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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or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: [e-mail] 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