. Any air in the single pipe lift from the tank is removed
from the oil, collected in the deaerator and then discharged to
outside.
! WARNING !
To prevent any fuel vapour being discharged within
the building, the deaerator must be tted outside, in
accordance with BS 5410-1, unless it is specically
designed to be installed inside.
The de-aerator must be mounted vertically at the same level as
(or above) the burner oil pump. Refer to Figure 3-3.
3.2 BURNER OIL CONNECTION
The burner fuel pump is supplied factory set for use with a two
pipe oil supply system.
For ease of access to the burner oil pump connections, the burner
should be removed from the boiler as follows:
1. Unscrew and remove the single burner fixing nut from the
stud on the burner flange (at the top of the burner) using a 13
mm spanner. Retain the fixing nut for re-fitting the burner.
2. Rotate the burner clockwise and carefully withdraw the
burner from the boiler. Refer to Figure 3-5.
RETURN
FROM PUMP
SUPPLY
TO PUMP
Figure 3-4: Tiger loop de-aeration device
An external deaerator must not be tted within 500 mm of a ue
terminal.
Always follow the manufacturers installation instructions supplied
with the deaerator.
Tiger Loop
1/4" BSP female
connections
SUPPLY
FROM TANK
Figure 3-5: Burner removal
SINGLE PIPE (GRAVITY) SYSTEM
For use on a single pipe system, it is necessary to t the
‘horseshoe’ washer into the tapping in the pump. Refer to Figure
3-6.
Figure 3-6: Fitting/location of ‘hoseshoe’ washer
Section 3: Oil Storage and Supply System Page 11
This page is intentionally left blank.
Section 3: Oil Storage and Supply SystemPage 12
4 INSTALLATION
4.1 INTRODUCTION
The boiler is supplied already fully assembled in a carton which
is carefully packed with packing materials. As the boiler is wall
mounted all of the content of the boiler casing must be removed
with the packaging before installation can begin, to give access to
the rear xing panel.
The installation procedure therefore begins with unpacking and
dismantling of the packed boiler.
4.2 BOILER LOCATION
The boiler should be xed to a wall that is rm, at and vertical. It
does not require any special base provisions as the temperature
of the boiler casing is less than 50°C.
Sufcient clearance must be allowed at the front of and below the
boiler to remove the burner and bafes for servicing.
4.3 REGULATIONS
! NOTE !
Failure to install and commission appliances correctly may
invalidate the boiler guarantee.
Installation of a Grant Vortex boiler must be in accordance with
the following recommendations:
• Building Regulations for England and Wales, or the Building
Standards for Scotland, as appropriate.
• Any relevant local Byelaws which you must check with the
local authority for the area concerned.
• The Water Supply (Water Fittings) Regulations 1999 or
the Water Supply (Fittings) (Scotland) Byelaws 2014, as
appropriate.
• 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 red
boilers).
The installation should also be in accordance with the latest
edition of the following British Standard Codes of Practice (and
any relevant amendments):
• BS 5410-1 (Code of practice for oil ring. Installations up
to 45 kW output capacity for space heating and hot water
supply purposes)
• BS EN 12828 (Heating systems in buildings. Design for
water-based heating systems)
• BS EN 12831-1 (Energy performance of buildings. Method
for calculation of the design heat load)
• BS EN 14336 (Heating systems in buildings. Installation and
commissioning of water-based heating systems)
• BS 7593 (Code of Practice for treatment of water in domestic
hot water central heating systems)
• BS 7671 (Requirements for Electrical installations, IET Wiring
Regulations)
• BS 7291 (Thermoplastics pipe and tting systems for hot and
cold water for domestic purposes and heating installations in
buildings. General requirements)
• BS 7074-1 (Application, selection and installation of
expansion vessels and ancillary equipment for sealed water
systems. Code of practice for domestic heating and hot water
supply)
• BS 2869 (Fuel oils for agricultural, domestic and industrial
engines and boilers. Specication)
4.4 HEATING SYSTEM DESIGN
CONSIDERATIONS
! WARNING !
Before starting any work on the boiler or fuel supply,
please read the Health and Safety information given in
Section 15.
To achieve the maximum efciency 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
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.
! NOTE !
The boiler should not be allowed to operate with return
temperatures of less than 40°C when the system is up to
temperature.
The use of a pipe thermostat is recommended to control the return
temperature when using weather compensating controls.
UNDERFLOOR:
• Flow temperature 50°C
• Return temperature 40°C
• Differential 10°C
In underoor systems, it is essential that the return temperature
must be maintained at or above 40°C to prevent internal corrosion
of the boiler water jacket.
Refer to Section 2.5 for the size and type of the connections and
Section 5 for the position of the connections.
OPEN VENTED SYSTEMS:
! NOTE !
The presence of ‘pumping over’ in an open vented heating
system connected to the Grant Vortex boiler will invalidate
the product guarantee.
Open vented systems must be correctly designed and installed.
The open safety vent pipe must be positioned to prevent ‘pumping
over’ (i.e. the discharge of water from the open safety vent pipe
into the feed and expansion cistern under the pressure created
by the circulator).For detailed information on the correct design of
open vented heating systems, and the correct location of the open
safety vent pipe, refer to the CIBSE Domestic Heating Design
Guide and OFTEC Technical Book 4 (Installation).
Section 4: Installation Page 13
4.5 PIPEWORK MATERIALS
Grant Vortex boilers are compatible with both copper and plastic
pipe. Where plastic pipe is used it must be of the oxygen barrier
type and be the correct class (to BS 7291-1) for the application
concerned.
On either sealed or open-vented systems; where plastic pipe is
used a minimum of ONE metre of copper pipe (or as per pipe
manufacturers instructions) MUST be connected between both
the boiler ow and return connections and the plastic pipe.
! NOTE !
Do not connect plastic pipe directly to the boiler.
Grant UK does not accept any responsibility for any damage,
however caused, to plastic piping or ttings.
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.
4.7 PREPARATION FOR
INSTALLATION
The following procedure must be performed before you can begin
dismantling the boiler for installation:
1. With the boiler on the pallet, open the carton and remove all
packing materials and the carton from the boiler.
2. Lift open lower front panel, slide panel to left or right and
detach from the boiler.
! WARNING !
When plastic pipe is used, the system MUST incorporate
a low level 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: MPCBS62).
UNDERFLOOR PIPEWORK
Plastic pipe may be used on underoor oor systems where the
plastic pipe is tted after the thermostatic mixing valve. Copper
tube must be used for at least the rst metre of ow and return
primary pipework between the boiler and the underoor mixing/
blending valves.
4.6 CONNECTIONS
4.6.1 FLOW AND RETURN CONNECTIONS
Refer to Section 5.
4.6.2 CONDENSATE CONNECTION
Grant Vortex Pro boilers are supplied with a factory-tted
condensate trap to provide the required 75 mm water seal in the
condensate discharge pipe from the boiler.
Refer to Section 6 for details of the condensate disposal pipework.
4.6.3 DRAIN COCK
A drain cock is tted at the bottom on the front of the boiler to
allow the heating system to be drained.
Figure 4-1: Boiler front panel open
3. Remove upper front panel. Pull bottom edge of panel sharply
upwards to disengage retaining clips and lift off from boiler
4. Remove internal packaging from within boiler casing.
5. Remove lling loop and exible oil hose packs from within
boiler.
4.8 DISMANTLING THE BOILER
Dismantle the boiler as follows, keeping all components, screws
and washers for re-assembly:
1. Slacken off hose clip on burner air inlet and remove snorkel
tube from boiler.
2. Unscrew earth wire from underside of top casing panel.
3. Slacken the three screws at rear of top casing panel.
Remove screws securing top panel to side panels.
Pull top front corner of side casing panel on both sides by 10
mm outwards to disengage tabs on top casing panel.
Pull top panel forwards to remove from boiler.
4. Disconnect plug from burner control box.
5. System model only – Disconnect plug from pump.
6. Unscrew inlet connection to condensate trap and remove
trap from boiler.
7. Remove retaining clip and thermostat phials from their pocket
(in right side of heat exchanger – below return connection).
Figure 4-2: Removing thermostat phials
8. System model only - Unscrew and disconnect pressure
gauge pipe from PRV body.
9. Slacken control panel retaining screws and remove control
panel from boiler.
Section 4: InstallationPage 14
10. Remove the two screws securing right hand side panel to
bottom panel. Remove right hand side panel from boiler by
lifting upwards to disengage tabs.
11. Repeat procedure to remove left hand side panel from boiler.
12. Slacken the three screws at rear of bottom casing panel and
remove bottom panel from boiler.
13. System model only - Unscrew upper pump union and remove
pump, complete with ow pipe, from boiler.
Figure 4-4: Removing clean-out door
18. Remove bafes from boiler shell.
Figure 4-3: Removing ow and return pipe
14. Non-system model – Unscrew compression connection on
boiler shell and remove ow pipe from boiler.
15. Unscrew top right compression connection and remove
return pipe from boiler.
16. Using a 13mm socket, slacken burner retaining nut (on top
of burner). Rotate burner clockwise (towards rear of boiler),
pull burner to the right until burner head is clear of mounting
ange and remove burner from boiler.
17. Using 13mm spanner, unscrew the two clean-out door
retaining nuts and remove door from front of boiler shell.
Figure 4-5: Removing bafes from boiler shell
19. Undo retaining screw and nut and remove transit bracket
from top of boiler shell.
20. Push boiler shell upwards to disengage it from mounting
bracket on back panel of boiler taking care not to damage the
insulation on the side of shell.
21. Lift boiler shell away from back panel and stand it upright on
the four feet.
22. Unscrew and remove the two transit screws securing
mounting bracket and back panel to pallet.
Section 4: Installation Page 15
4.9 INSTALLING THE BOILER
fixings supplied by Grant UK.
You are now ready to install the boiler.
The procedure is as follows:
1. If a back outlet ue system is to be used, remove the large
circular ue knock-out from back panel. If the rear outlet PRV
discharge is to be used, remove the knock-out from the back
panel (as shown in the gure below.
Figure 4-6: Installing the back panel
2. Locate and hold the back panel in the required position on
the wall. Check it is level using a spirit level on the top ange.
Mark position of the holes for the two keyhole slots. Remove
the back panel from the wall.
3. Drill and t wall xing plugs (supplied) in the two holes.
Fit the two screws (supplied) and mount the back panel on
the wall using the two keyhole slots.
Check again that the back panel is level before proceeding.
4. Mark the position of the four mounting bracket xings on to
the wall from the back panel. Also mark the positions of the
ow and return pipes, the cold mains (for lling loop), the
electrical power supply, and the condensate discharge pipe.
5. If using a back outlet ue and/or rear PRV outlet is to be
used, also mark these holes on to the wall.
Figure 4-7: Fixing the back panel
9. Unscrew and remove ue xing screw from ue outlet.
10. Lift the boiler shell and hang it on the mounting bracket –
ensuring that the mounting plates on either side of the shell
are fully located in the vertical slot of both mounting hooks.
11. Re-t the return pipe to top right hand connection on boiler
shell. Pass return pipe from system through hole in back
panel (either at top or bottom of panel, as required) and
connect to boiler return pipe.
! NOTE !
If side outlet ue is to be used (to either left or right) then
mark position as it may be necessary to cut ue hole
BEFORE installing boiler on to wall.
6. Remove the back panel from the wall. Drill the holes for the
mounting bracket xings and t the wall plugs provided. Drill
all other necessary holes. If required, core drill the wall for a
back outlet ue and drill a hole for the PRV discharge pipe.
Re-mount the back panel on the two keyholes slots.
7. Locate the mounting bracket on to the back panel, aligning
the four holes in the bracket with those in the back panel.
Ensure that the mounting ‘hooks’ are pointing upwards and
secure using the xings supplied with the boiler.
8. Check the mounting bracket is level.
Figure 4-8: Re-tting ow and return pipe
12. System model only - Re-t pump complete with ow pipe to
upper pump union on boiler shell. Ensure that rubber pump
union washer is tted. Pass ow pipe from system through
hole in back panel (either at top or bottom of panel, as
required) and connect to boiler ow pipe.
13. Non-system model – Re-t ow pipe to compression
connection on boiler shell. Pass ow pipe from system
through hole in back panel (either at top or bottom of panel,
as required) and connect to boiler ow pipe.
! NOTE !
It is recommended that the system ow and return pipes
are connected to the boiler at this point in the installation.
Two 22mm isolating valves are supplied for use with sealed
system models only. These must not be used on an open
vented system. These boiler isolating valves should be
located adjacent to the boiler in a convenient position.
14. Re-t burner. First remove burner securing nut, locate
burner head into hole in burner ange/boiler shell and locate
mounting screw through hole on top of burner. Re-t nut and
tighten to secure burner in place. Connect exible oil lines
Section 4: InstallationPage 16
from oil supply pipework to burner. It is recommended that
the copper oil lines are installed at this stage while the side
panels are not in place.
15. Re-t bafes into boiler shell – ensuring they are in the
correct order (check marking on each bafe) as shown
below.
Figure 4-9: Re-tting bafes into boiler shell
16. Locate clean-out door onto the two studs, re-t nuts and
tighten to secure door in place.
17. If side outlet ue system is to be used, remove ue ‘knock-
out’ from either the left or right side casing panel, as required.
18. Re-t left hand casing panel locating tabs on rear edge
of panel into slots in back panel. Firmly push side panel
downwards to fully engage tabs.
19. Repeat process to re-t right hand casing panel.
20. Pass ue through hole in side panel and secure.
21. Re-t bottom casing panel and secure in place with screws
(with washers).
22. If top outlet ue system is to be used, remove the ue ‘knock-
out’ in both the top casing panel and the top ange of the
back panel.
Fit the boiler connector (supplied in the ue kit) to the top of
the boiler shell, ensuring it is rmly connected and making a
seal on the neoprene gasket.
Refer to ue installation instructions for further details.
23. Re-t top casing panel and secure in place with screws (with
washers). Ensure that the ends of the front ange t into the
slots in the top front of side panels.
24. System model only - Re-t expansion vessel onto bracket
inside right hand side panel and reconnect expansion vessel
hose to connection on front right hand side of boiler shell.
Ensure rubber sealing washer is tted.
25. Re-t control panel – locating xing screws into slots in front
ange of bottom panel. Tighten screws to secure.
26. Re-locate thermostat bulbs in pocket at rear right hand side
of boiler shell.
27. System model only - Re-connect pressure gauge to PRV and
tighten.
28. Re-connect burner plug.
29. System model only - Re-connect pump plug.
30. Re-t condensate trap. Connect condensate discharge pipe
to outlet of trap.
31. Re-t snorkel tube to air inlet connection on burner. Tighten
hose clip to secure.
32. If balanced ue system is tted, connect other end of snorkel
tube to air inlet spigot of ue system.
33. If a conventional ue system is used, locate other end of
snorkel in top of boiler, ensuring that inlet to tube is not
restricted.
34. Fit ue system to boiler – refer to ue system installation
instructions.
35. Re-t upper front casing panel – hook top edge over front
edge of top panel, locate pins into spring retaining clip on
each side panel and push rmly home to secure.
36. Re-t lower front panel – with the panel at 45° to vertical,
locate the tabs into the horizontal slots in front of bottom
panel. Slide to either left or right and lift into closed position
against magnetic catches.
4.10 BEFORE YOU COMMISSION
To avoid the danger of dirt and foreign matter entering the boiler
the complete heating system should be thoroughly ushed
out – both 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 to be installed on an older system.
For optimum performance after installation, the boiler and the
associated heating system must be ushed in accordance with
the guidelines given in BS 7593 (Treatment of water in domestic
hot water central heating systems). This must involve the use
of a proprietary cleaner, such as Sentinel X300 (new systems),
Sentinel X400 (existing systems), or Fernox Restorer.
After cleaning, it is vitally important that all traces of the cleaner
are thoroughly ushed from the system.
For long term protection against corrosion and scale, after
cleaning/ushing a suitable inhibitor should be added to the
system water, such as Sentinel X100 or Fernox MB-1, in
accordance with the manufacturers’ instructions.
Failure to follow the above will invalidate the guarantee.
If the boiler is installed in a garage or out house, in order to
provide further protection should there be a power failure in cold
weather, a combined anti-freeze and corrosion inhibitor can
be used such as Sentinel X500 or Fernox Alphi-11. Follow the
manufacturers’ instructions supplied to achieve the level of antifreeze protection required.
For details of the Sentinel Products visit www.sentinel-solutions.
net and for Fernox products visit www.fernox.com.
Grant UK strongly recommends that a Grant Mag One in-line
magnetic lter/s (or equivalent*) is tted in the heating system
pipework. This should be installed and regularly serviced in
accordance with the lter manufacturer’s instructions.
* As measured by gauss. The MagOne magnetic lter has a gauss
value of 12000.
4.11 COMPLETION
Following installation of the boiler, instruct the user in the
operation of the boiler, the boiler controls, the heating controls and
the safety devices.
Please ensure that the OFTEC CD/10 installation completion
report (provided with the boiler) is completed in full, leaving the
top copy with the user and retain the carbon copy for your own
records.
Ensure that the User Handbook (supplied with the boiler) is
handed over to the user.
Section 4: Installation Page 17
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