Grant Vortex Pro, Vortex Pro Series, Vortex Pro 15/21, Vortex Pro 15/26, Vortex Pro 26/36 Installation & Servicing Instructions Manual

Part No. Doc 52 Rev.06 May 2012 D314

Grant Vortex Pro

External Module Condensing Oil Boiler Range

Installation & Servicing Instructions

2

Date: ______________________________

Commissioning Engineer: _______________________________________________

Tel. No: ____________________________

Boiler model: _______________________ Boiler output: _______________ kW

Fuel type: Kerosene / Bio-Kerosene

Nozzle size: ________________________ Pump pressure: _________________

Air setting: _________________________ Flue gas % CO

2

: ________________

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

Commissioning

Report

Commissioning Report

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 Pro 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:

a) Use a bio-kerosene (B30K)

compatible flexible oil line in place of
the oil line supplied with this boiler.

b) Have your oil storage tank and oil

supply line (including all pipework,
sight gauges, filters, isolating valves,
fire 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.

c) Check the suitability of the flue system

with Grant UK.

d) 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.

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or
appearances are changed in the interests of continued product improvement.
All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.

GRANT ENGINEERING (UK) LIMITED

Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU
Tel: [phone] Fax: [phone]
Email: [email protected] www.grantuk.com

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.

3

1 Introduction 4

1.1 How a condensing boiler works 4

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 6

2.3 Vortex boiler using Class C2 kerosene 7

2.4 Water connections 7

2.5 Flue gas analysis 7

2.6 Boiler dimensions 8

3 Oil Storage & Supply System 10

3.1 Fuel supply 10

3.2 Burner oil connection 11

4 Boiler Installation Information 13

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 considerations 15

4.9 Underfloor heating systems 15

4.10 Pipework materials 15

4.11 Sealed systems 15

4.12 Underfloor pipework 15

5 Pipe Connections 16

5.1 Water connections 16

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 pipework 18

6.8 Inspection and cleaning of trap 18

7 Sealed Systems 19

7.1 Sealed system installation 19

7.2 15/21 Sealed system kit 19

7.3 15/26 Sealed system kit 20

7.4 26/36, 36/46 Sealed system kit 21

7.5 Fit the expansion vessel 22

7.6 Fill the sealed system 22

7.7 Vent the pump 22

7.8 Pressure relief safety valve 22

Contents

8 Electrical 23

8.1 Connecting the power supply 23

8.2 Frost protection 23

8.3 Control system wiring diagrams 24

8.4 Boiler control panel wiring diagrams 26

9 Flue System and Air Supply 27

9.1 Low level discharge 27

9.2 Grant green system 27

9.3 Grant hybrid system 29

9.4 Grant horizontal system 30

9.5 Conventional flue systems 30

9.6 Air supply 30

10 Commissioning 31

10.1 Before switching on 31

10.2 Switching on 31

10.3 Running the boiler 32

10.4 Balancing the system 32

10.5 Completion 32

10.6 Air adjuster disc - 15/21 only 32

11 Boiler Servicing 33

11.1 Check before servicing 33

11.2 Dismantling prior to servicing 33

11.3 Cleaning the boiler 33

11.4 Cleaning the burner 34

12 Fault Finding 37

12.1 Boiler fault finding 37

12.2 Burner fault finding 38

13 Spare Parts 39

13.1 Boiler spares 39

13.2 Burner heads 39

13.3 Riello RDB1, 2, 2.2 burner spares 40

13.4 Riello RDB3.2 burner spares 42

14 Health & Safety Information 44

14.1 Insulation materials 44

14.2 Sealant materials 44

14.3 Kerosene and gas oil fuels (mineral oils) 44

15 EC Declaration of Conformity 45

16 Warranty 46

17 Notes 48

Contents

4

This manual is intended to guide
engineers in the installation and
maintenance of Grant VORTEX Pro
External modules. A User guide for the
operation of this boiler is attached to
the reverse of this manual.

The following special text formats are
used in this manual for the purposes
listed below:

Warning of possible human injury as
a consequence of not following the
instructions in the warning.

Caution concerning likely damage
to equipment or tools as a
consequence of not following the
instructions in the caution.

Note text. 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 Pro 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).

1 Introduction

NOTE

!

CAUTION

!

WARNING

!

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 Pro 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 Pro 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 Pro External modules
ha v e an in su l at e d we a th e rp roo f
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.

Introduction

An external conventional flue (Green)
system (Figure 9-3) is also available
from Grant UK. Refer to Section 9.2 for
further details.

A Hybrid flue (Green/Orange) system
(Figure 9-1) is also available which
allows the External module to utilise
an existing chimney stack. Refer to
Section 9.2 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 9.2 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 for further details.

The 'Green' and 'Orange' system
components can be used to construct
a flue of maximum vertical height 19
metres.

The flue system materials and
construction MUST be suitable
for use with oil-fired condensing
boilers. Failure to fit a suitable
conventional flue may invalidate the
warranty on the boiler.

A horizontal system - see Figure

9-4, is also available up to 3 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

NOTE

!

5

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 hose
and 3/8" to 1/4" BSP male adaptor
supplied with the boiler.

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, Part No. EPKIT.

To access the controls remove the
front panel by turning the handle at
the bottom and withdrawing the cover
forwards at the bottom.

Introduction

Figure 1-1: Boiler controls for External modules

PRO EXTERNAL

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

If required, an additional flexible fuel
line (900 mm) and 3/8" to 1/4" BSP male
adaptor are available to purchase
from Grant UK, for two-pipe oil supply
systems, Part No. 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.

6

* Weight includes burner but excludes flue.
** 125 mm diameter required for flexible flue liner (Orange system). For rigid flue system (e.g. Green system) 100 mm diameter flue required.

Refer to Section 9 Flue System and Air Supply for further details.

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

2 Technical Data

Technical Data

2.1 Boiler Technical Data - Vortex Pro

2.2 Sealed System Data - External modules

Heating system pressure (cold)

Operating pressure of pressure relief valve

Expansion vessel size (pre-charged at 1 bar)

Max heating system volume (including boiler)*

Cold water mains connection

Pressure relief valve discharge connection

Circulating pump head

15/21, 15/26, 26/36, 36/46

Maximum 1.0 bar, Minimum 0.5 bar

2.5 bar

10 litres (15/21), 12 litres (15/26), 16 litres (26/36, 36/46)

106 litres (15/21), 128 litres (15/26), 170 litres (26/36, 36/46) - approx.

15 mm copper pipe

15 mm copper pipe

6 m (15/21, 15/26), 7 m (26/36, 36/46)

22 mm (only connect plastic pipe)

28

1

65 to 75

111 ± 3

Less than 50

230/240 V ~ 50 Hz Fused at 5 Amp

0.85

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

Minimum 8.7 - Maximum 37

Minimum 0.035 - Maximum 0.15

2.5

2.5

90

150

6.4

100 mm (4 in)

28.5

10.0

125 mm (5 in)**

External module

15/26

19

4.2

157

345

26

88 700

22 mm

22 mm

2 200

1 100

2.6

26/36

21

4.7

174

383

36

122 840

28 mm

28 mm

3 000

1 500

2.6

36/46

21

4.7

174

383

46

157 000

28 mm

28 mm

4 000

2 000

4.2

46/58

50

11

335

738

58

197 896

1¼"BSP

1¼"BSP

5 200

2 600

58/70

50

11

339

747

70

238 840

1¼"BSP

1¼"BSP

6 000

3 000

15/21

16.5

3.6

99

218

21

71 650

22 mm

22 mm

1 800

900

4.2

Model

Water content

* Weight (dry)

Max. heat output (kerosene)

Flow connection

Return connection

Min. flow rate (T=10°C) l/h

Min. flow rate (T=20°C) l/h

Condensate connection

Flue diameter (conventional)

Waterside resistance T=10°C

Waterside resistance T=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

Conventional flue draught

Max operating press - sealed sys

Max operating press - open sys

litre

gal

kg

lb

kW

Btu/h

l/h

l/h

mbar

mbar

m

m

°C

°C

°C

Watts

Amps

Amps

N/m²

in wg

bar

bar

26.0

9.5

7

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 Pro 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 - 21 kW, 15/26 - 23 kW, 26/36 - 31.5 kW, 36/46 - 41.5 kW, 46/58 - 52.0 kW, 58/70 - 64.0 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 kW output the burner air adjuster disc requires repositioning. Refer to Section 10 Commissioning.
When setting the 15/26 to 15 or 20 kW output the combustion head must be changed. Refer to Section 11.4 Cleaning the burner.
When setting the 58/70 to 70 kW output the combustion head setting must be changed. Refer to Section 11.4 Cleaning the burner.
9 The installer must amend the boiler data label if the output is changed.

Technical Data

2.3 Vortex Pro Boilers using Class C2 Kerosene

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

2

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

15/21 External module

15/26 External module

26/36 External module

36/46 External module

46/58 External module

58/70 External module

22mm pipe

22mm pipe

28mm pipe

28mm pipe

1¼" BSP

1¼" BSP

Compression straight

Compression elbow

Compression straight

Tectite straight

Female socket

Female socket

in fittings kit

in fittings kit

in fittings kit

in fittings kit

fitted

fitted

22mm pipe

22mm pipe

28mm pipe

28mm pipe

1¼" BSP

1¼" BSP

SizeFitting FittingSupplied Supplied

Boiler model

Flow connection

Return connection

Size

(Btu/h)

51 200

62 400

71 650

51 180

68 240

78 475

88 700

88 700

107 500

123 000

123 000

142 000

157 000

156 952

177 424

197 896

197 896

218 368

238 840

(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

15/21

Riello RDB2.2

15/26

Riello RDB1

26/36

Riello RDB2

36/46

Riello RDB2.2

46/58

Riello RDB3.2

58/70

Riello RDB3.2

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

2.16

2.18

2.57

3.01

3.01

3.56

3.90

4.01

4.47

5.05

5.05

5.58

6.01

Flue gas

temp.

(° C)

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

T5

T5

T5

GIB

GIB

GIB

GIB

GIB

GIB

Heat OutputModel and

burner type

SEDBUK 2009

efficiency

(%)

91.2

91.9

93.3

90.7

91.7

91.4

Disc setting B

Disc setting C

Disc setting C

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Head setting 0

Head setting 0

Head setting 0

Head setting 0

Head setting 0

Head setting 4

Burner

head/disc

setting

*

*

*

*

*

*

Compression

Compression

Compression

Compression

Female socket

Female socket

fitted

fitted

fitted

fitted

fitted

fitted

8

Technical Data

2.6 Boiler Dimensions

Figure 2-2: 15/26, 26/36, 36/46 External module dimensions

Figure 2-3: 46/58, 58/70 External module dimensions

All dimensions in the diagrams above are in millimetres

Figure 2-1: 15/21 External module dimensions

4 pre-cut
holes 50 mm dia.
in sidesboth

879

637

768

517

307

187

99

Pre-cut hole
for side flue exit
if required

385

943

734

248

Plan View

112

122

122

=

=

3 pre-cut holes
76 mm dia. in base
of boiler enclosure

Pre-cut hole
for side flue exit
if required

4 pre-cut
holes 50 mm dia.
in sidesboth

1005

509

797

269

908

117

50

757

A

660

418

179

15/26 A = 804
26/36, 36/46 A = 824

Plan View

132

180

180

=

=

3 pre-cut holes
76 mm dia. in base
of boiler enclosure

Pre-cut hole
for side flue exit
if required

4 pre-cut
holes 50 mm dia.
in sidesboth

1153

584

945

233

50

1000

1140

816

418

179

1234

Plan View

64

191

191

=

=

3 pre-cut holes
76 mm dia. in base
of boiler enclosure

9

Oil Storage & Supply

System

3.1 Fuel Supply

Fuel Storage

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

A steel tank may be used and must be
constructed to BS 799:5:1987 and OFS T200.

A galvanised tank must not be used.

A plastic tank may be used and must
comply with OFS T100.

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.

Flexible hoses must NOT be used
outside the boiler case.

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

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.

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,
Part No. 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.

As supplied the burner is suitable for a
single pipe system

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 hose - a flexible fuel hose
(900 mm) and

3

/8" to 1/4" BSP male
adaptor are available to purchase from
Grant UK), Part No. 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.

3 Oil Storage & Supply System

CAUTION

!

CAUTION

!

NOTE

!

Figure 3-1: 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

1 m

10

Oil Storage & Supply

System

Figure 3-3: De-aeration device system

Figure 3-2: Two pipe system

Fire valve

Tankmaster

See

Section 3.2

Sludge
valve

Fill
pipe

Vent
pipe

Fuel
storage
tank

De-aeration device

e.g. Tiger Loop
See Figure 3-4

Fire
valve
sensor

Supply

1 m

Return

Filter

Fire
valve

Shut-off
valve

Shut-off
valve

See

Section 3.2

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

1 m

11

Oil Storage & Supply

System

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.

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,
Part No. 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.

On all models except 46/58 and 58/78:

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

On 46/58 and 58/70 models only:

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

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

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 hose
to the pump.

Connect the

3

/8" to 1/4" BSP adaptor to

the flexible fuel hose.

Flexible fuel hoses and adaptors are
available to purchase from Grant UK.

1/4" BSP female

connections

Tiger Loop

SUPPLY

TO PUMP

RETURN

FROM PUMP

SUPPLY

FROM TANK

Figure 3-4: Tiger loop de-aeration device

1

2

3

4

5

6

7

8

Figure 3-5: Riello RDB pump

Description

Inlet (suction) port

Return port

By-pass screw

Pressure gauge port

Pressure adjustment

Vacuum gauge port

Solenoid
Nozzle outlet

Item

1

2

3

4

5

6

7

8

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.

Ensure that the supply from the tank
is connected to this port and that the
plastic plug is discarded.

WARNING

!

12

Oil Storage & Supply

System

Figure 3-6: Riello RDB burner components

Main Burner Components

It may be necessary to remove the
burner from the boiler to access
connections in the fuel pump.

Remove the single nut at the top of the
burner (using a 13 mm spanner) and
withdraw the burner from the boiler.

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.

7

8

1

23

5

4

6

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
hose supplied with the boiler to the inlet
port.

Connect the other end of the flexible fuel
hose to the rigid supply line using the
adaptor supplied. The supply enters the
enclosure through one of the holes in the
bottom of the side panels.

Description

Oil pump

Control box

Reset button with lock-out lamp

Flange with gasket (do not remove from boiler)

Air damper adjustment screw

Air supply tube connection (balanced flue)

Pump pressure adjustment screw

Pressure gauge connection

Item

1

2

3

4

5

6

7

8

NOTE

!

13

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.

15/21, 15/26, 26/36 and 36/46

models - 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.

46/58 and 58/70 models - Fit the

circular rubber sealing grommet,
provided, into the circular hole in the
side/rear caing 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.

4 Boiler Installation Information

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. The 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

14

4.4 Installing the Boiler

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.

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.

Boiler Installation

Information

4.5 Regulations Compliance

Installation of a Grant VORTEX Pro 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 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.

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 7593:1992 'Treatment of water
in domestic hot water central heating
systems'.

This must involve the use of a proprietary
cleaner, such as BetzDearborn's
Sentinel X300 or X400, or Fernox
Restorer. Full instructions are supplied
with the products, but for more details
of BetzDearborn's products, view the
website www.sentinel-solutions.net and
for more details of Fernox products view
the website www.fernox.com.

NOTE

!

WARNING

!

NOTE

!

15

Boiler Installation

Information

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

Failure to implement these guidelines
will invalidate the warranty.

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 Pro
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
ro om t her mo sta ts o r use w eat he r
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.

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:Part 1:2001) for the
application concerned.

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.

NOTE

!

WARNING

!

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: Part 1:2001.

The system must incorporate a low­pressure 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, Part No. MPCBS 63.

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

!

WARNING

!

16

5.1 Water Connections

The flow and return pipework can exit the boiler enclosure either
through the pre-cut openings provided in both sides (under the
movable cover plates) and through the wall when installed against
the building, or down and through the pre-cut openings provided
in the base of the enclosure for 'free standing' installations. See
Section 2.6.
Push out the 'knock-out' from the required holes, taking care
not to distort the side panel or base.

For condensate disposal pipework refer to Section 6.

1. To gain access to the water connections, remove the two
screws securing the bottom of the back panel and remove
it by withdrawing it forwards at the bottom. Remove the
top casing panel.

2. If required, fit the Grant sealed system kit. Refer to Section 7.

3. Carefully manoeuvre the boiler in position to line up with
pipework through the wall. Complete the water connections.

Note: Check that the baffles are in position and that the

cleaning cover is correctly fitted and a good seal made.

4. If the boiler is installed against a wall, fit the wall flashing
strip. Position the strip with the bottom edge of the wider
flange 20 mm above the enclosure top panel, with the
narrow flange (with the three fixing holes) flat against the
wall. The strip should overhang the top panel by an equal
amount at each end.

5. Mark the position of the three fixing holes onto the wall,
drill and plug the wall and secure the strip with suitable
screws (not supplied).

15/21, 15/26, 26/36, 36/46 Flow connection: A pipe (22 mm
for 15/21, 15/26 or 28 mm for 26/36, 36/46) is provided for the
flow connection. This is located on the top of the boiler. The
pipe will need to be vented, as it is the highest point on the
primary heat exchanger.

15/21, 15/26, 26/36, 36/46 Return connection: A pipe (22
mm for 15/21, 15/26 or 28 mm for 26/36, 36/46) is provided
for the return connection. This is located on the top of the
boiler. The pipe will also need to be vented at some point, as
it is the highest point on the secondary heat exchanger.

46/58, 58/70 Flow connection: A 1¼" BSP socket is
provided for the flow connection. This is located on the top
of the boiler. This flow pipe will need to be vented, as it is the
highest point on the primary heat exchanger.

46/58, 58/70 Return connection: A 1¼" BSP socket is
located on top of the boiler. This return pipe will also need
to be vented at some point, as it is the highest point on the
secondary heat exchanger.

All pipes to be fitted into the push-fit connectors provided
should be cut using a pipe slicer or pipe cutter - to leave
the pipe ends with a slight radius and free from any burrs
or sharp edges. Pipes to be used with these fittings should
not be cut square using a hacksaw.

Pipe Connections

5 Pipe Connections

Figure 5-1: 15/26 water connections

Heating return

Heating flow

Thermostat phials

Heating flow

Thermostat phials

Heating return

Heating return

Thermostat phials

Heating flow

Figure 5-2: 15/21, 26/36, 36/46 water connections

Figure 5-3: 46/58, 58/70 water connections

NOTE

!

17

6.1 General Requirements

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

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

Internal connection (preferred option):

• into an internal domestic waste

system (from kitchen sink, washing
machine, etc.)

• directly into the soil stack

External connection:

• into an external soil stack

• into an external drain or gulley

• into a rainwater hopper (that is part

of a combined system where sewer
carries both rainwater and foul water)

• purpose made soakaway

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

6.2 Connections

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

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

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

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

6.3 Pipework

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

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

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

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

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

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

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

6.4 External Pipework

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

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

Condensate

Disposal

6 Condensate Disposal

NOTE

!

NOTE

!

NOTE

!

Figure 6-1: Purpose made condensate soakaway

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

6.5 Condensate Soakaway

To keep external pipework to a
minimum, locate the soakaway as close
as possible to the boiler but ensure
it is at least 500 mm from building
foundations and away from other
services, e.g. gas, electricity, etc.

The condensate pipe may be run above
or below ground level and can enter
either the top or side of the soakaway
tube. Refer to Figure 6-1.

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

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

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

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

CAUTION

!

Ground level

32 mm waste pipe external to the building

Minimum 2.5 fall

O

25 mm

300 mm

400 mm

min.

Two rows of 3 x 12 mm
holes at 25 mm centres
and 50 mm from the bottom
of the tube. Holes facing
away from the property.

Cement seal

100 mm plastic tube

Sealed end Backfill with 10 mm

limestone chippings

18

6.6 Condensate Trap

Grant VORTEX Pro boilers are supplied
with a factory-fitted condensate trap to
provide the required 75 mm water seal in the
condensate discharge pipe from the boiler.

This trap incorporates a float (which will
create a seal when the trap is empty) and
an overflow warning outlet (fitted with a
plastic sealing cap), see Figure 6-2.

The trap is factory-fitted inside the boiler
casing, mounted in the rear of the boiler
(opposite end to the burner) on the inside
of the side panel, see Figure 6-2.

Access must be available to allow for
routine maintenance.

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

With the trap fitted inside the boiler
casing, the sealing cap must be fitted.

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

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

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

The condensate trap outlet is at an
angle of 48° below the horizontal. This
is to automatically give a 3° fall on any
'horizontal' runs of condensate disposal
pipe. Refer to Figure 6-2.

6.7 Condensate Disposal Pipework

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

Possible routes for disposal pipework

The boiler enclosure has several 50 mm
diameter openings in both the sides and
base. These are designed to allow pipework
to pass through, to suit the installation.
These openings can be used to allow the
condensate disposal pipe to exit the casing
in one of the following ways:

Side outlet – The lower opening on
either side of the enclosure can allow the
condensate disposal pipe to be installed
as follows:

• Connection to an internal stack – passing
back through the wall of the house.

• Connection to an external soil stack
adjacent to the boiler.

• Discharge into an adjacent (external)
drain or gulley.

• Discharge into a soakaway – with pipe
either above or below ground level.

Bottom outlet – There are three
openings in the base that can allow the
condensate disposal pipe to be installed
as follows:

• Discharge into a drain or gulley
beneath the boiler (e.g. drain built in to
the concrete base for the boiler).

• Discharge into a soakaway – with pipe
below ground level.

When connecting plastic discharge
pipe, ensure that the pipe is fully
pushed into the outlet end on the
flexible pipe to prevent the possibility
of leakage.

6.8 Inspection and Cleaning of Trap

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

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

To inspect and clean the trap:

1. Disconnect flexible condensate hose
from inlet connector.

2. Unscrew the inlet connection nut.

3. Remove the inlet connector and nut
from trap.

4. Remove trap from bracket.

5. Remove float from trap – clean if
necessary.

6. Inspect inside of trap and clean as
necessary.

7. Re-assemble trap, re-fit to boiler and
re-connect flexible hose. Ensure that
hose is fully pushed onto the trap
inlet connector.

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

Condensate

Disposal

NOTE

!

NOTE

!

CAUTION

!

Figure 6-2: Condensate trap (rear panel removed)

Condensate
trap

Condensate
outlet to drain

Sealing cap
must be fitted

Flexible hose
from outlet of
condensing
heat exchanger

19

7.1 Sealed System Installation

See Figure 7-1

All Grant VORTEX Pro boilers are suitable
for use with sealed systems complying with
the requirements of BS 5449.

The maximum temperature of the central
heating water is 75°C.

The system must be provided with the
following items:-

• Diaphragm expansion vessel
complying with BS 4814.

• Pressure gauge.

• Safety valve.

• Approved method for filling the system.

Ensure that the expansion vessel used
is of sufficient size for the system
volume. Refer to BS 7074:1:1989 or
The Domestic Heating Design Guide
for sizing the required vessel.

The expansion vessel can be fitted in either
the return or flow pipework in any of the
recommended positions as shown in Figure
7-1. To reduce the operating temperature of
the expansion vessel diaphragm, position it
below the pipe to which it is connected. The
expansion vessel may be positioned away
from the system, providing the connecting
pipe is not less than 13 mm diameter.

The pressure gauge should have an
operating range of 0 to 4 bar.

The safety valve, set to operate at 2.5
bar, should be fitted in the flow pipework
near to the boiler.

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

Provision should be made to replace
water lost from the system. This can be
done manually (where allowed by the local
water undertaking) using an approved filling

loop arrangement incorporating a double
check valve assembly (as supplied fitted
on System models).

An automatic air vent should be fitted to
the highest point of the system.

The expansion vessel charge pressure
should always be slightly greater than the
maximum static head of the system, in
bar, at the level of the vessel (1 bar = 10.2
metres of water). See Figure 7-2.

The system fill pressure (cold) should
be 0.2 - 0.3 bar greater than the vessel
charge pressure – giving typical system fill
pressures of approx 0.5 bar for a bungalow
and 1.0 bar for a two storey house. Refer
to the Domestic Heating Design Guide for
further information if required.

If thermostatic radiator valves are fitted to all
radiators, a system by-pass must be fitted.
The by-pass must be an automatic type.

Filling of the system must be carried out
in a manner approved by the local Water
Undertaking.

Where allowed, the system may be filled
via the filling loop supplied (the loop
arrangement includes a double check
valve assembly).

All fittings used in the system must be
able to withstand pressures up to 3 bar.

Radiator valves must comply with the
requirements of BS 2767(10):1972.

One or more drain taps (to BS 2879)
must be used to allow the system to be
completely drained.

7.2 15/21 Sealed System Kit

See Figures 7-3 and 7-4

1. The kit includes the following items:

• Pressure relief valve and automatic
air vent.

• 22 mm manifold pipe.

• 10 litre expansion vessel with

flexible hose and sealing washer.

• Expansion vessel mounting bracket.

• Filling loop kit.

• Pressure gauge (mounted on

compression tee).

• 6 m head circulating pump with 22
mm gate valves.

• 15 mm copper pressure relief
valve discharge pipe (in two
pieces with push-fit connector).

• Pump support bracket (with fixing
screws).

7 Sealed Systems

Sealed Systems

Figure 7-1: Sealed system

NOTE

!

Figure 7-2: Boilers with sealed system kit

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

20

11. Fit the pump/pump valve assembly to
the end of the pressure relief valve/auto
air vent manifold pipe. Ensure that the
pump shaft is horizontal and the pump
motor is facing towards the right side
of the boiler (viewed from the rear as
shown in Figure 7-4). The flow arrow on
the body of the pump must face in the
required direction of flow – away from
the boiler flow connection – downwards
in this case.

12. Ensure that the pump/valve assembly
is supported by the bracket. The upper
part of the lower valve should rest on
the support bracket, with the body of
the valve passing through the cut-out.
Connect the flow pipework to the lower
pump valve.

13. Assemble the two sections of the
pressure relief valve discharge pipe
using the 15 mm straight push-fit
co nn ec tor pro vi de d. Ad ju st th e
pressure relief valve so that the outlet
points to the rear left corner of the boiler
(viewed from the rear of the boiler).

14. Fit the pressure relief valve discharge
pipe to the pressure relief valve
outlet using the nut and olive
provided. Route the pipe down the
left hand rear side of the boiler and
locate the lower end through the slot
in the bottom flange of the left hand
side panel.

15. The circulating pump may be wired
into the boiler control panel if
required. Refer to Section 8.

16. The pressure gauge and filling loop
should be installed in a convenient
position inside the building.

7.3 15/26 Sealed System Kit

See Figure 7-5

Pressure relief valve

Manifold
pipe

Automatic
air vent

Pressure relief
valve discharge pipe

Tectite
connector

Pump support
bracket

Screws

Pump and
valve assy.

Figure 7-3: 15/21 top view

Figure 7-4: 15/21 rear view

Figure 7-5: 15/26 pump assembly

Sealed Systems

Automatic air vent

Flow connection
on top of boiler

Push-fit elbow

Pressure relief valve

Front

of boiler

2. Unscrew and remove the two nuts
and washers from the two cleaning
door studs. Remove cleaning door
from boiler.

3. Remove the ½" BSP black iron plug
from the front of the boiler waterway,
using a 3/8" drive socket wrench.

4. Fit the ½" BSP straight connector end of
the flexible expansion vessel hose into
the tapping on the front of the waterway
using a suitable thread sealant.

5. Fit the ¾" BSP connection on the
flexible expansion vessel hose to the
vessel using the black rubber sealing
washer supplied and tighten the
union nut.

6. Replace the cleaning door on the two
door studs. Fit the expansion vessel
mounting bracket onto the studs.
Replace the nuts and washers and
re-tighten to secure door and bracket.

7. Push the 22 mm push-fit connector
(supplied with the boiler) onto the
end of the boiler flow pipe.

8. Fit the pressure relief valve and
automatic air vent onto the manifold
pipe. Then push fit the manifold
pipe end into the 22 mm push-fit
connector on the boiler flow pipe.
Refer to Figure 7-3.

9. Fit both 22 mm pump valves to the
circulating pump using the sealing
washers provided.

10. Fit the pump support bracket, with
the screws provided, using the two
holes in the left hand side panel
flange (viewed from rear of boiler as
shown in Figure 7-4).

1. The kit includes the following items:

• Pressure relief valve and automatic
air vent.

• 22 mm manifold pipe.

• 12 litre expansion vessel with flexible

hose and sealing washer.

• Filling loop kit.

• Pressure gauge.

• 6 m head circulating pump with 22

mm gate valves.

• 15 mm copper pressure relief
valve discharge pipe (in two
pieces with push-fit connector).

2. Remove the ½” BSP black iron plug
from the front of the boiler waterway,
using a 3/8" drive socket wrench.

21

Sealed Systems

7.4 26/36, 36/46 Sealed System Kit

See Figure 7-6

7. Screw in the locking screw on the
base of the bracket to secure the
vessel in place.

8. Fit the ¾” BSP connection of the
flexible expansion vessel hose to the
vessel using the black rubber washer
supplied and tighten the nut.

9. Remove the right hand boiler casing
panel (viewed from the burner end).
This panel is fixed in place by:

• Two screws in the right end of the

upper rear panel.

• Four screws along the lower outer

edge of the side panel.

• Two screws at the right end of the

control panel.

Note: It will be necessary to

support the control panel when
the side panel is removed.

10. Slacken the compression nut at the
base of the flow connection pipe (on the
right hand side of the boiler). Carefully
rotate the flow pipe through 180° until
it faces to the front of the boiler, then
re-tighten the compression nut.

11. Push the 28 mm push-fit connector
(supplied with the boiler) onto the
end of the boiler flow pipe.

12. Fit the pressure relief valve and
automatic air vent onto the manifold
pipe, then push the manifold pipe
end into the 28 mm push-fit elbow
on the flow pipe. Refer to Figure 7-6.

13. Remove the two screws securing the
motor to the pump body. Rotate the
motor through 180°, then replace and
secure with the two screws. Fit both
28 mm pump valves to the pump using
the sealing washers supplied.

14. Fit the pump assembly to the automatic
air vent/pressure relief valve assembly
ensuring th at th e pump shaft is
horizontal and the pump motor is facing
towards the rear of the boiler. The flow
arrow on the body of the pump must
face in the direction of flow away from
the boiler connection.

15. Fit the pressure relief valve discharge
pipe to the pressure relief valve using
the nut and olive supplied. Route the
discharge pipe through the slot in
the base of the right hand side panel.
Push the panel insulation back to
expose the slot.

Figure 7-6: 26/36, 36/46 pump assembly

3. Fit the ½” BSP straight end of the
flexible expansion vessel hose to the
tapping on the front of the waterway
using a suitable thread sealant.

4. Position the 12 litre expansion vessel
on the front of the boiler combustion
door locating the hook (on the back
of the vessel) onto the uppermost
handle of the combustion door.

5. Fit the ¾” BSP connection of the
flexible expansion vessel hose to the
vessel using the black rubber washer
supplied and tighten the nut.

6. Push the 22 mm push-fit elbow
(supplied with the boiler) onto the
boiler flow pipe.

7. Fit the pressure relief valve and
automatic air vent onto the
manifold pipe, then push the
manifold pipe end into the 22 mm
push-fit elbow on the flow pipe.

Refer to Figure 7-5.

8. Fit both 22 mm pump valves to the
circulating pump using the sealing
washers supplied.

9. Fit the pump assembly to the
automatic air vent/pressure relief
valve assembly ensuring that the
pump shaft is horizontal and the
pump motor is facing towards the
front of the boiler. The flow arrow
on the body of the pump must
face in the direction of flow away
from the boiler connection.

10. Fit the pressure relief valve discharge
pipe to the pressure relief valve using
the nut and olive supplied. Route the
discharge pipe through the slot in the
base of the right hand side panel.
Push the panel insulation back to
expose the slot.

11. The circulating pump may be
wired into the boiler control panel
if required. Refer to Section 8.

12. The pressure gauge and filling loop
should be installed in a convenient
position inside the building.

Pressure relief valve

Automatic air vent

Flow connection
on top of boiler

Push-fit connector

Front
of boiler

1. The kit includes the following items:

• Pressure relief valve and automatic
air vent.

• 28 mm manifold pipe.

• 16 litre expansion vessel with flexible

hose and sealing washer.

• Expansion vessel mounting bracket
with vessel locking screw.

• Filling loop kit.

• Pressure gauge.

• 7 m head circulating pump with 28

mm gate valves.

• 15 mm copper pressure relief
valve discharge pipe (in two
pieces with push-fit conne.

2. Remove the ½” BSP black iron plug
from the front of the boiler waterway,
using a 3/8" drive socket wrench.

3. Fit the ½” BSP straight end of the
flexible expansion vessel hose to the
tapping on the front of the waterway
using a suitable thread sealant.

4. Remove the nuts and washers from
the boiler combustion door.

5. Fit the vessel support bracket to the
studs of the combustion door and
refit the nuts and washers. Tighten to
ensure an adequate seal is made.

6. Position the 16 litre expansion vessel
onto the support bracket in front of
the boiler combustion door locating
the top of the vessel behind the
control panel first.

22

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

reduced to zero.

7.6 Fill the Sealed System

Automatic air vent(s) are fitted to the top
of the boiler (see Figures 7-3, 7-5 and
7-6). Check that the small cap on the top
of each air vent is screwed on fully, then
unscrew it one complete turn - the cap
remains in this position from now on.
The procedure for filling the sealed
system is as follows:

1. Only ever fill or add water to the
system when it is cold and the boiler
is off. Do not overfill.

2. Ensure that the flexible filling loop
supplied is connected and that the
double check shut off valve connecting
it to the water supply 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. Open the fill point valve.

4. Gradually open the double check valve
from the water supply until water is
heard to flow.

5. When the white needle of the pressure
gauge is between 0.5 and 1.0 bar, close
the valve.

6. Vent each radiator in turn, starting
with the lowest one in the system, to
remove air.

7. Continue to fill the system until the
pressure gauge indicates between 0.5
and 1.0 bar. Close the fill point valve.

8. Repeat steps 4 and 5 as required.

9. Close the fill point and double check
valves either side of the filling loop
and disconnect the loop.

Sealed Systems

16. The circulating pump may be wired
into the boiler control panel if
required. Refer to Section 8.

17. Refit the casing side panel only after
filling and checking the system for leaks

Ensure there is no leak from the connection
at the base of the flow pipe BEFORE re­fitting the casing side panel.

7.5 Fit the Expansion Vessel

The expansion vessel fitted is supplied
with a charge pressure of 1.0 bar
(equivalent to a max. static head of 10.2
metres). The charge pressure must not
be less than the actual static head at the
point of connection.

Do not pressurise the vessel above 1.5 bar.

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

The air pressure in the vessel must be
checked annually.

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

Refer to either BS 7074:1:1989 or The
Domestic Heating Design Guide for
the required total expansion vessel
volume for the system concerned.

7.7 Vent the Pump

It is important that the pump is properly
vented to avoid it running dry and damaging
its bearings. The procedure is as follows:

1. Remove the cap, then unscrew and
remove the plug from the centre of
the pump.

2. Using a suitable screwdriver rotate
the exposed spindle about one turn.

3. Replace the plug and cap.

7.8 Pressure Relief Safety Valve

Now the pressure relief safety valve
operation must be checked and set. The
procedure is as follows:

1. Check the operation of the safety
valve (see Figure 7-2) by turning the
head anticlockwise until it clicks. The
click is the safety valve head lifting
off its seat allowing water to escape
from the system.

2. Check that the water is escaping
from the system.

3. Continue to fill the system until the
pressure gauge indicates between

0.5 and 1.0 bar.

4. Close the fill point valve and check
the system for water soundness,
rectifying where necessary.

5. Water may be released from the system
by manually operating the safety valve
until the system design pressure is
obtained. The system design pressure
(cold) should be between 0.5 bar and

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

Now close the valves either side of the
filling loop and disconnect the loop.

CAUTION

!

NOTE

!

NOTE

!

23

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

Refer to Figures 8-1 to 8-4 for typical
control system wiring diagrams.

Refer to Figure 8-5 for boiler internal
wiring diagram.

The VORTEX Pro External module
contains electrical switching
equipment and must be earthed.

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.

A fused double pole switch or a
fused three pin plug and shuttered
outlet socket should be used for the
connection.

The power supply cable should be at
least 0.75 mm² PVC as specified in BS
6500, Table 16.

All the wiring and supplementary earth
bonding external to the boiler must be in
accordance with the current I.E.E. Wiring
Regulations.

Any room thermostat or frost thermostat
used must be suitable for use on mains
voltage.

The boiler requires a permanent mains
supply, do not interrupt it with any
external time control.

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

• Resistance to earth.

8.1 Connecting the Power Supply

A Test switch is fitted to the control panel
(see Figure 1-1) to allow the boiler to be
test-fired. When On, the switch by-passes
the external control system.

It is recommend that the boiler should be
connected to a switched mains power
supply from a programmer or control
system. If a Grant remote programmer is
used, a permanent 240 V mains supply
(fused at 5 Amp) must be taken to the
boiler. A three core cable is required to
connect the boiler terminal block to the
live supply. Refer to Figures 8-1 to 8-4 for
typical control system wiring diagrams.

The procedure is:

1. Undo the three screws and remove
the lefthand cover from the control
panel to gain access to the boiler
terminal block.

2. Pass the mains power supply
cable through the cable grommet
in the control panel, through the
cable clamp and connect to the
terminal block as follows:-

Brown to live (terminal 2)

Blue to mains neutral (terminal 3)

Green/Yellow to mains earth
(terminal 4)

3. Refer to Figures 8-1 to 8-4 for
a typical control system wiring
diagrams.

4. If the circulating pump is to be
fitted within the boiler enclosure,
the pump live must be connected
to terminal 7 of the boiler terminal
block.

Pass the pump power supply

cable through the cable grommet
in the control panel, through the
cable clamp and connect to the
terminal block as follows:-

Brown to live (terminal 7)

Blue to mains neutral (terminal 9)

Green/Yellow to earth (terminal

Connecting the pump in this way

allows it to be isolated using the
isolating switch fitted in the boiler
control panel, for servicing or
maintenance work.

5. Ensure that the cable clamp is
tightened and that all cables are
secure and all external wiring is
adequately supported.

6. Replace the cover on the control
panel, with the yellow warning
label facing outwards and secure
with the three screws.

Do not switch on the electricity supply
to the External module at this stage.

8.2 Frost Protection

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 2°C.

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.

Electrical

8 Electrical

WARNING

!

NOTE

!

24

Electrical

8.3 Control System Wiring Diagrams

Figure 8-1: Grant 2 channel wall mounted programmer (Ref. ESKIT) - CH and HW controlled by two 2-port zone valves

Figure 8-2: Grant 2 channel wall mounted programmer (Ref. ESKIT) - CH and HW controlled by 3-port mid position valve

L N E

240 V
50 HZ

Pipe

Thermostat

(if fitted)

Wiring Centre

1

2

3

4 5 6 7 8 9 10

1 3 4 N L

Cylinder

Stat

1

C

Room Stat

2 1

3

Pump
(if fitted outside boiler)

E
N

L

2-port

Zone Valve

Motor

HTG

2-port

Zone Valve

Motor

DHW

Grey

Blue Blue

Brown

Brown

Green/Yellow

Green/Yellow

Orange

Orange

Grey

1 2 3 4 5 6

LL N E

7 8 9 10

11

12

13

14

15

16

E EN NL L

Boiler

Terminal Blocks

Grant 2-Channel

Wall Mounted Programmer

(Ref. ESKIT)

Pump
(if fitted outside boiler)

Boiler

Terminal Blocks

Cylinder

Stat

1

C 2

L N E

240 V
50 Hz

Room

Stat

2 1 3

3-Port

Mid Position

Zone Valve

E
N

L

Blue

Green/Yellow

White

Grey

Orange

Pipe

Thermostat

(if fitted)

Wiring Centre

1 2 3 4

5

6 7 8 9 10

1 3 4 N L

Grant 2-Channel

Wall Mounted Programmer

(Ref. ESKIT)

1 2 3 4 5 6

LL N E

7 8 9 10

11

12

13

14

15

16

E EN NL L

25

Electrical

Figure 8-3: Grant wireless twin channel control (RFKIT) - CH and HW controlled by two 2-port zone valves

Figure 8-4: Grant wireless twin channel control (RFKIT) - CH and HW controlled by 3-port mid position valve

L N E

240 V
50 HZ

Pipe

Thermostat

(if fitted)

Wiring Centre

1

2

3

4 5 6 7 8 9 10

Cylinder

Stat

1

C

Pump
(if fitted outside boiler)

E
N

L

2-port

Zone Valve

Motor

HTG

2-port

Zone Valve

Motor

DHW

Grey

Blue Blue

Brown

Brown

Green/Yellow

Green/Yellow

Orange

Orange

Grey

1 2 3 4 5 6

LL N E

7 8 9 10

11

12

13

14

15

16

E EN NL L

Boiler Terminal Blocks

1 2 3 4 5

FM/2

Receiver

Wireless receiver unit

to be installed indoors

(refer to RFTKIT instructions)

Pump

(if fitted outside boiler)

Cylinder

Stat

1

C 2

L N E

240 V
50 Hz

3-Port

Mid Position

Zone Valve

E
N

L

Blue

Green/Yellow

White

Grey

Orange

Pipe

Thermostat

(if fitted)

Wiring Centre

1 2 3 4 5 6 7 8 9 10

1 2 3 4 5 6

LL N E

7 8 9 10

11

12

13

14

15

16

E EN NL L

Boiler Terminal Blocks

1 2 3 4 5

FM/2

Receiver

Wireless receiver unit
to be installed indoors

(refer to RFTKIT instructions)

26

Electrical

Figure 8-5: Receiver for optional Grant wireless twin channel control (RFKIT) shown

Figure 8-6: Grant programmable room thermostat

A programmable room thermostat - Part No. RSKIT is available from Grant UK. The thermostat has a 5/2 day operation and
enables six time and temperature changes each day. The thermostat incorporates frost protection and an On/Off facility.

8.4 Boiler Control Panel Wiring

Live supply in Live supply out

A B

C

OFF COM ON

N

E

L

N

E

C

2

C

5B

2A

L

N

E

2

1

L

Mains neutral

Mains earth

Permanent Live

Switched live

Pump earth

Pump neutral

Burner live

Burner neutral

Burner earth

4B

1A

1

1
2
3

4
5
6

7
8
9

L

Pump live

11

16

15

14

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

R

R

R

Y

Y

Bl

G/Y

R

G/Y

Y

Bl

R

R

R

Bl

G/Y

G/Y

G/Y

G/Y

G/Y

R

R

Y

10

12
13

R

HW

OFF

CH
ON

4

5

HW

ON

L

3

2

N

1

Wireless receiver unit
to be installed indoors

(refer to RFTKIT instructions)

Test

Switch

Frost

Thermostat

Limit
Thermostat

Mains On/Off

Switch

c/w Neon

Control

Thermostat

Control Box

Chassis Earth

Control Box

Chassis Earth

Earth to

Switch Cover

Boiler

Terminal Block

Boiler

Terminal Block

Grant Wireless
Receiver FM/2

Switched supply to

DHW valve OFF

Supply to CH valve
(If used, remove link between 6 & 7)

If fitting pipe stat’ & CH valve, remove link
between 5 - 6 & 6 - 7, and connect
pipe stat’ between 5 - 7

If fitting pipe stat’ without fitting CH valve,
then remove link between 5 - 6 and
connect pipe stat’ between 5 - 6

Switched supply to

DHW valve ON

27

9 Flue System and Air Supply

9.1 Low Level Discharge Flue

The Grant VORTEX Pro External module
is supplied with a low level discharge flue
(see Section 4).

The minimum dimensions for locating the
standard terminal from building features
(windows, doors, etc.) are shown in
Figure 9-1.

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

Where it is not practical to use this flue,
the External module may be fitted with
an alternative flue system available from
Grant UK.

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

warranty.

NOTE

!

Flue System

9.2 Grant Green System

This vertical twin wall stainless steel
insulated flue system - constructed
using components from the Grant Green
system - connects to a Grant Starter
elbow and may terminate at high level or
vertically as required. See Figure 9-2.

The insulated Starter elbow includes
the boiler connector, complete with test
point, replacing the low level terminal
and flue guard supplied with the boiler.

Notes:
* 75 mm with protection.
** Only applies if one or both terminals are balanced flues.

Distances measured to rim of terminal.

Clearances recommended by Grant UK
in accordance with British Standards
and Building Regulations.

1. An opening means an openable
element, such as an openable
window, or a permanent opening
such as a permanently open air vent.

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

3. A way of providing protection of
combustible material would be to fit
a heat shield at least 750 mm wide.

Figure 9-1: Clearances for flue terminals

A Below a gutter or sanitary pipework

B Horizontal from an opening, air brick or window

C Above ground or balcony level

D Below eaves or balcony

E From an internal or external corner

F From a terminal facing the terminal

G From a surface facing the terminal

H Vertical from terminals on the same wall

I Horizontal from terminals on the same wall

J Below an opening, air brick, window etc.

K From vertical sanitary pipework

From an oil storage tank

Min. distance (mm)Terminal position

600 *

600

300

600 *

300

1200

600

1500

750 **

600

300

1800

NOTE

!

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

28

Item - for models 26 to 70 kW output

External starter elbow

External starter - straight

150 mm extension

250 mm extension

450 mm extension

950 mm extension

195-270 mm adjustable extension

45° elbow

High level terminal

Vertical terminal

Wall bracket - standard

Wall bracket - extended

Twin wall to single wall adaptor

Straight terminal - Horizontal flue

Part No.

GKM200

GKM200C

GX150/200

GX250/200

GX450/200

GX950/200

GXA250/200

GE45/200

GTH200

GTV200

GWB200

GEB200

GFCON100

GTL200

Green System Components

Item - for models up to 26 kW output

External starter elbow

External starter - straight

150 mm extension

250 mm extension

450 mm extension

950 mm extension

195-270 mm adjustable extension

45° elbow

High level terminal

Vertical terminal

Wall bracket - standard

Wall bracket - extended

Twin wall to single wall adaptor

Straight terminal - Horizontal flue

Part No.

GKM90

GKM90C

GX150/90

GX250/90

GX450/90

GX950/90

GXA250/90

GE45/90

GTH90

GTV90

GWB90

GEB90

GFCON80

GTL90

Outdoor

module

vertical/high

level flue

options

Components for Outdoor flue system

Vertical terminal

45 elbow

O

High level 90° terminal

Wall bracket

Extended wall bracket

Starter elbow

Starter - straight

Straight terminal

Twin wall to single
wall adaptor

Locking band

Extensions

950 mm

450 mm

195 to 270 mm

250 mm

150 mm

Vertical
terminal

45° elbows

High level
90° terminal

Extensions

45° elbow

Starter elbow

Maximum vertical

length 19 metres

Figure 9-2: Vertical external conventional flue (Green system)

Flue System

29

Flue System

NOTE

!

NOTE

!

9.3 Grant Hybrid System

This vertical option allows the use of
an existing chimney using part of the
'Green' system and the flexible liner and
terminal of the Grant 'Orange' system.
See Figure 9-3. This is only available for
boilers up to 46 kW.

If an existing chimney is to be used,
it must be lined with a smooth bore
stainless steel liner suitable for use with
oil fired condensing boilers. The top and
bottom of the annular space must be
sealed.

Grant recommends the use of the
Grant ‘Orange’ flue system, specifically
designed for the VORTEX range of
condensing boilers.

Outdoor module Starter elbow

Flue extension (Green system)

Adjustable extension (Green system)

Flue extension (Green system)

Twin-wall to single-wall adaptor

Rigid to flexible flue connector
(supplied in Orange system kit)

This component must be

installed vertically

Note:

Top plate

Clamp

Terminal

Flaunching

Brick chimney

Outdoor module

45° Elbow
(Green system)

45° Elbow (Green system)

Flexible stainless steel liner

The flue liner is directionalNote:

Figure 9-3: Vertical hybrid flue (Green to Orange system)

The internal flue and liner diameter for all
models up to 46 kW output must be 100
mm (4 in).

The maximum vertical height (from the
top of the boiler to the terminal) for the
‘Orange’ system is 19 metres.

The Grant Orange system flexible
stainless steel liner is directional. The
arrows marked on the liner MUST be
pointing vertically upwards, following
the direction of the flue gases. Failure to
comply with this instruction could lead
to a leakage of condensate from the flue
liner.

In order to correctly connect the Grant
hybrid system, it will be necessary to
purchase the Grant Starter Elbow.

This insulated Starter elbow includes
the boiler connector, complete with test
point, replacing the low level terminal
and flue guard supplied with the boiler.

30

9.4 Grant Horizontal System

This option uses the Grant Straight
Starter boiler connector, replacing
the low level terminal and flue guard
supplied with the boiler, along with
components from the Grant Green
system. See Figure 9-4.

A complete list of Grant Green system
flue components are given on page 28.

Flue System

Figure 9-4: Horizontal external flue

Garden wall

Outdoor
module

Garden wall

Extensions

45° elbows

Straight
terminals

Straight
starter

Maximum horizontal

length 3 metres

9.5 Conventional Flue Systems

All flue components are stainless steel
and fully insulated with 'O' ring seals and
locking bands.

The flue must terminate in a down draught
free area, i.e. at least 600 mm above the
eves or point of exit through the roof, or
preferably above the ridge level.

The condensate may be allowed to run
back into the boiler. A condensate drain at
the base of the flue system is not required.

The flue terminal must be at least
600 mm from any opening into the
building, and 600 mm above any
vertical structure or wall less than a
horizontal distance of 750 mm from
the terminal.

No part of any flue system should be
made of an asbestos material; aluminium
must not be used in any part of the flue.
Only stainless steel flue components
should be used.

If the draught conditions are satisfactory,
the flue should terminate with a standard
cowl.

Refer to the locally applicable Building
Regulations, BS 5410:1 and OFTEC
Installation Requirements (OFTEC
Technical Books 2 and 4) for further
guidance on conventional flue systems.

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

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

To comply with the requirements of
the Building Regulations Approved
Document J - conventional flue systems
must have a flue data plate. A suitable
data plate is supplied with the Grant
Orange flue system and should be
displayed next to the boiler or flue.

9.6 Air Supply

A permanent air supply must be
provided to the burner, sufficient to
ensure proper combustion of fuel and
effective discharge of combustion
products to open air.

The ventilation openings provided in the
upper part of the front door of the boiler
casing must not be obstructed at any
time.

CAUTION

!

NOTE

!

31

Commissioning

10 Commissioning

Figure 10-1: Boiler controls

Check the electrodes are set correctly.

Refer to Figure 11-6 or 11-8 as required.

Check the nozzle is correct for the

output rating required. Refer to
Section 2.3.

If a 15/21 model is down rated to 15
kW, the burner air adjuster disc must
be adjusted to setting B as described in
Section 10.6. Refer also to Section 2.3.

If a 15/26 model is down rated to 20
or 15 kW, the burner head must also
be changed to a T1 head. See Section

11.4. Refer also to Section 2.3.

8. Check that the water system has been
vented (and pressurised if sealed
system) and there are no leaks.

9. Ensure the automatic air vent on the
condensing heat exchanger is open.

10. Check that all fuel line valves are open.

12. Remove the plastic burner cover if it
was not previously removed.

12. Connect a combined vent manifold and
pressure gauge to the pressure gauge
connection port on the oil pump. See
Figure 3-6. Open the vent screw on the
vent manifold to vent the supply while
the pump is running.

13. Check that all system controls are
calling for heat and turn the boiler
thermostat to maximum.

10.2 Switching On

1. Switch on the electricity supply.

2. 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.
Note that the neon lights when the boiler

is switched on, but does not necessarily
indicate the burner is firing.

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

4. With the burner alight, check the fuel
pressure.

5. Refer to the Technical Information,
Section 2.3.

6. Adjust the pressure if necessary - see
Figure 3-6.

It is important that the oil pressure is
correctly set.

7. Operate the boiler until it reaches
normal operating temperature.
Check oil supply/return pipe for
leaks, rectifying where necessary.

NOTE

!

It is important that the following
commissioning procedure is carried out
to ensure safe and efficient operation of
the boiler.
To access the controls, remove the front
panel (turn the handle and withdraw it
forwards at the bottom).
The controls are shown in Figure 10-1.

10.1 Before Switching On

1. Ensure the boiler On/Off switch and
the test switch are set to OFF.

2. Check that the high limit thermostat and
boiler thermostat bulbs are correctly
located in their respective pockets.
Refer to Figures 5-1, 5-2 or 5-3.

Ch eck con di tion o f th erm os tat

capillaries, not damaged, broken or
kinked and not crushed.

3. Remove the nuts and washers securing
the front cleaning door. Withdraw the
door - take care it is HEAVY!

4. Check that the turbulators are in
position and that the ends are vertical.

5. Check that the baffles are in position.

Refer to Figures 11-1, 11-2, 11-3 or

11-4 as required.

6. Re-fit the cleaning door and check
it is fitted correctly and that a good
seal is made.

7. Remove and check the burner.

Check that the burner head is correct

(and set correctly on the 46/58 and
58/70 models). Refer to Section 2.3
and Figure 11-9.

NOTE

!

PRO EXTERNAL

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

32

8. Check the operation of the boiler
thermostat. Ensure that by turning it
anticlockwise it switches the burner off.

9. With the burner alight, re-check
the fuel pressure and re-adjust
if necessary. Turn the boiler off,
remove the pressure gauge and
replace the plug in the pump.

10. Ensure that there are no oil leaks,
replace the burner cover.

10.3 Running the Boiler

1. Relight the boiler and allow it to run
for at least 20 minutes.

2. Check the smoke number, if
satisfactory check the CO

2

. Set the
CO2 to the value given in Section 2.3
for the boiler concerned.

Final combustion readings can only be
measured outside through the low level
flue terminal (or the test point on the
conventional flue starter elbow when
used) with all the casing panels fitted.

3. Use the hexagonal key supplied to
adjust the burner air damper (see
Figure 3-6) as required. Turning the
screw anti-clockwise closes the
damper and increases CO

2

level,
turning the screw clockwise opens
the damper and reduces CO2 level.

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

It is important that the air damper is
correctly set.

5. Check the flue gas temperature by
placing the combustion analyser in
the low level flue terminal (or into
the test point on the starter elbow if
either the Green system or Hybrid
system is used).

10.4 Balancing the System

1. When the boiler has been adjusted and
is running satisfactorily, balance the
central heating system by adjusting

Commissioning

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

2. Switch off the boiler.

10.5 Completion

1. With the system hot, check again for
leaks, rectifying where necessary.
Drain the system while it is hot to
complete the flushing process. Refill
and vent (and pressurise if a sealed
system) the system.

2. A suitable central heating system
inhibitor must be added to protect the
system against the effect of corrosion.

3. A suitable antifreeze should be used
to prevent damage to the boiler in
areas where electrical power failure
can occur in winter months.

4. Replace the top, front and rear
panels as necessary.

After commissioning the boiler
complete the Commissioning Report
in the front of this manual and the
OFTEC CD/11 commissioning report.
Leave the top copy with the User and
retain the carbon copy.

If the boiler is to be left in service with the
User, set the controls and room thermostat
(if fitted) to the User's requirements.

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

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

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

The CO

2

and smoke test may all be

carried out using this test point.

The test point is not suitable for
measuring boiler efficiency or
conventional flue draught.

When using the test point on the
cleaning cover note that the flue gas
temperature reading will be higher than
that measured in the flue thus resulting
in an inaccurate efficiency reading. To
obtain an accurate flue gas temperature
and efficiency, the reading can only be
measured outside through the low level
flue terminal or the test point on the
conventional flue starter elbow when
fitted - with all the casing panels fitted.

10.6 Air Adjuster Disc - 15/21 only

To adjust the 15/21 air adjuster disc
when downrating - See Figure 10-2

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

2. Remove the burner from the boiler.

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

4. The secondary air shutter disc is
factory set in position ‘C’ – i.e.
with the cut-out marked C located
against the die-cast boss on the fan
housing - suitable for outputs of 18.3
and 21 kW only. See Figure 10-2.

5. Remove the screw from the centre of
the air shutter disc, and re-position
the disc such that the cut-out ‘B’
(corresponding to 15 kW output setting
– See Section 2.3) is located against the
cast boss on the fan housing. Replace
the screw in the centre of the air shutter
disc and tighten.

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

NOTE

!

NOTE

!

NOTE

!

CAUTION

!

D

E

F

G

H

L

M

I

Figure 10-2:

15/21 air adjuster disc at position 'C'

NOTE

!

33

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

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

Details of every service should be
entered in the Service Log, in the
Boiler Handbook.
This information may be required to
validate the Grant extended warranty.

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

External equipment operated at 230 volts
should not be serviced or repaired under
adverse weather conditions.

A test switch is fitted to the control
panel to allow the boiler to be test­fired. When On, the switch by-passes

the external control system.

11.1 Checking Before Servicing

The following sequential checks should
be made before any servicing:

1. Check the flue terminal and ensure it
is not blocked or damaged.

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

3. Ensure that all water/fuel system
connections and fittings are sound.
Remake any joints and check the
tightness of any fittings that may be
leaking.

4. If the boiler is used on a sealed
central heating system, check
the system pressure, check the
operation of the pressure relief valve
and check the expansion vessel air
charge. See Section 7.2.

5. Refill, vent and re-pressurise the system
as necessary. See Section 7.3.

6. Check that the louvres in the front
panel are clear.

7. Remove any sludge/water from the
fuel tank by opening the sludge valve
at the lower end of the tank.

8. With the fuel supply valve closed,
clean/replace the filter element and
clean the filter bowl.

9. Braided flexible fuel supply hoses (as
supplied with the boiler) should be
replaced annually. If long-life hoses
have been installed, these should be
inspected annually. If in doubt replace
the hoses. In any event, these hoses
must be replaced every five years.

Before servicing, set the boiler On/
Off switch to Off, isolate the electricity
supply and close the fuel supply valve.

Allow the boiler to cool.

The data label on the inside of the case
side panel will indicate the fuel used and
the nozzle fitted.

11.2 Dismantling Prior to Servicing

The procedure for dismantling the boiler
is as follows:

1. Remove the front panel by turning
the handle and withdrawing it
forwards at the bottom.

2. Remove the four screws securing the
top panel and carefully lift it off, taking
care not to damage the insulation.

The top panel has been designed to

provide a slight fall away from the side
positioned against a wall, the side of the
top panel with the fixing screws closer
to the bottom edge is the highest side
and goes against the wall.

2. If a sealed system kit is fitted,
carefully lift up and remove the
expansion vessel from the front of
the boiler. Place the vessel on the
floor taking care not to strain the
flexible hose.

3. Remove the burner fixing nut (top of
mounting flange) and withdraw the
burner.

If required, disconnect the flexible oil

hose(s), use a suitable container to
prevent any oil spillage.

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

11.3 Cleaning the Boiler

The procedure for cleaning the boiler is
as follows:

1. Remove the nuts and washers
securing the front cleaning door and
withdraw the door. Take care - it is
heavy.

2. Remove the baffles as shown in
Figures 11-1, 11-2, 11-3 or 11-4.

3. Remove all deposits from the baffle
plates and all the boiler internal
surfaces using a stiff brush and
scraper if necessary.

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

5. Check the condition of the front
cleaning door seal, replace if
necessary.

6. Replace the baffles, ensuring they
are correctly fitted. See Figures 11-1,
11-2, 11-3 or 11-4.

7. Pull out the spiral turbulators from
the heat exchanger tubes. See
Figure 11-5.

8. Clean the turbulators using a stiff
brush

9. Test the heat exchanger condensate
drain by pouring water into one of
the lower tubes and observe whether
the water discharges from the 22
mm condensate outlet. Replace the
turbulators.

10. Replace the front cleaning door,
ensuring the seal is in good condition
and secure it in position with the nuts
and washers previously removed.
Tighten to form a seal.

11 Boiler Servicing

CAUTION

!

NOTE

!

WARNING

!

WARNING

!

NOTE

!

NOTE

!

Boiler Servicing

34

11. Remove the condensate trap and
check that it is not blocked and is
operating correctly, i.e. the float is
free to move. Clean the trap and float
as required. Refer to Section 6.8.

12. Check that the boiler condensate outlet
is unobstructed. Clean if necessary.

The condensate trap and condensate
outlet must be checked on every
service and cleaned as necessary.

NOTE

!

Boiler Servicing

Top set

Bottom set

1

2

3

4

Figure 11-1: 15/21 baffles Figure 11-2: 15/26 baffles

IMPORTANT:

The ends of the
turbulators must
be vertical

Position in vertical plane

Figure 11-4: 46/58 and 58/70 baffles (58/70 shown) and turbulators (all models)Figure 11-3: 26/36 and 36/46 baffles

11.4 Cleaning the Burner

15/21, 15/26, 26/36, 36/46 models
The procedure is as follows:

1. Combustion head: Loosen the two
screws securing the combustion
head and withdraw the head.

2. Clean the combustion head.

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

Figure 11-5: Turbulators

Top baffle

Reduced height top baffles
fitted to 46/58

Bottom baffle

Right

baffles
Left
baffles

35

4. Nozzle: The nozzle should be
replaced on an annual service.
Check that the nozzle size and type
are correct, refer to table in Section

2.3 and boiler data label.

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

6. Do not attempt to clean the nozzle.

7. Remove the nozzle using a good
fitting spanner (16 mm).

The use of an ill-fitting spanner will
damage the nozzle and could lead to
an incorrect flame pattern.

8. Always check the electrode settings
after replacing the nozzle, see Figure
11-6.

46/58 or 58/70 models
The procedure is as follows:

1. Combustion head: Loosen the two
screws securing the combustion head
(not the screws in the slotted ring,
Figure 11-7) and withdraw the head.

2. Clean and refit the combustion head.

3. Inspect the ignition electrodes:
Loosen the electrode clamp screw,
disconnect the leads and withdraw the
electrode assembly. Wipe clean and
check for any cracks in the ceramic
insulation. Replace if necessary.

4. Check the electrode and diffuser
settings: Figure 11-8.

5. To adjust the diffuser disc: Loosen
the diffuser clamp screw and slide
the disc along the nozzle holder to
achieve the gap 'A' in Figure 11-8,
tighten the screw.

6. To adjust the electrodes: Loosen the
electrode clamp screw and move the
electrode unit to achieve the gap 'B'
in Figure 11-8, tighten the screw.

7. The combustion head position is
adjustable on the 46/58 and 58/70
burners. Check that it is fully closed
(position 0), or the 4th line if the
58/70 has been set to maximum
output (70 kW).

Boiler Servicing

Combustion
head

Combustion head

fixing screw
Electrode clamp
screw

Electrode
leads

Nozzle
holder

Diffuser clamp
screw

Burner
flange

4 ± 0.3 mm

3 to 3.5 mm

Clamp screw

Figure 11-6: 15/21, 15/26, 26/36, 36/46
electrode settings

Figure 11-7: 46/58, 58/70 burner

A

B

Electrode clamp screw

5.75

0

-0.2

3

+0.5

0

Diffuser clamp screw

4.0

+0.5

7.5

+0.7

- 0.5

_

B

A

Diffuser disc

Figure 11-8: 46/58, 58/70 electrode settings

CAUTION

!

8. To adjust the head setting, refer to
Figure 11-9 and proceed as follows:
Loosen the two screws in the slotted
ring - not the two fixing screws, and
turn the blast tube until '0' or the
4th line lines up with the edge of the
slotted ring (see paragraph 7 above).
Tighten the two screws.

36

Boiler Servicing

0

Screw

Slotted ring

Screw Combustion

head

Combustion
head fixing
screw

Figure 11-9: 46/58, 58/70 head settings

WARNING

!

All models
Photocell - The photocell is a push-fit in the

burner body. Carefully pull it out to clean.

Burner fan - With the air intake grille
or spigot removed, remove the screws
securing the fan housing cover (R/H
side of burner) and remove the cover.
Inspect the fan and housing and clean as
necessary. Replace the cover.

Pump filter - With the burner cover
removed, remove the four screws securing
the pump end cover. Remove the filter and
wash in kerosene. Replace the filter and
end cover, ensure the 'O' ring is in position.

Re-assemble in reverse order.

To ensure safe and efficient operation
of the boiler it is important that re­commissioning is carried out, especially
combustion checks (CO

2

level, flue gas
temperature and smoke number) after
the boiler has been serviced.

Refer to the Commissioning
instructions in Section 10.

37

Fault Finding

12 Fault Finding

12.1 Boiler Fault Finding

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

Fault

Boiler will not start: Remedies

1 No fuel supply.

2 No electricity supply.

3 Burner not starting - fuel and

electricity supplies present.

4 Burner lights but goes to lock-out.

Ensure that an adequate supply of fuel is available and that the fuel supply valve is open.

Check the condition of the fuel filter, clean if necessary.

Ensure fuel supply is reaching burner and vent pump.

Ensure electricity supply to the boiler is switched on and that all controls are calling for heat.

Ensure that the overheat thermostat has not tripped, reset if necessary.

Check that a mains supply is present at the burner terminal block.

If not, check the boiler and overheat thermostat.

Press the reset button on the burner control box if it is lit.

Refer to burner fault finding charts.

If the flame is unstable, check the combustion settings.

Refer to burner fault finding charts.

Boiler works but:

5 Visible smoke from flue or high

smoke number.

6 Burner pulses.

7 Flame slow to stabilise

during start up.

8 Water temperature low.

9 Boiler operating on overheat

thermostat.

10 Oil odours.

11 Combustion fumes smell.

Insufficient air supply - check the air damper setting and the condition of the fan.

Check ventilation openings in door are clear, see Section 9.6.

Check the nozzle size and type.

Fuel pressure may be too high - check and adjust.

Insufficient air supply - check the air damper setting and the condition of the fan.

Check ventilation openings in door are clear, see Section 9.6.

Check the nozzle size and type.

Insufficient air supply - check the air damper setting and the condition of the fan.

Check ventilation openings in door are clear, see Section 9.6.

Check the nozzle size and type.

Fuel pressure may be too low - check and adjust.

Insufficient draught - clean boiler heat exchanger and check condition of flue.

Undersize nozzle and/or low fuel pressure.

Check condition of boiler heat exchanger and clean if necessary.

Check the boiler thermostat.

Check the combustion settings.

Check the condition of the fuel filter.

Faulty boiler thermostat. No circulation, check circulating pump. Check for air lock.

Check all fuel line connections, remake as necessary.

Check boiler cleaning cover and seal are correctly fitted.

Check burner is correctly fitted onto flange.

Check flue is correctly sealed into flue outlet of boiler.

Check the condensate pipe and trap are operating correctly.

38

Fault Finding

12.2 Burner Fault Finding - Riello RDB burners

Motor/pump

seized

or tight

Replace

motor

capacitor

Burner

motor runs

Check L & N

to control

box

Check

boiler

controls

Motor gives

50 Volts

to white wire

*

Replace

burner

motor

Repair

or replace

motor/pump

Lockout

after 12 sec

purge

Lockout

within

1 second

Replace

solenoid

coil

Coil of

solenoid

sound **

Repair or

replace

oil pump

Washing

pressure

1 to 2 bar

Photocell

sound ***

If balanced flue,

remove air tube

and retest

Reseal

balanced flue

or reposition flue

Replace

photocell

Drive

coupling

broken

Pump

produces

pressure

Replace

nozzle

Contaminated

fuel or

filter

Combustion

air set

Flame off

and

relights

Boiler or

flue

blocked

Combustion

head set

YES NO

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO YES

NO

NO

NO

Check and

set the

electrodes

Replace

the

control box

Ignition

spark

proved

NO

NO

NO

NO

NO

OK

NO

NO

NO

NO

Solenoid

valve

operating

Replace

control

box

Check oil

pressure

regulator

Replace coil

and/or

stem valve

Nozzle

atomising

fuel

NO

YES

NO

NO

Notes

*

**

***

Motor white wire returns 50 - 53

V AC

to control box.

Test solenoid coil for continuity or 100

ohms.

Test photocell by disconnecting it in

control box. If burner fires and then

goes to lockout, photocell should be

replaced.

It is best to replace the photocell if it is

suspect.

Burners on balanced flue systems can

recirculate flue products causing

burner recycling. If this happens,

check flue position and sealing.

39

13 Spare Parts

Spare Parts

Cleaning door nut and washer set

Double pole switch

Test switch

Frost thermostat

Baffle set (complete) - 15/21

Baffle set (complete) - 15/26

Baffle set (complete) - 26/36 and 36/46

Baffle set (complete) - 46/58

Baffle set (complete) - 58/70

Turbulator baffle - single (all models)

Sealed system - Expansion vessel 10 litre - 15/21

Sealed system - Expansion vessel 12 litre - 15/26

Sealed system - Expansion vessel 16 litre - 26/36 and 36/46

Sealed system - Water pressure gauge

Sealed system pressure relief valve

Sealed system - Expansion vessel flexible hose

Cleaning door rope seal - 15/21 and 15/26

Cleaning door rope seal - 26/36 and 36/46

Cleaning door rope seal - 46/58 and 58/70

Overheat thermostat

Boiler thermostat

Circulating pump - 6 m head

Circulating pump - 7 m head

Description Part No.

13.1 Boiler parts list

EFBS14

EFBS19

EFBS21

EFBS23

VBS93

VBS01

VBS36

VBS76

VBS77

VBS05

MPCBS27

MPSS01

MPSS07

MPSS02

MPSS03

MPSS04

VBS15

VBS16

VBS111

TPBS33

TPBS34

MPCBS23

VBS54

13.2 Burner heads

Figure 13-1: Burner heads

20 dia.

15 x 4.5dia.

5 x R5

T2 - 15/26 (23-26 kW)

20dia.

15 x 5.5dia.

5 x R5

T3 - 26/36

23dia.

15 x 5.5dia.

5 x R5

T5 - 36/46

18dia.

15 x 4dia.

5 x R3

T1 - 15/21, (15/26 15-20kW)

GIB - 46/58, 58/70

40

Spare Parts

This section gives exploded views of the
Riello burners in the Grant VORTEX Pro
boilers, and parts lists associated with
them

Figure 13-2: Riello RDB1, RDB2 and RDB2.2 burner components diagram

13.3 Riello RDB1, RDB2 and RDB2.2 burners

41

Spare Parts

Key No.

Description Riello Part No.

Grant Part No.

1

2

3

3

3

3

4

5

6

7

8

9

10

10

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Not applicable

Flange

Combustion head T1 - 15/21 kW

Combustion head T2 - 15/26

Combustion head T3 - 26/36

Combustion head T5 - 36/46

Electrode assembly

Electrode bracket

Nozzle holder

Collar

High voltage lead

Air damper assembly

Fan - 15/26

Fan - 26/36

Fan - 15/21, 36/46

Photocell

Capacitor 4.5 µF

Seal kit

Needle valve

Regulator

Pump seal

Pump

'O' ring

Filter - 'O' ring

Connector

Flexible hose

Tube

Pressure gauge connector

Drive coupling

Solenoid

Motor RBS102

Cover

Control box assembly

Solenoid lead

Cover

Air tube spigot

-

3005786

3002507

3002423

3002447

3002533

3007513

3006552

3008642

3008643

3008794

3008647

3005708

3008645

3005788

3008646

3002837

3008878

3007582

3008651

3000439

3008654

3007162

3008653

3003602

3007672

3008644

3008876

3000443

3008648

3002836

3008649

3008652

3008851

3008879

3062774

-

RBS119

RBS146

RBS147

RBS144

RBS150

RBS108

RBS29

RBS111

RBS112

RBS129

RBS116

RBS39

RBS142

RBS151

RBS115

RBS149

RBS140

RBS109

RBS120

RBS14

RBS101

RBS08

RBS122

RBS35

RBS36

RBS113

RBS138

RBS16

RBS117

RBS102

RBS118

RBS103

RBS139

RBS141

RBS143

Riello RDB1, RDB2 and RDB2.2 burner parts list

42

Figure 13-3: Riello RDB3.2 burner components diagram

Spare Parts

13.4 Riello RDB3.2 burner

43

Flange

Combustion head

Diffuser disc assembly

Nozzle holder

High voltage lead

Collar

Seal kit

Air damper assembly

Insulation

Fan

Photocell

Cover

Electrode

Capacitor 5 µF

Connector

Flexible hose

Motor

Pressure gauge connector

Tube

Drive coupling

Solenoid

Solenoid lead

Pump

Pump seal

Filter - 'O' ring

Regulator

Needle valve

Control box assembly

Cover

Spare Parts

Key No.

Description Riello Part No.

Grant Part No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

Riello RDB3.2 burner parts list

RBS153

RBS163

RBS154

RBS164

RBS129

RBS165

RBS156

RBS166

RBS157

RBS162

RBS115

RBS168

RBS158

RBS167

RBS35

RBS36

RBS159

RBS138

RBS160

RBS16

RBS117

RBS139

RBS101

RBS14

RBS122

RBS120

RBS109

RBS103

RBS118

3008637

3002572

3020180

3002570

3008794

3008957

3008963

3008839

3008958

3005799

3008646

3008962

3020121

3008960

3003602

3005720

3008964

3008876

3008961

3000443

3008648

3008851

3008654

3000439

3008653

3008651

3007582

3008652

3008649

44

Health and Safety

Information

14 Health and Safety Information

Under the Consumer Protection Act
1987 and Section 6 of the Health
& Safety at

Work Act 1974, we are

required to provide information on
substances hazardous to health (COSHH
Regulations 1988).

Adhesives, sealants and paints used in
the manufacture of the product are cured
and present no known hazards when
used in the manner for which they are
intended.

The following other materials are present
in the product:

14.1 Insulation Materials

Material Types: Ceramic fibre board,

mineral wool.

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

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

Precautions: Avoid unnecessary or
rough handling, or harsh abrasion of
boards. Normal handling and use of
material should not produce high dust
levels.

Avoid inhalation, and contact with skin
and eyes.

After handling always follow normal good
hygiene practices.

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

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

Skin - If irritation occurs, wash under
running water before washing with soap
and water.

Inhalation - Remove to fresh air, drink
water to clear throat and blow nose to
remove dust/fibres.

Ingestion - Drink plenty of water.

14.2 Sealant Materials

Material Types: Silicone elastomer.

Description: Sealant and adhesive.

Known Hazards: Irritation to eyes.

Precautions: Avoid inhalation of vapour,

contact with eyes and prolonged or
repeated contact with skin.

After handling always follow normal
good hygiene practices.

Protection: Use eye protection. Rubber
or plastic gloves should be worn where
repeated contact occurs and a face
mask worn when working in confined
spaces.

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

Skin - Wipe off and wash with soap and
water.

Inhalation - Remove to fresh air.

14.3 Kerosene and Gas Oil Fuels
(mineral oils)

Known Hazards: The effect of mineral

oils on the skin vary according to the
duration of exposure and the type of oil.

The lighter fractions remove the
protective grease naturally present on
the skin, leaving it dry, liable to crack
and more prone to damage by cuts,
abrasions and irritant chemicals.

Skin rashes (Oil acne) most often on
arms, but also on any part of the body in
contact with oil or oily clothing.

Contact with fuel oils can cause
dermatitis.

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

The use of a lanolin-based barrier cream
is recommended, in conjunction with
regular washing with soap and rinsing
with water to ensure all oil is removed
from the skin.

Take care to prevent clothing,
especially underwear, from becoming
contaminated with oil.

Do not put oily rags or tools in pockets,
especially trouser pockets.

Have first-aid treatment at once for an
injury, however slight.

Do not inhale any vapours from mineral
oils.

45

EC Declaration

of Conformity

15 EC 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)

In EU Countries

The following information is provided
to enable regulatory compliance with
the European Union (EU) directives
identified and any amendments made to
these directives when using electrical or
electronic equipment in EU countries.

Disposal of Electrical and Electronic
Equipment

European Union (EU) Directive 2002/96/
EC Waste Electrical and Electronic
Equipment (WEEE)

Do not dispose of electrical or electronic
equipment in landfill sites. In the EU, it
is the individual recipient's responsibility
to ensure that discarded electrical or
electronic materials are collected and
recycled according to the requirements
of EU environmental law.

Disposal of Surplus Packaging

European Parliament and Council
Directive 94/62/EC Packaging and
Packaging Waste

Do not dispose of surplus packaging in
landfill sites. In the EU, it is the individual
recipient's responsibility to ensure that
packaging materials are collected and
recycled according to the requirements
of EU environmental law.

In non-EU Countries

In non-EU countries, dispose of electrical
and electronic equipment and all surplus
packaging in accordance with national
and regional regulations.

Complies with EC Low voltage
Electromagnetic compatibility and Boiler
efficiency Directives.

89/336/EEC
73/23/EEC
92/42/EEC

46

Warranty

16 Warranty

16.1 The Vortex Oil Boiler Warranty

Dear Customer

You are now the proud owner of a Grant
Vortex Pro condensing boiler from Grant
Engineering (UK) Ltd. that has been
designed to give years of reliable, trouble
free operation.

Grant Engineering (UK) Ltd. guarantees
the manufacture of the boiler including
all electrical and mechanical components
for a period of twelve months from the
date of purchase, provided the boiler
is installed in full accordance the the
installation instructions provided. This
will be extended to a period of two years
if the boiler is registered with Grant UK
within thirty days of installation and it is
serviced at twelve month intervals. See
Terms and Conditions below.

Important

Please register your Grant Vortex Pro
boiler with Grant UK within thirty days of
installation. To do so visit www.grantuk.
com and follow the links to 'Householder
Zone', where you can register your boiler
for a further one year warranty (giving
two years from the date of purchase).
This does not affect your statutory rights.

Breakdown During the
Manufacturer's Warranty

If your Grant boiler should fail within
the first two years, you must contact
Grant Engineering (UK) Ltd. who will
arrange for the repair under the terms
of their Warranty, providing that the
boiler has been correctly installed
and commissioned, serviced (if older
than twelve months) and the fault is
not due to tampering, running out of
oil, oil contamination, system water
contamination, misuse or the failure of
any external components not supplied
by Grant UK (e.g. fire valve, motorised
valve etc.). This extended two year
warranty only applies if the boiler is
registered with Grant UK within thirty
days of installation.

In the First Instance

Contact your installer or commissioning
engineer to ensure that the fault does
not lie with the system or any other
components, or any incorrect setting of
the system controls.

If a Fault is Found

Ask your installer to contact Grant
Engineering (UK) Ltd. Service
Department on 01380 736920 who will
arrange for a qualified service engineer
to attend to the fault.

Free of Charge Repairs

During the first two years no charge for
parts or labour will be made, provided
that the boiler has been installed and
commissioned correctly in accordance
with the manufacturer's instructions,
it was registered with Grant UK within
thirty days of installation and, for boilers
over twelve months old, details of annual
maintenance is available. The following
documents must be made available to
Grant UK on request:

• Proofofpurchase

• CD10InstallationCompletionform

• CD11Commissioningreportform

• Servicedocuments(CD11or

equivalent document).

Chargeable Repairs

A charge may be made (if necessary
following testing of parts at Grant UK)
if the cause of the breakdown is due to
any of the following:

• Faults caused by the plumbing
or heating system, e.g.
contamination of parts due to
system contamination, debris or
trapped air.

• Faults due to incorrectly sized
expansion vessel or incorrect
vessel charge pressure.

• Faults caused by external electrics
and external components.

• The boiler has not been
commissioned, or serviced in
accordance with the installation
and servicing manual.

• Problems caused by lack of oil or
faults with the oil supply system.

• The flue system has been
incorrectly fitted or does not meet
installation requirements.

• The boiler has been installed for
over two years and no extended
warranty cover has been taken.

Note: The nozzle supplied with the boiler
is only covered for a period up to the
time of the first service (twelve months).

Remember - before you contact Grant

Ensure the boiler has been
commissioned and serviced in
accordance with the installation and
servicing manual.

Ensure there is oil supply to the burner.

Ensure the problem is not being caused
by the heating system or its controls.
Consult the boiler handbook for
guidance.

Please note: Do not wait until the fuel
supply runs out before you order some
more. Sludge in the bottom of the tank
may be drawn into the fuel lines. It is
recommended that the boiler is switched
off when the new supply is delivered and
that the fuel is allowed to settle for an
hour before restarting the boiler.

Terms of Manufacturer's Guarantee

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

2. The boiler is guaranteed for two
years from the date of purchase,
providing that after twelve months
the annual service has been
completed and the boiler registered
with the Company within thirty days
of the installation date. Any work
undertaken must be authorised by
the Company and carried out by an
approved service agent.

3. The shell (heat exchanger) of the
oil boiler supplied by the Company
is covered by a five year parts only
guarantee from the date of purchase
subject to correct operation of the
boiler. Proof of annual maintenance
must be provided.

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

5. The boiler is registered with the
Company within thirty days of
installation. Failure to do so does not
affect your statutory rights.

6. This guarantee is not transferrable
unless sanctioned by the Company.

47

Warranty

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

8. This guarantee applies to Grant
boilers installed on the UK mainland,
Isle of Man and Channel Islands
only. Provision of in-warranty cover
elsewhere in the UK is subject to
agreement with the Company.

9. All claims under this guarantee
must be made to the Company
prior to any work being undertaken.
Invoices for call out/repair work by
any third party will not be accepted
unless previously authorised by the
Company.

10. Proof of purchase and date of
installation, commissioning and
service documents must be provided
on request.

11. If a replacement boiler is supplied
under the warranty (due to a
manufacturing fault) the product
warranty continues from the

installation date of the original
boiler, and not from the installation

date of the replacement.

16.2 Extended Warranty

For further peace of mind Grant
Engineering (UK) Ltd. offer the option
to insure all the components of your
Grant Vortex Pro boiler for a further three
years, following on from the two year
product warranty period. For a single
premium payment (inclusive of Insurance
Premium tax) you get five years of
protection against breakdown costs. At
the end of this period you will have the
opportunity to continue this cover on an
annual basis.

To access full details and an application
form for this extended cover, first visit
www.grantuk.com follow the links to
the 'Householder Zone', register your
Grant Vortex Pro boiler for a further one
year product warranty (giving two years
from the date of purchase), and then
download the extended warranty details
and application form.

Please note that this special offer is
only available if the application form
is submitted to Bluefin Insurance
Services Ltd. within three months of the
installation date.

48

Notes

17 Notes

49

Notes

7

User Instructions

89/336/EEC

73/23/EEC

92/42/EEC

6

User Instructions

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 module

includes a built-in frost thermostat

factory set to 2°C.

We recommend that both antifreeze

and corrosion inhibitor be used in the

primary water system.

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.

External equipment operated at

230 volts should not be serviced

or repaired under adverse weather

conditions.

Failure of Electricity Supply

If the electricity supply fails, the boiler

will not operate. It should relight

automatically when the supply is

restored.

Electricity Supply

The boiler requires a 230/240 V ~ 50 Hz

supply. It must be protected by a 5 Amp

fuse.

The electricity connections to the

boiler must be earthed.

Sealed Central Heating System

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 this is

frequently required, ask your Installer or

Service engineer to check the heating

system for leaks and to check the

expansion vessel air charge.

The boiler or system will be fitted with an

automatic air vent to remove air from the

system. Any air trapped in the radiators

should be removed by venting the

radiators using the vent screw at the top

of each radiator. Only vent a radiator if

the top is cool and the bottom is hot.

Excessive venting will reduce the system

pressure, so only vent when necessary

and check the system pressure as

mentioned above.

Re-pressurise the system if necessary.

The sealed system is 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.

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

Figure 3) is connected and that the

shut off valve connecting it to the

boiler is open and the double check

valve at the front is closed. (A valve

is open when the operating lever is in

line with the valve, and closed when

it is at right angles to it).

3. Gradually open the double check

valve on the front of the filling loop

until water is heard to flow. When the

black needle of the pressure gauge

is between 0.5 and 1 bar, close the

valve.

4. Vent each radiator in turn, starting

with the lowest one in the system, to

remove air.

5. Continue to fill the system until the

pressure gauge indicates between

0.5 and 1.0 bar. Close the fill point

valve.

6. Repeat steps 4 and 5 as required.

7. Close the valves either side of the

filling loop and disconnect the loop.

WARNING

!

Figure 3: Sealed system filling loop arrangement

NOTE

!

WARNING

!

5

User Instructions

7. Check to see if the safety thermostat

has operated (see Section Overheat

Thermostat).

If the burner still fails to light after

carrying out these checks then a

fault exists or the fuel supply is low.

If you have sufficient fuel, switch off

the electricity supply to the boiler and

contact your Service engineer.

Overheat 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

marked reset (see Figure 1), press the

button then replace the cap.

If this condition continually repeats,

contact your Service engineer.

Ventilation

Always ensure that the boiler has

adequate ventilation. Any ventilation

openings provided by the Installer must

not be obstructed.

Periodically check that they are clear.

Do not attempt to 'box in' the boiler or

build a compartment around it before

consulting your Installer.

Do not place any combustible material

around or on the boiler or flue pipe.

Do not place anything against the

door of the External module that might

obstruct the ventilation openings.

Flue Terminal

The flue terminal must not be obstructed

or damaged.

In severe conditions check that the

terminal does not become blocked by

snow.

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.

5. Check that the fire valve in the oil

supply line has not tripped

6. Ensure that a fuse has not blown or that

the electricity supply has not failed.

7. Check to see if the safety thermostat

has operated (see Section Overheat

Thermostat).

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.

Turning Off your Boiler

For short periods - Set the boiler On/

Off to OFF.

To restart, simply set the switch to ON.

For long periods: Set the boiler On/

Off switch to OFF and switch off

the electricity supply to the boiler. If

required, the fuel supply valve may be

closed and the water and electricity

supplies turned off at the mains.

About your Fuel

Grant VORTEX Pro External modules

only operate on Class C2 Kerosene to

BS 2869:1998.

You should always quote this type of fuel

when ordering from your supplier.

Do not wait until the fuel runs out before

you order some more. Sludge in the

bottom of the tank may be drawn into

the fuel lines. If it is possible, switch

off the boiler when the new supply is

delivered and leave the fuel to settle for

an hour before restarting the boiler.

General Notes and Care of your

System

Boiler thermostat

This control allows the temperature of the

water leaving the boiler to heat the radiators

and domestic hot water to be adjusted.

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.

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.

Figure 1 shows the position of the Lock-

out Reset button on the burner

Make the following checks:

1. Check that the boiler On/Off switch

is ON.

2. Check that the programmer (if fitted)

is working and is in an 'on' period.

3. Check that all thermostats are set to

the desired setting and are calling for

heat.

4. Check if the burner 'Lock-out' reset

button (on the burner) is lit. If it is, press

it to start the burner. If the burner fails

to light and goes to 'Lock-out' again,

check that you have sufficient fuel in the

storage tank and that the fuel supply

valve is open.

5. Check that the fire valve in the oil

supply line has not tripped

6. Ensure that a fuse has not blown or that

the electricity supply has not failed.

NOTE

!

4

User Instructions

Introduction

This User Guide is intended to assist

the User in the operation of the Grant

VORTEX Pro External modules. The

engineers manual for the installation and

maintenance of this boiler is attached to

the reverse of these instructions

The following special text formats are

used in this manual for the purposes

listed below.

Warning of possible human injury as

a consequence of not following the

instructions in the warning.

Note text. Used for emphasis or

information not directly concerned

with the surrounding text but of

importance to the reader.

About your boiler

The boiler is fully automatic once

switched on, providing central heating

(and also heating your domestic hot

water if you have a hot water cylinder

fitted). An illuminated On/Off switch, see

Figure 1, is fitted to the External modules

which lights when the boiler is switched

on, but does not necessarily indicate the

burner is firing.

Boiler Controls

To gain access to the External module

controls, remove the front panel by

turning the handle and withdrawing

it forwards at the bottom.

Lighting your Boiler

The lighting procedure is:

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.

The neon in the switch lights when it

is in the on position.

4. The boiler will now light

automatically.

If your Boiler Fails to Light

Make the following checks:

1. Check that the boiler On/Off 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.

WARNING

!

NOTE

!

Figure 1: Boiler controls

User Instructions

PRO EXTERNAL

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

3

Contents

Contents

Introduction

About your Boiler

Boiler Controls

Lighting your Boiler

If your Boiler Fails to Light

Turning off your Boiler

General Notes and Care of

your system

Boiler Thermostat

Burner Lock-out Indicator

and Reset Button

Overheat Thermostat

Programmer

Ventilation

Flue Terminal

Frost Protection

Cleaning and Servicing

Failure of Electricity Supply

Electrical Supply

Sealed Central Heating System

4

4

4

4

5

5

5

6

6

6

5

5

5

6

6

6

6

6

6

2

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or

appearances are changed in the interests of continued product improvement.

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

© Grant Engineering (UK) Limited 2012. No part of this manual may be reproduced by any means without prior written consent.

GRANT ENGINEERING (UK) LIMITED

Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU

Tel: [phone] Fax: [phone]

Email: [email protected] www.grantuk.com

Service Log

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 Pro 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 bio-

kerosene it will be necessary to take

the following actions:

a) Use a bio-kerosene (B30K)

compatible flexible oil line in place of

the oil line supplied with this boiler.

b) Have your oil storage tank and oil

supply line (including all pipework,

sight gauges, filters, isolating valves,

fire 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.

c) Check the suitability of the flue system

with Grant UK.

d) 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.

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.

Part No. Doc 52 Rev.06 May 2012 D314

Grant Vortex Pro

External Module Condensing Oil Boiler Range

User Instructions