GRANT VTXOMWH16-21 Vortex Eco Wall Hung Instruction Manual

VTXOMWH16-21 Vortex Eco Wall Hung

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Specifications

• Product Name: Grant Vortex Eco Wall Hung External and Wall Hung
  External System Condensing Oil Boiler Range

• Product Code: VTXOMWH16/21, VTXSOMWH16/21

• Fuel Type: Suitable for use with Class C2 Kerosene

• Serial Number Identifier: 764, 766

Product Usage Instructions

1. Introduction

1.1 How a Condensing Boiler Operates: Lorem
ipsum dolor sit amet, consectetur adipiscing elit. Proin eget ante
vel nunc feugiat aliquet.

1.2 Boiler Description: Nulla facilisi. Integer
in dui eget velit ultricies tincidunt. Quisque nec nibh nec nisi
ultrices lacinia.

1.3 Flue Options: Sed malesuada ante sit amet
justo malesuada, at semper nisi sagittis.

1.4 Boiler Components: Fusce auctor, purus eget
fermentum egestas, felis sapien tincidunt lorem.

2. Technical Data

2.1 Boiler Technical Data: Vivamus eget est nec
leo pharetra rhoncus.

2.2 Sealed System Data: Donec cursus, felis sit
amet volutpat semper, odio arcu efficitur libero.

2.3 Burner Settings: Etiam auctor erat ac
gravida vestibulum.

2.4 Flue Gas Analysis: Nunc ac diam nec eros
rutrum scelerisque.

2.5 Water Connections: Aenean in magna nec enim
consectetur sagittis.

2.6 Boiler Dimensions: Maecenas in ex eget
metus varius fringilla.

3. Oil Storage and Supply System

3.1 Fuel Supply: Curabitur ut mauris et nunc
posuere vestibulum.

3.2 Burner Oil Connection: Nam maximus nisl et
neque sagittis, sed tempor nisl lacinia.

4. Installation

4.1 Introduction: Duis fermentum augue at eros
fringilla, vitae gravida ex tempus.

4.2 Boiler Location: Ut auctor turpis a velit
tincidunt, eget scelerisque nisi aliquam.

4.3 Regulations Compliance: Phasellus varius
purus ut metus cursus, nec auctor nisi mollis.

4.4 Heating System Design Considerations:
Integer euismod purus vel lectus molestie, ut hendrerit libero
consequat.

4.5 Pipework Materials: Suspendisse potenti.
Mauris vel ipsum nec turpis ultrices euismod.

4.6 Connections: Nullam non neque at nisl
pulvinar tincidunt.

4.7 Preparation for Installation: Vestibulum
sit amet mauris vel tortor bibendum interdum.

4.8 Dismantling the Boiler: Integer id elit sed
diam ornare posuere.

4.9 Installing the Boiler: Sed ultricies justo
eget dapibus aliquet.

4.10 Filling the Heating System: Proin auctor
risus at urna accumsan, id ornare mi efficitur.

4.11 Before You Commission: Fusce scelerisque
tellus ut sapien ullamcorper, at vehicula odio convallis.

Frequently Asked Questions (FAQ)

Q: How often should the boiler be serviced?

A: The boiler should be serviced at least every
twelve months, and the details should be entered in the Service Log
in the user handbook.

Q: What fuel types are suitable for Grant Vortex boilers?

A: All Grant Vortex boilers are suitable for
use with Class C2 Kerosene. The use of Class D Gas Oil on specific
models is not recommended due to non-compliance with
regulations.

Q: Can the boiler operate on Bio-Fuel?

A: Yes, the appliance can operate on
Bio-Kerosene (B30K) with proper reference to the provided
information in the manual.

“`

Grant Vortex Eco
Wall Hung External and Wall Hung External System Condensing Oil Boiler Range Installation and Servicing Instructions
UK | DOC 0127 | Rev 3.1 | March 2024

IMPORTANT NOTE FOR INSTALLERS
These instructions are intended to guide installers on the installation, commissioning and servicing of the Grant Vortex oil boiler. After installing the boiler, leave these instructions with the user. A user handbook is available to guide users in the operation of the oil boiler.
SPECIAL TEXT FORMATS
The following special text formats are used in these instructions for the purposes listed below:
! WARNING !
Warning of possible human injury as a consequence of not following the instructions in the warning.
! CAUTION !
Caution concerning likely damage to equipment or tools as a consequence of not following the instructions in the caution.
! NOTE !
Used for emphasis or information not directly concerned with the surrounding text but of importance to the reader.

PRODUCT CODES AND SERIAL NUMBERS COVERED
The serial numbers used on Grant oil boilers consist of a fifteen digit numerical code with the final three digits being the product identifier.
For example:
100000200218764
These instructions cover the following product codes and serial numbers:

Product code VTXOMWH16/21 VTXSOMWH16/21

Serial number identifier 764 766

SERVICING
The boiler should be serviced at least every twelve months and the details entered in the Service Log in the user handbook.
FUEL TYPE
All Grant Vortex boilers are suitable for use with Class C2 Kerosene. The use of Class D Gas Oil on all Grant Vortex Low NOx and Blue Flame boilers DOES NOT comply with ErP requirements or EU regulations, and as a result Grant UK does not condone its use. To use Bio-Kerosene (B30K), refer to the information below:
OPERATION ON BIO-FUEL
All Grant Vortex condensing boilers manufactured since May 2011 are suitable for operation on both standard Kerosene (Class C2 to BS 2869) and also bio- kerosene – up to a 30% blend (B30K). All burner settings and nozzle sizes (as detailed in Section 2.3 of these instructions) are correct for both standard kerosene and biokerosene (B30K). In order to operate this boiler on bio- kerosene, it will be necessary to take the following actions: · Use a bio- kerosene (B30K) compatible flexible oil line in
place of the oil line supplied with the boiler. · Have the oil storage tank and oil supply line (including all
pipework, sight gauges, 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. · Check the suitability of the flue system with Grant UK. · Use only bio-kerosene (B30K) that conforms to OPS24. IMPORTANT: Under no circumstances, should the boiler be used with bio-kerosene without the above actions being taken first.
! NOTE !
This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by children without supervision.

GRANT ENGINEERING (UK) LIMITED Frankland Road, Blagrove Industrial Estate, Swindon, SN5 8YG Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: [email protected] www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement. However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the author or others involved in its publication. All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. © Grant Engineering (UK) Limited. No part of this manual may be reproduced by any means without prior written consent.
Page 2

CONTENTS

1

INTRODUCTION

4

1.1

How a condensing boiler operates 4

1.2

Boiler description

4

1.3

Flue options

4

1.4

Boiler components

5

2

TECHNICAL DATA

6

2.1

Boiler technical data

6

2.2

Sealed system data

6

2.3

Burner settings

7

2.4

Flue gas analysis

7

2.5

Water connections

7

2.6

Boiler dimensions

8

3

OIL STORAGE AND SUPPLY SYSTEM 9

3.1

Fuel supply

9

3.2

Burner oil connection

11

4

INSTALLATION

12

4.1

Introduction

12

4.2

Boiler location

12

4.3

Regulations compliance

12

4.4

Heating system design

considerations

12

4.5

Pipework materials

13

4.6

Connections

13

4.7

Preparation for installation

13

4.8

Dismantling the boiler

13

4.9

Installing the boiler

15

4.10 Filling the heating system

16

4.11 Before you commission

16

4.12 Completion

16

5

PIPE CONNECTIONS

17

5.1

Water connections

17

5.2

Water connections – system models 17

6

CONDENSATE DISPOSAL

18

6.1

General requirements

18

6.2

Connections

18

6.3

Pipework

18

6.4

External pipework

18

6.5

Condensate soakaway

19

6.6

Condensate trap

19

6.7

Condensate disposal pipework

20

6.8

Inspection and cleaning of trap

20

7

SEALED SYSTEMS

21

7.1

Sealed system requirements

21

7.2

Filling the sealed system

22

7.3

Venting the pump

22

7.4

Pressure relief (safety) valve

operation

22

7.5

System models

23

8

ELECTRICAL

24

8.1

General

24

8.2

Connecting the power supply

24

8.3

Frost protection

25

8.4

Control system wiring diagrams

26

8.5

Boiler control panel wiring diagrams 28

9

FLUE SYSTEM AND AIR SUPPLY

29

9.1

Air supply

29

9.2

Conventional flue systems

29

9.3

External conventional flue

(green system)

29

9.4

Flue clearances

31

10

COMMISSIONING

33

10.1 Before switching on

34

10.2 Burner settings

34

10.3 Switching on

35

10.4 Running the boiler

36

10.5 Balancing the system

36

10.6 Completion

36

10.7 Information for the user

36

11

SERVICING

37

11.1 Checks before servicing

37

11.2 Dismantling prior to servicing

37

11.3 Cleaning the boiler

38

11.4 Cleaning the burner

38

11.5 Cleaning the burner:

Other components

39

11.6 Recommissioning

39

11.7 Burner components

40

12

FAULT FINDING

41

12.1 Boiler fault finding

41

12.2 Burner fault finding charts

42

13

SPARE PARTS

45

13.1 Boiler parts list

45

13.2 Sealed system parts list

45

13.3 Ecoflam Max 1 LN Burner

46

14

DECLARATION OF CONFORMITY

48

15

HEALTH AND SAFETY INFORMATION 49

15.1 Insulation materials

49

15.2 Sealant and adhesive

49

15.3 Kerosene and Gas Oil fuels

49

16

END OF LIFE INFORMATION

50

17

PRODUCT FICHE

51

18

GUARANTEE

52

A1

WILO-PARA 25-130/7-50/SC-6#GRA

CIRCULATING PUMP

54

Contents

Page 3

1 INTRODUCTION

1.1 HOW A CONDENSING BOILER OPERATES
During the combustion process, hydrogen and oxygen combine to produce heat and water vapour. The water vapour produced is in the form of superheated steam in the heat exchanger. This superheated steam contains sensible heat (available heat) and latent heat (heat locked up in the flue gas). A conventional boiler cannot recover any of the latent heat and this energy is lost to the atmosphere through the flue.
The Grant Vortex condensing boiler contains an extra heat exchanger which is designed to recover the latent heat normally lost by a conventional boiler. It does this by cooling the flue gases to below 90°C, thus extracting more sensible heat and some of the latent heat. This is achieved by cooling the flue gases to their dew point (approximately 55°C).
To ensure maximum efficiency, the boiler return temperature should be 55°C or less, this will enable the latent heat to be condensed out of the flue gases.
· The boiler will achieve net thermal efficiencies of 100%.
To achieve maximum performance from the Grant Vortex boiler, it is recommended that the heating system is designed so that a temperature differential of 20°C between the flow and return is maintained.
The Grant Vortex boiler will however still operate at extremely high efficiencies even when it is not in condensing mode and therefore is suitable for fitting to an existing heating system without alteration to the radiator sizes. The boiler is capable of a maximum flow temperature of 75°C.
1.2 BOILER DESCRIPTION
The Grant Vortex Eco external modules have an insulated waterproof enclosure made of galvanised steel with a powder coated finish and are designed for external installation, mounted on a suitable external wall.
The Grant Vortex Eco Wall Hung range of automatic pressure jet oil boilers have been designed for use with a fully pumped central heating system with indirect domestic hot water cylinder.
They are not suitable for use with either a direct cylinder or a `primatic’ cylinder or gravity hot water.
The boilers are suitable for use on open vented or sealed central heating systems. System models are supplied with the necessary components factory fitted. Refer to Section 7.
All boilers are supplied with the control panel and burner factory fitted.
The boilers are supplied with a flue terminal but can be connected to a conventional flue system.
All the models in the current Grant Vortex Eco range of boilers are designed to comply with the maximum NOx emissions* under the Energy-related Products Directive (ErP).

• From the 26th September 2018, the maximum NOx emissions for all new oil fired boilers (up to and including 400kW for both new build and replacement boiler installations) is 120mg/kWh.

1.3 FLUE OPTIONS
Grant Vortex Eco External Wall Hung boilers are supplied with a 45° conventional flue terminal (see Figure 1-1). There is one flue outlet position on these boilers, directly on top of the module (see Figure 2-1). The terminal can be rotated to direct the plume in the desired direction.
It is possible to discharge the products of combustion at a higher level by using the following components from the Grant `Green’ flue system: · External module starter (available as a straight section only
on the External Wall Hung boilers)
· Fixed extensions 150mm, 250mm, 450mm and 950mm · Adjustable extension 195 to 270mm · 45° elbow · High level 90° or vertical terminal It is possible to extend the flue system by 19m vertically (from the boiler outlet) using this system.
Please note, the flue may only be brought up vertically from Grant Vortex Eco External Wall Hung boilers.
Please refer to Sections 4.9 and 9 for more detailed instructions on how to install the flue system. Conventional flues only may be fitted to Grant Vortex Eco External boilers.
! NOTE !
The flue system materials and construction MUST be suitable for use with oil- fired condensing boilers. Failure to fit a suitable conventional flue may invalidate the guarantee on the boiler.

Page 4

Section 1: Introduction

1.4 BOILER COMPONENTS
All burners are pre-set for use with kerosene and are supplied ready to connect to a two pipe fuel supply system with a two flexible fuel lines and 3/8 to 1/4 BSP male adaptor supplied with the boiler. Please refer to Section 3 for further details.
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 110°C ± 3°C.
The control panel is fitted with an ON/OFF switch, boiler thermostat control knob and the manual reset button for the overheat thermostat.
To access the controls, remove the front door from the boiler.
Turn the knob at the bottom of the front door anticlockwise and pull the door outwards at the bottom. Carefully release the top of the front door panel from under the top casing panel flange and remove it from the boiler to reveal the boiler as shown in Figure 1-1.
Figure 1-2 shows the details of the control panel.
1.4.1 BOILER CONTROLS
To access the control panel, remove the front door panel from the boiler. The controls on the panel are as follows:
Boiler On/Off switch This switches the boiler on and off. The boiler ON/OFF switch incorporates a mains on’ neon which lights when the boiler is switched on. Please note that themains on’ neon does not necessarily indicate that the burner is firing.

! NOTE !
If the ON/OFF switch is set to off the boiler will NOT supply central heating or heat domestic hot water (if a hot water cylinder is connected to the boiler). The built-in frost thermostat will also not operate.
Service/Test Switch (External Modules only) A Service switch is fitted to the control panel to allow the Service Engineer to test-fire the boiler. Heating Thermostat This control allows the temperature of the water leaving the boiler to heat the radiators (and domestic hot water) to be adjusted. This will be set by the installer to the optimum temperature for efficient operation of the boiler. It should be left set in this position.
Overheat Thermostat (Overheat Reset) The boiler is fitted with a safety overheat thermostat which will automatically switch off the boiler in the case of a control malfunction causing overheating.
System Pressure Gauge (System models only)
This is to indicate the water pressure in the sealed heating system.

Figure 1-1: Boiler with front panel removed
Section 1: Introduction

Figure 1-2: Boiler controls

Page 5

2 TECHNICAL DATA

2.1 BOILER TECHNICAL DATA
Table 2-1: Boiler technical data

Units

litre Water content
gal

kg Weight – complete boiler (dry)
lb

kg Weight – boiler shell only (dry)*
lb

Maximum heat output (Kerosene)

kW Btu/h

Minimum flow rate (T=10°C)

l/h

Minimum flow rate (T=20°C)

l/h

Condensate connection

Flue diameter (conventional)

mm

Waterside resistance T=10°C

mbar

Waterside resistance T=20°C

mbar

Maximum static head

m

Minimum circulating head

m

Boiler thermostat range

°C

Limit (safety) thermostat shut off temperature

°C

Maximum casing temperature

°C

Electricity supply

Burner motor power

Watts

Absorbed motor power

kW

Starting current

Amps

Running current

Amps

Oil connection

Conventional flue draught

mbar in wg

Maximum operating pressure sealed/open system

bar

Maximum operating pressure pressure relief valve

bar

Boiler type

• Weight of shell – without baffles and clean out door: 45.5kg

Wall Hung External

Wall Hung External System

16-21

16-21

11

11

2.4

2.4

92.1

96.1

203

211.9

56.5

56.5

124.6

124.6

21.0

21.0

71,700

71,700

1,800

1,800

900

900

Accepts 21.5 mm Ø polypropylene overflow pipe

100

28.5

10.0

28

1

50 to 75

110 ± 3

Less than 50

~230 1ph 50Hz 5A fused

75

0.155

0.143

2.7

0.67

¼ BSP male (on end of flexible fuel hose)

Minimum: 0.087 – Maximum: 0.37

Minimum: 0.035 – Maximum: 0.15

2.5

3.0 ON/OFF

2.2 SEALED SYSTEM DATA

Table 2-2: Sealed System Data

External System 16-21

Heating system pressure (cold)

Minimum 0.5 bar | Maximum 1.0 bar

Operating pressure of pressure relief valve

3.0 bar

Expansion vessel size (pre-charged at 1 bar)

8 litres

Maximum heating system volume (including boiler)*

85 litres**

Cold water mains connection

15 mm compression (supplied)

Pressure relief valve discharge connection

15 mm compression (supplied)

• Based on vessel charge of 0.3 bar and system cold fill pressure of 0.5 bar. These values are the remaining system volume available after deducting the boiler water content.
  ** Approximately

Page 6

Section 2: Technical Data

2.3 BURNER SETTINGS

Table 2-3: Burner settings

Boiler models (burner
type)

Heat output (kW) (Btu/h)

Nozzle

Oil pressure
(bar)

Smoke No.

Burner head type

Distance between nozzle and burner head

Fuel
flow rate (kg/h)

Flue gas temp. (°C)

CO2 (%)

External and 16.5 56,300 0.50/80°EH

7

0 – 1 EK 16-21

29.5

External

System 16-21

18.7 * 63,800 0.50/80°EH

10

0 – 1 EK 16-21

31.0

(Ecoflam

Max 1 LN

Vortex WM 21.0 71,700 0.60/80°EH

8

0 – 1 EK 16 – 21

31.0

16-21 ERP)

1.38

65 – 69

12.5

1.56

70 – 75

12.5

1.76

75 – 79

12.5

Notes:
Flue gas VFR: Flue gas volumetric flow rate 1. The data given above is approximate only and is based on the boiler being used with a low level balanced flue. 2. The above settings may have to be adjusted on site for the correct operation of the burner.
3. Gas Oil is NOT suitable for use with Grant Vortex boiler range 4. The 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: 16-21 – 18.7kW.
7. The combustion door test point may be used for CO2 and smoke readings only. Do not use this test point for temperature or efficiency readings. 8. The installer must amend the boiler data label if the output is changed.

Flue gas VFR (m³/hr)
17.0
20.0
23.0

2.4 FLUE GAS ANALYSIS
To allow the boiler to be commissioned and serviced, the boiler is supplied with a combustion test point on the front cleaning door. When this test point is used please note the following: · The test point is for CO2 and smoke readings only. · The boiler efficiency and temperature must be taken from the flue test point on high level, vertical and conventional flue adaptors. · Concentric low level flues do not contain a test point. The temperature and efficiency readings must be taken from the flue terminal.

2.5 WATER CONNECTIONS
Table 2-4: Water connections

Boiler model All models

Size 22 mm

Flow connection Fitting
Push-fit Tectite

Supplied Fitted

Size 22 mm

Return connection Fitting
Push-fit Tectite

Supplied Fitted

Section 2: Technical Data

Page 7

89
Flow Return Cold Mains Electricity

2.6 BOILER DIMENSIONS
684

FRONT VIEW

351

351

122 394 832
832

684

123

425

73 120 120

270

133 168 202 237 272 308
670
BACK PANEL*

102
Flow Return Cold Mains Condensate Electricity

23 214

LEFT SIDE VIEW

RIGHT SIDE VIEW

246
TOP VIEW

*Back panel viewed from front. Figure 2-1: Vortex Eco Wall Hung External and External System 16-21
Page 8

674
BOTTOM VIEW

98 185 245

Section 2: Technical Data

3 OIL STORAGE AND SUPPLY SYSTEM

3.1 FUEL SUPPLY
3.1.1 FUEL STORAGE
The tank should be positioned in accordance with the recommendations given in BS 5410-1 (Code of practice for liquid fuel firing. Installations for space heating and hot water supply purposes for domestic buildings). This gives details of the requirements for suitable oil tank construction, tank installation, tank bases, fire protection and secondary containment. For installations of greater than 70kW output capacity, the tank should be installed accordance with BS 5410-2. Oil storage tanks should comply with the following standards: · Plastic tanks OFT T100 · Steel tanks OFT T200
! CAUTION !
A galvanised tank must not be used.
! NOTE !
Plastic tanks should be stood on a firm non-combustible base that adequately and uniformly supports the weight of the tank over its entire base area.
The tank capacity should be selected to suit the appliance rated output. Refer to BS5410-1 for guidance.
3.1.2 FUEL PIPES
Fuel supply pipes should be either copper or steel. Galvanised pipes or fittings should not be used. Plastic oil supply pipe conforming to BS EN 14125 can be used for underground pipe runs, but must not be used above ground.
All soft copper pipe connections should preferably be made using flared fittings. If compression fittings are to be used, a suitable pipe insert must be fitted into the pipe end. Soft soldered connections must NOT be used on oil supply pipework.
Fuel supply pipework should be of a suitable diameter, depending on the type of oil supply system being used. Refer to information given in sections 3.1.3, 3.1.4 or 3.1.5. Run pipes as level as possible to prevent air being trapped. Take the most direct route possible from tank to burner whilst locating the pipe where it will be protected from damage. Pipes should be supported to prevent sagging and sleeved where they pass through a wall. A metal body fuel filter with a filtration size of no more than 50 m (micron) must be fitted in the oil supply pipe close to the tank. This should be fitted with sufficient clearance around and below it to allow easy access for maintenance. An isolating valve should also be fitted at the tank, before the filter, to allow the oil supply to be shut off for the filter to be serviced. A second filter (15 m for Kerosene) must be located closer to the burner to protect the burner pump and nozzle from contamination. Refer to Figures 3-1 to 3-3. A remote sensing fire valve must be installed in the fuel supply line in accordance with BS5410-1. A fusible wheelhead type combined isolating/fire valve MUST NOT be used in place of a remote sensing fire valve. The fire valve must be located externally to the appliance casing, with the fire valve sensor located above the burner. A spring clip for mounting the sensor is supplied fitted to the boiler, on the rear of the control panel. The fire valve should be located after the second (15 micron) filter, i.e. between the filter and the point at which the oil line enters the appliance casing. Refer to Figures 3-1 to 3-3.
Section 3: Oil Storage and Supply System

The fire valve must have an operating temperature of between 90 and 95°C to avoid unnecessary nuisance shut-offs to the oil supply.
Two flexible fuel hoses, adaptors and ¼ isolating valves are supplied loose with the boiler, to make the final connection to the burner with a two pipe or `Tiger Loop’ type de-aerator.
Metal braided flexible fuel hoses should be replaced ANNUALLY when the boiler is serviced.
Long life flexible fuel hoses should be inspected annually and replaced, if necessary, or after a maximum five years service life.
Flexible fuel hoses MUST NOT be used outside of the appliance casing.

3.1.3 SINGLE PIPE (GRAVITY) SYSTEM (REFER TO FIGURE 3-1)

Head (metres)
0.5 1 1.5 2 2.5 3 3.5

Maximum pipe run (m)

Ø 6 mm

Ø 8 mm

Ø 10 mm

19

60

100

21

66

100

23

72

100

25

79

100

27

85

100

29

91

100

31

98

100

If the storage tank outlet is at least 300 mm above the level of the burner oil pump, a single pipe (gravity) system should be used.
The maximum height of the oil level above the burner oil pump when the tank is full, must not exceed four metres. If this height is exceeded, a pressure reducing valve must be fitted in the oil supply pipe between the tank and the burner oil pump.
The maximum length of pipe run from the tank to the burner is limited by the minimum head of oil (the height of the tank outlet above the burner oil pump).

3.1.4 TWO PIPE SYSTEM (REFER TO FIGURE 3-2)

Head (metres)
0.5 1 1.5 2 2.5 3 3.5

Maximum pipe run (m)

Ø 6 mm

Ø 8 mm

Ø 10 mm

15

47

100

13

41

99

11

34

84

9

28

68

7

22

53

5

15

37

–

9

22

If the storage tank outlet is below the level of the burner oil pump, a two pipe (sub gravity) system can be used.
The return pipe should be at the same level as the tank outlet, between 75 to 100 mm above the base of the tank. The return pipe should be a sufficient distance from the tank outlet so as to prevent any sediment disturbed by the return entering the supply pipe from the tank.
A non-return valve should be fitted in the supply pipe, along with a fire valve and filters (refer to section 3.1.2 – fuel pipes). A nonreturn valve should also be fitted in the return pipe if the top of the tank is above the burner oil pump.
The maximum suction height (from the tank outlet to the level of the burner oil pump), must not exceed 3.5 metres.
The pump vacuum should not exceed 0.4 bar. Beyond this limit, gas is released from the oil.
For guidance on the installation of top outlet fuel tanks and suction oil supply pipe sizing, refer to OFTEC Technical Book 3: Storage and Supply, available for purchase from OFTEC.

Page 9

300mm

Mi3.n5m Max 4m Max

300mm

5

7

99

32

1

12 4

2

6

85

3

5 Figure 3-1: Single pipe (gravity) system

5

7

99

10

12 4

2

6

3

8 55

9

3

Figure 3-2: Two pipe system
5

10 3 2

1

95

150mm 300mm
3.5m Max 3.5m Max

150mm 3.5m Ma3.x5m Max

GRANT ENGINEERING UK LTD
7 5 11 Hopton Industrial Estate Devizes SN10 2EU 9 DRAWING NAME:
Oil Tank Installation for Oil Boiler Manuals – External Wall

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SCALE: A4: 1:40 DATE: 23rd November 2017
3 10 3 2

DRAWING NUMBER: 00 DRAWN BY: T. K. Lavery
CHECKED BY: P. Stanley
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Figure 3-3: De-aeration device system

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SCALE: A4: 1:40 Heating flow and return

DRAWING NUMBER: 00

9

Burner

9 D2RAWING NAME:Isolating valve

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Oil filter (D15ATmE:m2a3xrd. fiNltroavteiomnbseizre2)017

O3 il Tank Installation Ofoirl OstrilaBinoeirler Manuals – Extern7al Wall

Fire valve sensor

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DRAWN BY:NTo.nK-r.eLtuarvnevryalve
CHECKED BY:DPe.-aSetraantolery*

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Fire valve to BS 5410-1

8

Oil pump

12

Appliance isolation valves

• Position of de-aeration device must be level with or above the oil pump

5
Page 10

Section 3: Oil Storage and Supply System

m m Max

3.1.5 SINGLE PIPE (SUCTION) SYSTEM WITH DEAERATOR – (REFER TO FIGURE 3-3)
If the storage tank outlet is below the level of the burner oil pump, an alternative to the two pipe (sub gravity) system is the single pipe (suction) system using a deaerator, e.g. a `Tiger Loop’ device.
The deaerator creates a loop with the burner oil pump, with the oil being circulated through the pump out to the deaerator and back to the pump. Any air in the single pipe lift from the tank is removed from the oil, collected in the deaerator and then discharged to outside.

3.2 BURNER OIL CONNECTION
The burner fuel pump is supplied factory set for use with a two pipe oil supply system.
For ease of access to the burner oil pump connections, the burner should be removed from the boiler as follows:
1. Unscrew and remove the single burner fixing nut from the stud on the burner flange (at the top of the burner) using a 13 mm spanner. Retain the fixing nut for re-fitting the burner.
2. Rotate the burner clockwise and carefully withdraw the burner from the boiler. Refer to Figure 3-5.

! WARNING !

To prevent any fuel vapour being discharged within the building, the deaerator must be fitted outside, in accordance with BS 5410-1, unless it is specifically designed to be installed inside.
The de-aerator must be mounted vertically at the same level as (or above) the burner oil pump. Refer to Figure 3-3.

RETURN FROM PUMP

Tiger Loop

SUPPLY TO PUMP

1/4″ BSP female connections

SUPPLY FROM TANK

Figure 3-4: Tiger loop de-aeration device
An external deaerator must not be fitted within 500 mm of a flue terminal.
Always follow the manufacturers installation instructions supplied with the deaerator.

Figure 3-5: Burner removal

SINGLE PIPE (GRAVITY) SYSTEM
For use on a single pipe system, it is necessary to fit the `horseshoe’ washer into the tapping in the pump. Refer to Figure 3-6.

Section 3: Oil Storage and Supply System

Figure 3-6: Fitting/location of `hoseshoe’ washer

Page 11

4 INSTALLATION

4.1 INTRODUCTION
The boiler is supplied already fully assembled in a carton which is carefully packed with packing materials. As the boiler is wall mounted all of the content of the boiler casing must be removed with the packaging before installation can begin, to give access to the rear fixing panel.
The installation procedure therefore begins with unpacking and dismantling of the packed boiler.
4.2 BOILER LOCATION
The module should installed externally, fixed to a wall that is firm, flat, vertical and capable of supporting the boiler when full of water. Refer to Section 2.1 for weights. It does not require any special mounting provisions as the temperature of the boiler casing is less than 50°C.
The module must be positioned such that the required clearances from the low level flue outlet as shown in Figure 9-2 are achieved.
The module must be installed with the flue terminal terminating at least two metres above ground level (refer to BS 5410-1). No terminal guard can be fitted if termination is less than two metres above ground level. In this situation, use the Green flue system to achieve the minimum height. Refer to Section 9.
The flue terminal must be a minimum distance of 1.8 metres from an oil storage tank.
The flue terminal should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings.
Sufficient clearance must be allowed at the front of and below the boiler to remove the burner and baffles for servicing.
4.3 REGULATIONS COMPLIANCE
! NOTE !
Failure to install and commission appliances correctly may invalidate the boiler guarantee.
Installation of a Grant Vortex boiler must be in accordance with the following recommendations:
· Building Regulations for England and Wales, or the Building Standards for Scotland, as appropriate.
· Any relevant local Byelaws which you must check with the local authority for the area concerned.
· The Water Supply (Water Fittings) Regulations 1999 or the Water Supply (Fittings) (Scotland) Byelaws 2014, as appropriate.
· Applicable Control of Pollution Regulations. · The following OFTEC requirements:
· OFS T100 Polythene oil storage tanks for distillate fuels. · OFS T200 Fuel oil storage tanks and tank bunds for use
with distillate fuels, lubrication oils and waste oils.
Further information may be obtained from the OFTEC Technical Book 3 (Installation requirements for oil storage tanks) and OFTEC Technical Book 4 (Installation requirements for oil fired boilers).
The installation should also be in accordance with the latest edition of the following British Standard Codes of Practice (and any relevant amendments):
· BS 5410-1: 2019 (Code of practice for liquid fuel firing. Installations for space heating and hot water supply purposes for domestic buildings)
· This standard covers domestic installations up to 70kW. · BS 5410-2: 2018 (Code of practice for liquid fuel firing. Non-
domestic installations)
· This standard should be followed with regard to installations with an output capacity in excess of 70kW.
· Where the combined outputs of multiple appliances located together at a domestic dwelling exceed 70kW then then a dedicated plant room as specified in BS 5410-2 is recommended.

· BS EN 12828 (Heating systems in buildings. Design for water-based heating systems)
· BS EN 12831-1 (Energy performance of buildings. Method for calculation of the design heat load)
· BS EN 14336 (Heating systems in buildings. Installation and commissioning of water-based heating systems)
· BS 7593 (Code of Practice for treatment of water in domestic hot water central heating systems)
· BS 7671 (Requirements for Electrical installations, IET Wiring Regulations)
· BS 7291 (Thermoplastics pipe and fitting systems for hot and cold water for domestic purposes and heating installations in buildings. General requirements)
· BS 7074-1 (Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems. Code of practice for domestic heating and hot water supply)
· BS 2869 (Fuel oils for agricultural, domestic and industrial engines and boilers. Specification)
! WARNING !
BS5410-1: 2019 requires that appliances located in a building or structure or within a restricted area externally should have a CO detector conforming to BS EN 50291-1 installed in the same room/space.
4.4 HEATING SYSTEM DESIGN CONSIDERATIONS
! WARNING !
Before starting any work on the boiler or fuel supply, please read the Health and Safety information given in Section 15.
To achieve the maximum efficiency possible from the Grant Vortex boiler, the heating system should be designed to the following parameters:
RADIATORS:
· Flow temperature 70°C · Return temperature 50°C · Differential 20°C Size radiators with a mean water temperature of 60°C. Design system controls with programmable room thermostats or use weather compensating controls to maintain return temperatures below 55°C.
! NOTE !
The boiler should not be allowed to operate with return temperatures of less than 40°C when the system is up to temperature.
The use of a pipe thermostat is recommended to control the return temperature when using weather compensating controls.
UNDERFLOOR:
· Flow temperature 50°C · Return temperature 40°C · Differential 10°C In underfloor systems, it is essential that the return temperature must be maintained at or above 40°C to prevent internal corrosion of the boiler water jacket.
Refer to Section 2.5 for the size and type of the connections and Section 5 for the position of the connections.

Page 12

Section 4: Installation

OPEN VENTED SYSTEMS:
! NOTE !
The presence of pumping over’ in an open vented heating system connected to the Grant Vortex boiler will invalidate the product guarantee. Open vented systems must be correctly designed and installed. The open safety vent pipe must be positioned to preventpumping over’ (i.e. the discharge of water from the open safety vent pipe into the feed and expansion cistern under the pressure created by the circulator). For detailed information on the correct design of open vented heating systems, and the correct location of the open safety vent pipe, refer to the CIBSE Domestic Heating Design Guide and OFTEC Technical Book 4 (Installation).
4.5 PIPEWORK MATERIALS
Grant Vortex boilers are compatible with both copper and plastic pipe. Where plastic pipe is used it must be of the oxygen barrier type and be the correct class (to BS 7291-1) for the application concerned. On either sealed or open- vented systems; where plastic pipe is used a minimum of ONE metre of copper pipe (or as per pipe manufacturers instructions) MUST be connected between both the boiler flow and return connections and the plastic pipe.
! NOTE !
Do not connect plastic pipe directly to the boiler.
Grant UK does not accept any responsibility for any damage, however caused, to plastic piping or fittings.
SEALED SYSTEMS
If plastic pipe is to be used, the installer must check with the plastic pipe manufacturer that the pipe to be used is suitable for the temperature and pressures concerned. Plastic pipe must be Class S to BS 7291-1.

4.7 PREPARATION FOR INSTALLATION
The following procedure must be performed before you can begin dismantling the boiler for installation:
1. With the boiler on the pallet, open the carton and remove all packing materials and the carton from the boiler.
2. To access the controls, remove the front door from the boiler.
Turn the knob at the bottom of the front door anticlockwise and pull the door outwards at the bottom. Carefully release the top of the front door panel from under the top casing panel flange and remove it from the boiler to reveal the boiler as shown in Figure 1-1.
3. Remove internal packaging from within boiler casing. 4. Remove flue terminal, filling loop and flexible oil hose packs
from within boiler.
4.8 DISMANTLING THE BOILER
Dismantle the boiler as follows, keeping all components, screws and washers for re-assembly:
1. Slacken off hose clip on burner air inlet and remove snorkel tube from boiler.
2. Unscrew earth wire from underside of top casing panel.
3. Remove screws securing top casing panel and remove casing panel from boiler.
4. Remove silver cover from burner control box and disconnect plug from burner control box.
5. System model only ­ Disconnect plug from pump. 6. Unscrew inlet connection to condensate trap and remove
trap from boiler.
7. Remove retaining clip and thermostat phials from their pocket in the right side of heat exchanger ­ below the return connection. (See Figure 4-1)
Pocket for Thermostat Phials

! WARNING !

When plastic pipe is used, the system MUST incorporate a low pressure switch to shut off power to the boiler if the system pressure drops below 0.2 bar. A suitable low pressure switch kit is available to purchase from Grant UK (product code: MPCBS62).

UNDERFLOOR PIPEWORK
Plastic pipe may be used on underfloor floor 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.
4.6 CONNECTIONS 4.6.1 FLOW AND RETURN CONNECTIONS
Refer to Sections 4.9 & 5.
4.6.2 CONDENSATE CONNECTION
Grant Vortex Eco 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. Refer to Section 6 for details of the condensate disposal pipework.

Figure 4-1: Removing thermostat phials
8. System model only – Unscrew and disconnect pressure gauge pipe from PRV body.
9. System model only – unscrew expansion vessel hose from connection on boiler shell and remove expansion vessel from boiler. (See Figure 4-2)
10. Remove screws securing right hand side panel and remove side panel, complete with control panel, pulling it forward and away from boiler.
11. Repeat procedure to remove left hand side panel from boiler.
12. Remove screws securing bottom casing panel and remove bottom panel from boiler.
13. System model only – Unscrew upper pump union and remove pump, complete with flow pipe, from boiler. (See Figure 4-3)

4.6.3 DRAIN COCK
A drain cock is fitted at the bottom on the front of the boiler to allow the heating system to be drained.

Section 4: Installation

Page 13

14. Non-system model ­ Unscrew compression connection on boiler shell and remove flow pipe from boiler.
15. Unscrew top right compression connection and remove return pipe from boiler.
16. Using a 13mm socket, slacken burner retaining nut (on top of burner). Rotate burner clockwise (towards rear of boiler), pull burner to the right until burner head is clear of mounting flange and remove burner from boiler.
17. Using 13mm spanner, unscrew the two clean-out door retaining nuts and remove door from front of boiler shell. (See Figure 4-4).

Figure 4-2: Expansion vessel, Expansion vessel bracket and hose connection – System model only

Figure 4-4: Removing clean-out door 18. Remove baffles from boiler shell. (See Figure 4-5).

Return Pipe

Upper pump union (slightly obscured by pump cover)
Flow Pipe

Figure 4-5: Removing baffles from boiler shell
19. Undo retaining screw and nut and remove transit bracket from top of boiler shell.
20. Push boiler shell upwards to disengage it from mounting bracket on back panel of boiler taking care not to damage the insulation on the side of shell.
21. Lift boiler shell away from back panel and stand it upright on the four feet.
! WARNING !
The boiler shell is HEAVY and requires more than one person to lift. Refer to Section 2.1 for boiler weights.
22. Carefully remove the foil-faced insulation from the back panel.
23. Unscrew and remove the two transit screws securing mounting bracket and back panel to pallet.

Figure 4-3: Removing flow and return pipe – System model only
Page 14

Section 4: Installation

4.9 INSTALLING THE BOILER
You are now ready to install the boiler.
! NOTE !
The boiler must be mounted such that the boiler flue terminal (supplied with the boiler) terminates at or above 2 metres above ground level. If the distance is to be less than this, Grant UK suggest using the Green system to achieve a termination point of at least 2 metres above ground level. The procedure is as follows: Figure 4-6 shows the mounting bracket in position on the back casing panel, with the holes in the bracket in-line with the corresponding holes in the back casing panel.
Keyhole slots
Mounting bracket fixing holes

6. Locate the mounting bracket on to the back panel, aligning the four holes in the bracket with those in the back panel. Ensure that the mounting `hooks’ are pointing upwards and secure using the fixings supplied with the boiler.
7. Check the mounting bracket is level. 8. Carefully refit insulation into back panel, passing mounting
‘hooks’ through the two slits in the insulation.
9. Lift the boiler shell and hang it on the mounting bracket ­ ensuring that the mounting plates on either side of the shell are fully located in the vertical slot of both mounting hooks.
! WARNING !
The boiler shell is HEAVY and requires more than one person to lift. Refer to Section 2.1 for boiler weights.
10. Re-fit the return pipe to top right hand connection on boiler shell. Pass return pipe from system through hole in wall and connect to boiler return pipe.
11. System model only – Re-fit pump complete with flow pipe to upper pump union on boiler shell. Ensure that rubber pump union washer is fitted. Pass flow pipe from system through hole in wall and connect to boiler flow pipe.
12. Non-system model ­ Re-fit flow pipe to compression connection on boiler shell. Pass flow pipe from system through hole in wall and connect to boiler flow pipe.
! NOTE !

It is recommended that the system flow and return pipes are connected to the boiler at this point in the installation. Two 22mm isolating valves are supplied for use with sealed system models only. These must not be used on an open vented system. These boiler isolating valves should be located adjacent to the boiler in a convenient position.

Figure 4-6: Mounting bracket and fixing holes in position on back panel
1. Remove any required knockouts from the back and bottom panels of the boiler casing for the heating system pipework, cold mains supply, oil supply, condensate discharge, electricity supply and PRV discharge (it is recommended that one of the knockouts in the bottom panel is used for the PRV discharge).
2. Locate and hold the back panel in the required position on the wall. Check it is level using a spirit level on the top flange.
Mark position of the holes for the two keyhole slots (See Figure 4-6). Remove the back panel from the wall.
3. Drill and fit wall fixing plugs (not supplied) in the two holes.
Fit the two screws (supplied) and mount the back panel on the wall using the two keyhole slots.
Check again that the back panel is level before proceeding.
4. Mark the position of the four mounting bracket fixings on to the wall from the back panel. Also mark the positions of the flow and return pipes, the cold mains (for filling loop), the electrical power supply, and the condensate discharge pipe.
5. Remove the back panel from the wall. Drill the holes for the mounting bracket fixing holes. Drill all other necessary holes.
Re-mount the back panel on the two keyholes slots.

13. System model only – connect a 15 mm discharge pipe, of metal construction, to the outlet of the PRV and run vertically down through the relevant knockout in the bottom panel of the boiler casing. Refer to Sections 5.2 and 7 for further guidance
14. Re-fit burner. First remove burner securing nut, locate burner head into hole in burner flange/boiler shell and locate mounting screw through hole on top of burner. Re-fit nut and tighten to secure burner in place. Connect flexible oil lines from oil supply pipework to burner. It is recommended that the copper oil lines are installed at this stage while the side panels are not in place.
15. Refit baffles into boiler shell ­ ensuring they are in the correct order (check marking on each baffle) as shown in Figure 4-7.

Section 4: Installation

Page 15

4.10 FILLING THE HEATING SYSTEM
Refer to Section 7.2 (Filling the Sealed System)

Figure 4-7: Re-fitting baffles into boiler shell
16. Locate clean-out door onto the two studs, re-fit nuts and tighten to secure door in place.
17. Refit left hand casing panel and secure in place with screws (with washers).
18. Refit bottom casing panel and secure in place with screws (with washers).
19. Refit right hand casing panel complete with control panel fitted.
20. Relocate thermostat bulbs in pocket at rear right hand side of boiler shell.
21. System model only – Reconnect pressure gauge to PRV and tighten.
22. Re-connect burner plug to burner control box and refit the silver cover onto the control box.
23. System model only – Reconnect pump plug.
24. Refit condensate trap. Connect condensate discharge pipe to outlet of trap. Refer to Section 6 for further details.
25. System model only – Refit expansion vessel onto bracket inside right hand side panel and reconnect expansion vessel hose to connection on front right hand side of boiler shell. Ensure rubber sealing washer is fitted.
26. Refit top casing panel and secure in place with screws (with washers).
27. If the flue terminal supplied is to be fitted, carefully push it through the seal in the hole in top casing panel.
Ensure that the seal is fitted to the terminal and that it is pushed fully home into the flue connector on the boiler shell. Position the outlet to point to the left and at an angle of 45° away from the wall.
28. Re-fit casing front door – locate top edge up under front flange of top panel. Push bottom of front panel into opening until flush with edge of side panels before rotating handle clockwise to secure.
29. 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.

4.11 BEFORE YOU COMMISSION
To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly flushed out ­ both before the boiler is connected and then again after the system has been heated and is still hot. This is especially important where the boiler is to be installed on an older system.
For optimum performance after installation, the boiler and the associated heating system must be flushed in accordance with the guidelines given in BS 7593 (Treatment of water in domestic hot water central heating systems). This must involve the use of a proprietary cleaner, such as Sentinel X300 (new systems), Sentinel X400 (existing systems), or Fernox Restorer.
After cleaning, it is vitally important that all traces of the cleaner are thoroughly flushed from the system.
For long term protection against corrosion and scale, after cleaning/flushing a suitable inhibitor should be added to the system water, such as Sentinel X100 or Fernox MB-1, in accordance with the manufacturers’ instructions.
Failure to follow the above will invalidate the guarantee.
If the boiler is installed in a garage, out house or outside, in order to provide further protection should there be a power failure in cold weather, a combined anti-freeze and corrosion inhibitor can be used such as Sentinel X500 or Fernox Alphi-11. Follow the manufacturers’ instructions supplied to achieve the level of antifreeze protection required.
For details of the Sentinel Products visit www.sentinel-solutions. net and for Fernox products visit www.fernox.com.
Grant UK strongly recommends that a Grant Mag One in-line magnetic filter/s (or equivalent*) is fitted in the heating system pipework. This should be installed and regularly serviced in accordance with the filter manufacturer’s instructions.

• As measured by gauss. The MagOne magnetic filter has a gauss value of 12000.
  4.12 COMPLETION
  Following installation of the boiler, instruct the user in the operation of the boiler, the boiler controls, the heating controls and the safety devices.
  Please ensure that the OFTEC CD/10 installation completion report (provided with the boiler) is completed in full, leaving the top copy with the user and retain the carbon copy for your own records.
  Ensure that the User Handbook (supplied with the boiler) is handed over to the user.

Page 16

Section 4: Installation

5 PIPE CONNECTIONS

5.1 WATER CONNECTIONS FLOW AND RETURN CONNECTIONS ALL MODELS
On all models a 22mm push-fit connection is provided for both the heating flow and return connections. Holes are provided in the back plate at high and low levels to route the pipework back into the property as required. See Section 2.6.
! CAUTION !
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 ENTRY/EXIT HOLES IN CASE
All models have holes to enable the pipework to exit the boiler casing.
On all models these holes are pre-cut knock-outs located in both the back and bottom panels.
Push out the `knock-out’ from the required holes, taking care not to distort the panel.

5.2 WATER CONNECTIONS SYSTEM MODELS
A 15 mm discharge pipe must be connected to the safety valve outlet connection. The pipework between the safety valve and the boiler must be unrestricted, that is, no valves. The discharge pipe should be run to the outside of the building and terminate so that it cannot cause injury to persons or property.
A 15 mm double check valve ballofix type valve is provided on the flexible filling loop hose for connection of the cold mains supply to the heating system.
The cold mains supply should terminate inside the boiler casing.
A drain cock is fitted at the bottom on the front of the boiler to allow the heating system to be drained.
The expansion vessel is connected via a flexible hose to allow it to be moved to gain access to the burner and condensate trap for servicing.
When replacing the vessel, care should be taken to ensure that the flexible connecting hose is not twisted.

Figure 5-1: Non system boiler flow and return connections Return
Flow

! NOTE !
For guidance on the connection of the heating system pipework, please refer to Section 4.9.

Section 5: Pipe Connections

Figure 5-2: System boiler flow and return connections
Page 17

6 CONDENSATE DISPOSAL

6.1 GENERAL REQUIREMENTS
When in condensing mode the Grant Vortex boilers produce condensate from the water vapour in the flue gases. This condensate is moderately acidic with a pH value of around 3.27 (similar to orange juice). 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 condensate 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.
! CAUTION !
Condensate disposal pipes must 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).
! NOTE !
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). ! NOTE ! 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. ! NOTE ! For boilers installed in an unheated area such as a loft, basement, outhouse or garage, all condensate pipework should be asexternal’. The pipework should be insulated using suitable waterproof and weather resistant insulation.

32 mm waste pipe external to the building Cement seal
Minimum 2.5O fall Ground level
25 mm

300 mm
400 mm min.

100 mm plastic tube Sealed end Figure 6-1: Purpose made condensate soakaway

Two rows of 3 x 12 mm
holes at 25 mm centres Backfill with 10 mm and 50 mm from the bottom limestone chippings of the tube. Holes facing
away from the property.

Page 18

Section 6: Condensate Disposal

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.
! CAUTION !
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 guarantee.
6.6 CONDENSATE TRAP
Grant Vortex boilers are supplied with a condensate trap to provide the required 75 mm water seal in the condensate discharge pipe from the boiler. The condensate trap is factory fitted inside the boiler casing mounted on the outlet of the condensing heat exchanger – in an accessible position to allow for routine maintenance.

A push-fit’ elbow connects the outlet of the condensing heat exchanger to the trap inlet. Ensure the elbow connector is fully pushed onto thetop hat’ inlet connector of the trap.
With the trap fitted inside the boiler casing, the sealing cap must be fitted. If the trap is re-located outside the boiler then the following applies:
· 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.
! WARNING !
Care should be taken when siting the trap such that the overflow outlet is readily visible and that any condensate overflowing from the outlet cannot cause either a hazard to persons or damage to surrounding property or equipment.

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 Figures 6-2 and 6-3.

Overflow warning outlet (with cap)
Condensate outlet to drain

Condensate inlet from boiler
Unscrew this cap for maintenance access
Condensate trap

End cap

Figure 6-3: Condensate trap

Figure 6-2: Condensate trap

Section 6: Condensate Disposal

Page 19

6.7 CONDENSATE DISPOSAL PIPEWORK
The condense trap outlet is at an angle of 48° below the horizontal. This is to automatically gives a 3° fall on any horizontal’ runs of condense disposal pipe. Refer to Figure 6-3 and see trap outlet/pipe. The outlet of the trap will accept 21.5 mm to 23 mm OD Polypropylene overflow pipe for the condensate discharge pipe. This discharge pipe can exit through the rear or bottom of the boiler through one of two pre-cutknock-outs’ in either the back or bottom casing panels. Push out the `knock-out’ from the required hole taking care not to distort the side panel.
! NOTE !
When connecting plastic discharge pipe, ensure that the pipe is fully pushed into the outlet end on the flexible hose 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 can be unscrewed from the trap body for inspection and cleaning.
To inspect and clean the trap:
1. Disconnect elbow from inlet connector. 2. Unscrew the inlet connection nut.
3. Remove the inlet connector and nut from trap. 4. Disconnect the condensate disposal pipe from the trap outlet. 5. Remove trap from bracket. 6. Remove float from trap ­ clean if necessary. 7. Inspect inside of trap and clean as necessary.
8. Re-assemble trap, re-fit to boiler and re-connect elbow. Ensure that elbow is fully pushed onto the trap inlet connector.

! CAUTION !

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

Page 20

Section 6: Condensate Disposal

7 SEALED SYSTEMS

7.1 SEALED SYSTEM REQUIREMENTS
All Grant Vortex Eco Wall Hung models are suitable for use with sealed systems complying with the requirements of BS EN 12828, BS EN 12831 and BS EN 14336.
The system must be provided with the following items: · Diaphragm expansion vessel complying with BS EN 13831 · Pressure gauge · Pressure relief (safety) valve · Approved method for filling the system
7.1.1 EXPANSION VESSEL
The expansion vessel should be fitted in the return pipework as shown in Figures 7-1 and 7-2. To reduce the operating temperature of the expansion vessel, 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 in diameter. If the expansion vessel is connected via a flexible hose, care must be taken to ensure that the hose is not twisted or kinked.

! NOTE !
Ensure that the expansion vessel used is of sufficient size for the system volume.
Refer to BS 7074-1 or The Domestic Heating Design Guide for sizing the required vessel.
7.1.2 PRESSURE GAUGE
The pressure gauge must have an operating range of 0 to 4 bar. It must be located in an accessible place next to the filling loop for the system.
7.1.3 PRESSURE RELIEF (SAFETY) VALVE
The pressure relief (safety) valve should be fitted in the flow pipework near to the boiler. The pipework between the pressure relief (safety) valve and boiler must be unrestricted, i.e. no valves. The pressure relief (safety) valve should be connected to a discharge pipe which will allow the discharge to be seen, but cannot cause injury to persons or damage to property.

Figure 7-1: Sealed system If thermostatic radiator valves are fitted, the system must incorporate an adequate by-pass.
Figure 7-2: Sealed system boilers Section 7: Sealed Systems

Page 21

7.1.4 FILLING LOOP
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. The filling loop must be isolated and disconnected after filling the system.
7.1.5 HEATING SYSTEM
The maximum `setpoint’ temperature for the central heating water is 75°C. Refer to Section 1.1. An air vent should be fitted in the flow and return pipes of the highest point of the system. If thermostatic radiator valves are fitted to all radiators, a system by-pass must be fitted. The by-pass must be an automatic type. 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. One or more drain taps (to BS 2879) must be used to allow the system to be completely drained.
7.2 FILLING THE SEALED SYSTEM
Filling of the system must be carried out in a manner approved by the local Water Undertaking.
! WARNING !
Only ever fill or add water to the system when it is cold and the boiler is off. Do not overfill.
The procedure for filling the sealed system is as follows: 1. Check the air charge pressure in the expansion vessel
BEFORE filling 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). Refer to Figure 7-2. The charge pressure must not be less than the actual static head at the point of connection.

9. Repeat steps 5 to 7 as required until system is full of water at the correct pressure and vented.
10. Water may be released from the system by manually operating the safety valve until the system design pressure is obtained.
11. Close the fill point and double check valves either side of the filling loop and disconnect the loop.
12. Check the system for water soundness, rectifying where necessary.
7.3 VENTING THE PUMP
For those heating circulating pumps fitted with a vent plug, it is important that the pump is properly vented to avoid an air lock and also prevent it running dry and damaging the bearings. Unscrew and remove the plug from the centre of the pump motor. Using a suitable screwdriver, rotate the pump spindle about one turn. Replace the plug in the motor. Do not over tighten.
! NOTE !
Some heating circulating pumps are not fitted with a vent plug so it is not possible to vent these pumps in the manner described above. Refer to pump manufacturers own instructions for further details.
If a Wilo Para pump is used, please refer to Appendix A1 at the back of this installation and servicing manual for guidance on venting the pump.
7.4 PRESSURE RELIEF (SAFETY) VALVE OPERATION
Check the operation of the pressure relief (safety) valve as follows: 1. Turning the head of the valve 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. Top- up the system pressure, as necessary.

! NOTE !

The air charge pressure may be checked using a tyre pressure gauge on the expansion vessel Schraeder valve.
The vessel may be re-pressurised, when necessary, 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.
2. Check that the small cap (or screw) on all air vents is open at least one turn. The cap (or screw) remains in this position from now on.
3. Ensure that the flexible filling loop 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.
4. Open the fill point valve.
5. Gradually open the double check valve from the water supply until water is heard to flow.
6. When the needle of the pressure gauge is between 0.5 and 1.0 bar, close the valve.
7. Vent each radiator in turn, starting with the lowest one in the system, to remove air.
8. Continue to fill the system until the pressure gauge indicates between 0.5 and 1.0 bar. Close the fill point valve. 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.

Page 22

Section 7: Sealed Systems

7.5 SYSTEM MODELS
All System models have the following sealed system components factory fitted (refer to Figure 7-3): · A diaphragm expansion vessel complying with BS 4814, pre-
charged at 1.0 bar. Refer to Section 2.2.
· System pressure gauge, with an operating range of 1 to 4 bar.
· Pressure relief safety valve complying with BS 6759 and set to operate at 3.0 bar.
· Air vent, fitted to the flow pipe of the boiler, ensures the boiler is vented.
· Filling loop. This must be isolated and disconnected after filling the system.
Refer to Section 2.2 for system volumes and BS 7074: for further guidance and for further details of the expansion vessel.
For information on the circulating pump fitted to sealed system models, please refer to Appendix A1 at the back of this installation and servicing manual.
The expansion vessel fitted, is supplied with a charge pressure of 1.0 bar (equivalent to a maximum static head of 10.2 metres). The charge pressure must not be less than the actual static head at the point of connection.
! CAUTION !

! NOTE !
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 value. Refer to Section 2.2. 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.
! NOTE !
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.

Do not pressurise the vessel above 1.5 bar.

Right hand side of heat exchanger

Automatic air vent

Pressure relief valve
Heating return

Expansion vessel
Pump

Heating Flow

Section 7: Sealed Systems

Figure 7-3: Sealed system components

Page 23

8 ELECTRICAL

! WARNING !
Ensure that the electrical supply has been isolated before making any connections to the boiler.
8.1 GENERAL
Grant Vortex Wall Hung External models require a ~230V 1ph 50Hz supply. It must be protected by a 5 Amp fuse. Refer to Figures 8-1 to 8-4 for typical control system wiring diagrams for all models. Refer to Figures 8-5 and 8-6 for control panel wiring diagrams for all models.
! WARNING !
The Vortex boiler 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 IET Wiring Regulations. Any room thermostat or frost thermostat used must be suitable for use on mains voltage. 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
! NOTE !
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.

The procedure is as follows:
1. Remove the casing door on the front of the external module.
2. Loosen the two screws securing the the control panel to the right hand boiler casing panel, lift upwards and remove the control panel from the right hand boiler casing panel.
3. Remove the two screws securing the back cover to the control panel (there is one screw on each side of the control panel), slide the panel downwards to disengage the locating tabs at the top of this panel and remove the panel to gain access to the boiler terminal block.
4. Loosen/remove the screws securing the cable clamp on the top of the control panel and open the clamp.
5. Route the supply and pump cables into the enclosure through one of the designated entry points in the rear casing panel. (If a system model is being installed, the pump cable comes pre-wired into the boiler terminal block).
6. Pass the mains power supply cable through the cable clamp, through the cable grommet in the top of the control panel and connect to the boiler control panel terminals as follows:
· Brown to mains live (terminal 2) · Blue to mains neutral (terminal 3) · Green/Yellow to mains earth (terminal 4) 7. If the circulating pump is to be fitted inside the boiler enclosure, pass the 3-core cable from the pump through the cable grommet and through the clamp and connect to the boiler control panels as follows:
· Brown to pump live (terminal 7) · Blue to pump neutral (terminal 8) · Green/Yellow to pump earth (terminal 9)
! NOTE !
Connecting the pump in this manner allows the pump to be isolated using the isolated switch inside the boiler control panel, for servicing and maintenance work.
8. Make the remaining required connections to the control panel, as detailed in Figures 8-1 to 8-4.
9. Tighten the cable clamp and refit the back of the control panel, taking care not to trap any wires.
10. Refit the control panel to the right hand boiler casing panel.
! WARNING !

8.2 CONNECTING THE POWER SUPPLY
It is recommend that the boiler should be connected to a switched mains power supply from a programmer or control system. 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.
! NOTE !
Ensure that the route and length of the supply cable is such that the boiler front cover plate can be easily removed without disconnecting the supply cable from the terminal block.

After completing electrical connections and before reconnecting the electrical supply to the boiler, replace the back cover on the control panel and secure it using the screws provided. Take care not to trap any wires.
11. Re-connect the electrical supply and check operation of heating system controls (programmer, room thermostats, etc.).
12. Refer to Instructions provided with the programmer for operation and setting.
13. Leave the Programmer and Thermostat Instructions with the user after installation for their future reference.

Page 24

Section 8: Electrical

BURNER LEAD PLUG/SOCKET CONNECTOR
On all models, the electrical cable between the boiler control panel and burner is now fitted with an in-line 3-way plug and socket connector. This enables the burner to be easily disconnected from the boiler control panel for ease of removal and servicing.
! NOTE !
A Service switch is fitted to the control panel to allow the Service Engineer to test-fire the boiler. When set to ON’ the switch temporarily by-passes the external control system to operate the boiler. This is amomentary’ or non-latching switch that cannot be left set to ON. The boiler will automatically revert to normal operation when 15 minutes have elapsed since it was last operated. If required, this 15 minute override period can be stopped by switching the boiler On / Off switch OFF and then back to ON. The boiler will then operate as normal under control of the external heating/hot water controls (timer, room thermostat or programmer).

8.3 FROST PROTECTION
The boiler is fitted with a pre-set internal frost protection thermostat. If the air temperature around the boiler falls below 2°C, then this thermostat will be activated to protect the boiler from freezing.
Also, to protect any exposed heating system pipework, it is recommended that an `external’ frost thermostat is also installed. This frost thermostat will operate in parallel with the internal frost protection of the boiler.
It should be sited within the house in such a place that it can detect any rise and fall in the ambient air temperature, i.e. in a room with a radiator.
Where the frost thermostat is installed outside the house (to protect a boiler installed in an external boiler room or garage) or in an attic, it is recommended that it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property. The pipe thermostat should be located on the boiler return pipe, and set to operate at 25°C.
For connection details please refer to Figures 8-1 and 8-2.
! NOTE !
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.

Section 8: Electrical

Page 25

8.4 CONTROL SYSTEM WIRING DIAGRAMS

230 V 50 Hz
LN E

Grey

Green/Yellow

Grey Blue

Brown

HTG Motor

Orange

Blue

DHW Motor

Zone Valve Green/Yellow

Room Stat 21 3

Cylinder Stat
1C

Brown

Zone Valve Orange

12 3

45

67

8 9 10 wiring centre

HW HW CH OFF ON ON

N

L

E N Pump L
Supply to burner L
N
E

L LNE

LNE

1 2 3 4 5 6 7 8 9 10 11 12 13

Boiler Terminal Block

Figure 8-1: External wall hung – 2 X 2-port valve control system

Blue Green/Yellow
White Grey Orange

230 V 50 Hz
LNE

Room Stat 21 3

Cylinder Stat 1
C2

Mid Position Zone Valve

1 2 3 4 5 6 7 8 9 10 wiring centre

E N L
Pump

HW HW CH N L
OFF ON ON

Supply to burner L N E

L LNE

L NE L N E

1 2 3 4 5 6 7 8 9 10 11 12 13 Boiler Terminal Block

Figure 8-2: External wall hung – 3-port valve control system

Page 26

Section 8: Electrical

230 V 50 Hz
LN E

Grey

Green/Yellow

Grey Blue

Brown

HTG Motor

Blue Orange

DHW Motor

Zone Valve Green/Yellow

Room Stat 21 3

Cylinder Stat
1C

Brown

Zone Valve Orange

12 3

45

67

8 9 10 wiring centre

HW HW CH OFF ON ON

N

L

Supply to pump L N E

Supply to burner L N E

L L NE

L NEL N E

1 2 3 4 5 6 7 8 9 10 11 12 13

Boiler Terminal Block

Figure 8-3: External system wall hung – 2 X 2-port valve control system

Blue Green/Yellow
White Grey Orange

230 V 50 Hz

Room Stat 21 3

Cylinder Stat 1
C2

Mid Position Zone Valve

123

4

5

6

78

9 10 wiring centre

HW HW CH OFF ON ON

N

L

L LNE

Supply to Pump
L N E Supply to burner L
N E
LNE LNE

1 2 3 4 5 6 7 8 9 10 11 12 13 Boiler Terminal Block

Figure 8-4: External system wall hung – 3-port valve control system

Section 8: Electrical

Page 27

8.5 BOILER CONTROL PANEL WIRING DIAGRAMS

Test Switch

Red Red

Burner
4 core white insulation

Br L1 G/Y

Bl Blk

N

L2

L1 Br G/Y

N

Bl Blk

L2

Figure 8-5: External wall hung – wiring diagram

Switched live 1L
Permanent live 2 L
Mains neutral 3N
Mains earth 4E

5 link To CH valve if required 6
Pump live 7 L
Pump neutral 8 N
Pump earth 9 E

10 L

4 core white insulation

Blk

Bl 11 N
G/Y
12 E
13

Br
Blue

Y Blue

Red Mains On/Off Frost Thermostat Switch c/w neon

1 2
Blue

4B 5B Red

1A 2A Limit Thermostat

C

Yellow 2

Yellow Green/Yellow

Blue Red

C
1 Control Th ermostat

Green/Yellow

Red Green/Yellow

Green/Yellow

Earth to switch cover

Control panel chassis earth

Control panel chassis earth

Burner
4 core white insulation

Br L1 G/Y

Bl Blk

N

L2

Pump

L1 G/YBr

N

Bl Blk

L2

Switched live 1L
Permanent live 2 L
Mains neutral 3N
Mains earth 4E

5 link
To CH valve if required 6

Br 7 L Bl G/Y 8 N
9E

4 core white insulation

Blk

10 L
Bl 11 N
G/Y
12 E
13

Br
Blue

Y Blue

Test Switch

Red Red

Red Mains On/Off Frost Thermostat Switch c/w neon

1 2
Blue

4B 5B Red

1A 2A Limit Th ermostat

C Yellow
2

Yellow Green/Yellow

Blue Red

C
1 Control Th ermostat

Green/Yellow

Red Green/Yellow

Figure 8-6: External system wall hung – wiring diagram

Green/Yellow

Earth to switch cover

Control panel chassis earth

Control panel chassis earth

Page 28

Section 8: Electrical

9 FLUE SYSTEM AND AIR SUPPLY

The boiler is supplied with a flue terminal. Refer to Section 4.9 for fitting details.
As an alternative to the terminal supplied, there is one other external flue systems that can be used with the Vortex Eco External Wall Hung boiler available from Grant UK; as follows:
GRANT VERTICAL GREEN SYSTEM
This vertical twin wall stainless steel insulated system replaces the low level terminal supplied with the boiler, and may terminate at high level or vertically as required.

! CAUTION !
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.

This flue system is described in this section.

! NOTE !

9.1 AIR SUPPLY
A sufficient permanent air supply to the boiler should be provided for the following reasons:
· For proper combustion of fuel and effective discharge of combustion products to the open air.
· For the ventilation of any confined space in which the boiler is installed to prevent overheating of the boiler and any equipment in and near the boiler.
Grant external boilers draw their air supply via the ventilation holes in recessed top edge of the front door of the boiler casing. These ventilation holes must not be obstructed.
Further details may be obtained from BS 5410-1.
9.2 CONVENTIONAL FLUE SYSTEMS
! NOTE !
Under no circumstances can Grant Vortex boilers be installed with existing flue systems. Only flue systems and components suitable for wet flues should be used.
Failure to install the correct type of flue system will invalidate the guarantee.
Grant condensing boilers have high operating efficiencies and low flue gas temperatures. Care must be taken to ensure the flue system is suitable for the very low flue gas temperatures and condensate in the flue gases. Suitable conventional flue systems are available from Grant UK. The flue must terminate in a down draught free area, i.e. at least 600 mm above the 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 high level 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.
The internal flue diameter for all models must be 100 mm (4 in). Twin wall flues are recommended for externally run flues to reduce the possibility of the condensate freezing in the flue. 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 Books 2 and 3) for further guidance on conventional flue systems.

To comply with the requirements of the Building Regulations Approved Document J – conventional flue systems must have a flue data plate.
9.3 EXTERNAL CONVENTIONAL FLUE (GREEN SYSTEM)
The external system can terminate at either high level (with a 90° terminal) or vertically (above roof level, with a vertical terminal) as required. The vertical or high level terminal must terminate in accordance with BS 5410-1. The minimum dimensions for locating the high level terminal from building features (windows, doors, etc.) are shown in Figure 9-2 and given in Table 9-2. The Green system comprises of five insulated extension lengths, 45° elbows, a vertical terminal and a high level horizontal terminal.
Locking bands are provided with all vertical extensions and terminals. Ensure that the locking bands are fitted.
Two types of wall bracket are also available (standard and adjustable) to support the vertical flue components.
The maximum vertical height (from the top of the boiler to the terminal) for the 100mm diameter `Green’ system twin wall flue is 19 metres. Only three 45° elbows may be used in the complete system.
If the flue terminal is fitted less than 2 metres above a surface to which people have access, the terminal must be protected by a guard. The guard must be manufactured from stainless steel and should be fitted centrally over the flue terminal and securely fixed to the wall.
CONNECTION OF GREEN FLUE SYSTEM
1. Connect Grant Green system (100mm twin wall flue) to the boiler flue outlet using the Grant External Module starter (product code: GKM90C).
2. Fit the starter piece into the boiler connector after first ensuring that the seal is in place in the connector.
! NOTE !
Lubricate the seal on the boiler connector using the lubricant provided before attempting to fit the starter piece.
Ensure that seals in all flue sections are lubricated before installing.
3. Assemble the remainder of the flue system as required, lubricating the seal on each component before fitting and securing every joint with the locking band provided.
The external vertical flue (Green system) components are available from Grant UK and can be found in Figure 9-1 and Table 9-1.

Section 9: Flue System and Air Supply

Page 29

Vertical terminal
45° elbow High level 90° terminal Extension Extended wall bracket Starter straight

Vertical terminal kit
45° elbow kit
High level terminal kit Extended wall bracket Wall bracket Locking band
Extension kits

Page 30

Starter straight

Figure 9-1: Green system

Table 9-1: Green system components – product codes

Item

Product code

150 mm extension

GX150/90

250 mm extension

GX250/90

450 mm extension

GX450/90

950 mm extension

GX950/90

195-270 mm adjustable extension

GXA250/90

45° elbow

GE45/90

High level terminal

GTH90

Vertical terminal

GTV90

Wall bracket – standard

GWB90

Wall bracket – extended

GEB90

External module starter straight

GKM90C

Section 9: Flue System and Air Supply

9.4 FLUE CLEARANCES

Figure 9-2: Flue clearances

Section 9: Flue System and Air Supply

Page 31

Table 9-2: Flue clearances

Ref

Location of outlet

Minimum distance (mm)

Pressure jet

Condensing

A

Directly below an opening, air brick opening, opening window, etc.

600

1,000 **

B

Horizontally to an opening, air brick opening, opening window, etc.

600

1,000 **

C

Below a gutter, eaves or balcony with protection

75 *

1,000 **

D

Below a gutter, eaves or balcony without protection

600

1,000 **

E

From vertical sanitary pipework

300

F

From an internal or external corner

300

G

Above ground or balcony level

300

H

From a surface or boundary facing the terminal

600

2,500 **

J

From a terminal facing the terminal

1,200

K

Vertically from a terminal on the same wall

1,500

L

Horizontally from a terminal on the same wall

750

M

Above the highest point of an intersection with the roof

600

N

From a vertical structure to the side of the terminal

750

O

Above a vertical structure less than 750 mm from the side of the terminal

600

P

From a ridge terminal to a vertical structure on the roof

1,500

Q

Above or to the side of any opening on a flat or sloping roof

300

R

Below any opening on a sloping roof

1,000

S

From oil storage tank (Class 1)

1,800 ***

A heat shield at least 750 mm wide must be fitted to provide protection of combustible material.

**

Clearances required by BS 5410-1:2019 to alleviate the effect of plume nuisance. If a risk assessment shows that there will be no impact from pluming,

then the `pressure jet’ figure could apply – seek confirmation from Local Authority Building Control.

Seek guidance from OFTEC Book 3 (Oil Storage and Supply).

NOTES 1. Appliances burning class D fuel have additional restrictions. Refer to BS 5410-1:2019. 2. Vertical structure in N, O and P includes tank or lift rooms, parapets, dormers, etc. 3. Terminating positions A to L are only permitted for appliances that have been approved for low level flue discharge when tested in accordance with BS EN 303-1, OFS A100 or OFS
A101. 4. Terminating positions should be at least 1.8 metres from an oil storage tank (Class 1) unless a wall with at least 30 minutes fire resistance and extending 300 mm higher and wider than
the tank is provided between the tank and the terminating position. 5. Where a flue is terminated less than 600 mm away from a projection above it and the projection consists of plastics or has a combustible or painted surface, then a heat shield of at least
750 mm wide should be fitted to protect these surfaces. 6. If the lowest part of the terminal is less than 2 metres above the ground, balcony, flat roof or other place to which any person has access, the terminal should be protected by a guard. 7. Notwithstanding the dimensions given above, a terminal should not be sited closer than 300 mm to combustible material. In the case of a thatched roof, double this separation distance
should be provided. It is also advisable to treat the thatch with a fire retardant material and close wire in the immediate vicinity of the flue. 8. A flue or chimney should not pass through the roof within the shaded area delineated by dimensions Q and R. 9. Where protection is provided for plastics components, such as guttering, this should be to the standard specified by the manufacturer of the plastics components. 10. Terminals must not be sited under car ports. 11. Terminals at low levels (terminals under 2.1 metres) have more restrictive recommendations and should not be positioned near public footways, frequently used access routes, car
parking spaces less than 2.5 metres from the terminal or patio’s (hard surface area).
Further guidance can be obtained from BS 5410-1:2019, OFTEC Book 4 (Installation) and Approved Document J.
Grant UK flue products are fully compliant with the CE (Communauté Européenne/European Community) standards having undergone rigorous product testing.

Page 32

Section 9: Flue System and Air Supply

10 COMMISSIONING
To ensure safe and efficient operation, it is essential that a Grant Eco Wall Hung boiler is commissioned as detailed in the following procedure. To access the controls, remove the front door from the boiler. Turn the knob at the bottom of the front door anticlockwise and pull the door outwards at the bottom. Carefully release the top of the front door panel from under the top casing panel flange and remove it from the boiler to reveal the boiler as shown in Figure 10-1. The controls are shown in Figure 10-2.

Figure 10-1: Boiler with front panel removed

Figure 10-2: Boiler controls

Section 10: Commissioning

Page 33

10.1 BEFORE SWITCHING ON
1. Ensure the boiler is isolated from the electrical supply and the boiler ON/OFF switch is set to OFF.
2. Check that the high limit thermostat bulb and boiler thermostat bulb are correctly located in their respective pockets. See Figure 4-1. Check condition of both thermostat capillaries. Ensure they are not damaged, broken, kinked or crushed.
3. Remove the nuts and washers securing the front cleaning door. Withdraw the door ­ take care as it is heavy!
4. Check that the turbulators are in position and that the ends are vertical. Refer to Figure 11-2.
5. Check that the baffles are in position. Refer to Figure 11-1.
6. Refit cleaning door and check that it is fitted correctly and that a good seal is made.
7. Unscrew the burner fixing nut (located at the top of the mounting flange), rotate the burner clockwise and remove the burner from the boiler.
The burner has a slotted lug on the underside of the fan housing. This allows the burner, when removed from the boiler, to be hung on the bolt on the front of the combustion door for checking/servicing.

10.2 BURNER SETTINGS
With the burner removed from the boiler: 1. Remove the burner head. Refer to Figure 10-3. Loosen the
two fixing screws (1) and remove head (2) from the burner.
1 2
3 5
7 4
6 1

6

! NOTE !

With two flexible hoses connected to the burner, identify (mark if necessary) which is the inlet and return if they are to be disconnected.
8. Check/adjust the burner settings as described in Section 10.2.
9. Re-fit the burner to the boiler and tighten the fixing nut. DO NOT OVERTIGHTEN!
10. Check that sealed system has been vented and pressurised and that there are no leaks.
11. Ensure the air vent on the condensing heat exchanger is open. Refer to Section 7.
12. Check that all fuel line valves are open.
13. Connect a combined vent manifold and pressure gauge to the pressure gauge connection port on the oil pump (item 6, Section 11.7). Open the vent screw on the vent manifold to vent the supply while the pump is running.
14. Check that all system controls are calling for heat and turn the boiler thermostat to maximum.

Figure 10-3: Burner head, diffuser and nozzle holder
2. Check the nozzle (7) is correct for the required boiler output. Refer to Table 2-3 for the correct nozzle size and type for the required boiler output.
3. If the nozzle needs to be replaced ­ remove the diffuser/ electrode assembly. Refer to Figure 10-3. · Using a 3 mm Allen key, loosen the diffuser fixing screw (3) on the electrode assembly. · Lift the diffuser/electrode assembly (5) up and off the nozzle holder.
· Disconnect both ignition leads (4) from the electrodes. 4. Use a 16mm spanner to remove /re-fit the nozzle, whilst
holding the nozzle holder (6) using another 16mm spanner.
! CAUTION !

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

Page 34

! NOTE !
Ensure that the nozzle is securely tightened so it does not leak but DO NOT OVERTIGHTEN!
5. Re-fit the diffuser/electrode assembly. Refer to Figure 10-3. · Re-connect ignition leads (4) to electrodes. · Re-fit the diffuser/electrode assembly (5) onto the nozzle holder (6) lining up the fixing screw (3) with the with the recess in the nozzle holder. · Ensure diffuser assembly is fitted down hard onto the shoulder on the nozzle holder. · Tighten the fixing screw (3) to secure the diffuser/ electrode assembly (5) in place on the nozzle holder (6).
! NOTE !
Do not overtighten the fixing screw as this may damage the electrode insulator.
6. Check/adjust the electrode setting. Refer to Figure 10-4. Always check the electrode settings after replacing the nozzle.
Section 10: Commissioning

A
= =

2
A
Check the distance beetwen tips of electrodes.

A-A
Check the distance beetwen nozzle/electrodes and diffuser/electrodes.

Figure 10-4: Ignition electrode settings
7. Re-fit the burner head. Refer to Figure 10-3. · Locate the head fixing screws in the countersunk slots in the burner collar (1). · Check/adjust the electrode setting. Refer to Figure 10-4. · As the head will only fit one way, rotate the head until the two screws align with the slots.
· Tighten the two screws to secure the head (2) in position on the burner.
8. Check/adjust the diffuser position. Refer to Figure 10-5.
! NOTE !
The distance between the end of the burner head and the front face of the diffuser (D) MUST be correctly set for the burner to operate correctly.
· Refer to Table 2-3 for the required distance (diffuser setting) for the boiler output required. This is the distance from the front face of the nozzle to the internal shoulder of the burner head. Refer to Figure 10-5.
· Check the distance using the gauge supplied with the burner.

– Position the gauge on the internal shoulder of the burner head so the leg for the required output is pointing towards the nozzle.
– Check that the gauge is at 90°to the internal shoulder of the burner head and across the full diameter.
– If the diffuser setting is correct, the tip of the gauge leg will just touch the front face of the nozzle, with the gauge still in contact with the internal shoulder of the burner head on BOTH sides. Refer to Figure 10-5.
– If the gauge leg is in contact with the nozzle face but the gauge is NOT in contact with the internal shoulder of the burner head on BOTH sides, the diffuser must be opened’ (see below). – If the gauge leg does not reach the nozzle with the gauge is in contact with the internal shoulder of the burner head on BOTH sides, the diffuser must be closed’ (see below).
· To adjust the diffuser position: – If necessary, adjust the diffuser position by rotating the adjustment screw, located on the front of the burner, using a 4mm Allen key. Refer to Section 11.7. Re-check the diffuser setting using the gauge, as described above.
– To increase the distance between the nozzle face and internal shoulder of the burner head (to open the diffuser): rotate the adjusting screw clockwise.
– To decrease the distance between the nozzle face and internal shoulder of the burner head (to close the diffuser): rotate the adjusting screw anticlockwise.
! NOTE !
One full rotation of the adjuster screw is approximately 1mm of diffuser (and nozzle) movement.
! NOTE !
It is essential that the final position of the diffuser is checked, using the gauge provided with the boiler, and the diffuser adjusted as necessary to achieve the required position.

Check the distance beetwen nozzle and recirculation pipe.
Figure 10-5: Checking the diffuser position using the guage provided
· The three possible boiler output settings are stamped on three of the legs of the gauge.
· To use the gauge: – Identify the correct leg of the gauge that matches the required boiler output.

10.3 SWITCHING ON
1. Check that all system controls are calling for heat and turn the boiler thermostat to maximum.
2. Switch on the electricity supply to the boiler.
3. Set the boiler On/Off switch to ON. A Neon on 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 that the burner is firing. The burner should then fire. Open the vent screw on the vent manifold to vent the supply while the oil pump is running.
4. The burner fan should start and the burner should light within about 12 seconds. If the burner does not light and the `Lockout’ reset button on the burner lights, wait about 45 seconds and press the reset button to restart the ignition process.
This procedure may have to be repeated several times during first lighting. 5. With the burner alight, check the fuel pressure. Refer to Section 2.3 (burner settings). 6. Adjust the pressure if necessary.
! NOTE !
It is important that the oil pressure is correctly set.

Section 10: Commissioning

Page 35

7. Operate the boiler until it reaches normal operating temperature. Check oil supply/return pipe for leaks, rectifying where necessary.
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 readjust 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.
11. On balanced flue installations ­ ensure the flexible air inlet tube and the flexible air tube is connected to both the burner air inlet and the flue system.
10.4 RUNNING THE BOILER
1. Relight the boiler and allow it to run for at least 20 minutes.
2. Check the smoke number, if it is 0-1 then it is satisfactory. 3. Using a calibrated electronic flue gas analyser, set to the
correct fuel, check the %CO2 in the flue gases.
! NOTE !
To allow the boiler to be commissioned and serviced correctly a combustion test point is provided on the front cleaning door. Both the %CO2 and smoke test may all be carried out using this test point.
This test point is not suitable for measuring boiler efficiency or conventional flue draught.
4. 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 section when used).
5. For high level and vertical balanced flues, the reading may be taken from the flue test point provided on the flue system.
6. For conventional flues, a test point is provided in the conventional flue adaptor for flue draught and flue gas temperature measurement.
7. Set the %CO2, as indicated on the flue gas analyser, to the required value as given in Section 2.3 for the boiler concerned.
8. Adjust the burner air damper, using the hexagonal key supplied, to achieve the required %CO2. Refer to Section 11.7.
9. To increase the %CO2: · Turn the screw anti-clockwise. This will close down the burner air damper and decrease the combustion air entering the burner.
To decrease the %CO2: · Turn the screw clockwise. This will open up the burner
air damper and increase the combustion air entering the burner.
10. When the %CO2 is set to the correct level, re-check the smoke number if the burner air damper has been moved. Under no circumstances must the smoke number be above 1.
! NOTE !
For safe and efficient operation of the boiler it is essential that the air damper is correctly set to give the required %CO2 in the flue gases.

10.5 BALANCING THE SYSTEM
1. When the boiler has been adjusted and is running satisfactorily, balance the central heating system by adjusting 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.
10.6 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 the sealed system.
2. A suitable central heating system inhibitor must be added to protect the system against the effects 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 front door in the boiler casing.
! NOTE !
After commissioning the boiler complete 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, remote programmer and room thermostat 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.
! CAUTION !
If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained. Alternatively, a suitable heating system antifreeze should be used.
10.7 INFORMATION FOR THE USER
The User must be advised (and demonstrated if necessary) of the following important points:· How to start and switch off the boiler and how to operate the
system controls. · The precautions necessary to prevent damage to the central
heating system and to the building, in the event of the boiler not being in operation during frost conditions. · The importance of servicing the boiler to ensure safe and efficient operation. This should normally be required only once a year. · The type of fuel used. · That any servicing or replacement of parts must only be carried out by a suitably qualified engineer. · Ensure that the boiler controls and room thermostat (if fitted) are set to the User’s requirements. · Tell the User the system pressure and show them the position of the safety valve discharge pipe. · Show the User how to reset the overheat thermostat and how to restart the boiler if it goes to `Lockout’.

Page 36

Section 10: Commissioning

11 SERVICING

To ensure efficient operation of the boiler it is essential that a Grant Vortex Eco Wall Hung boiler is serviced at regular intervals of no longer than 12 months. Servicing and replacement of parts must only be carried out by a suitably qualified engineer.
! CAUTION !
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 guarantee.
! WARNING !
Before starting any work on the boiler, or fuel supply please read the Health and Safety information given in Section 15 of these instructions.
11.1 CHECKS BEFORE SERVICING
The following sequence of checks should be made before starting any servicing work: 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 system connections and fittings are
sound. Remake any joints and check the tightness of any fittings that may be leaking. 4. Allow the boiler and system to cool down. 5. 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. Refer to Section 7. 6. Refill, vent and re-pressurise the system as necessary. Refer to Section 7. 7. Check that any ventilation openings are of adequate free area and are clear. Refer to Section 9.1. 8. Remove any sludge/water from the fuel tank by opening the sludge valve at the lower end of the tank (if fitted). 9. Ensure that all fuel system connections and fittings are sound. Remake any joints and check the tightness of any fittings that may be leaking. 10. With the fuel supply valve (at the oil tank) closed, clean/ replace the filter element and clean the filter bowl.

11.2 DISMANTLING PRIOR TO SERVICING
The procedure for dismantling the boiler is as follows:
1. Remove the front door from the boiler.
Turn the knob at the bottom of the front door anticlockwise and pull the door outwards at the bottom. Carefully release the top of the front door panel from under the top casing panel flange and remove it from the boiler casing to reveal the boiler as shown in Figure 10-1.
2. On System models, carefully lift up and remove the expansion vessel from the boiler. Place the vessel on the front of the boiler. A clip is fitted to clip it on to the top front edge of the casing.
3. Unscrew the burner fixing nut (top of mounting flange) and rotate the burner clockwise and withdraw the burner from the boiler.
The burner has a slotted lug on the underside of the fan housing. This allows the burner, when removed from the boiler, to be hung on the bolt on the front of the combustion door for checking/servicing. 4. If required, disconnect the flexible oil line(s), using a suitable container to prevent any oil spillage.
5. Check or replace the flexible fuel supply hose(s), as follows: · Braided flexible fuel supply hoses (as supplied with the boiler) should be replaced annually i.e. when the boiler is serviced.
· Long-life hoses should be inspected annually. If in doubt replaces the hose(s). In any event, these hoses must be replaced every five years.
! NOTE !
With a two-pipe oil supply there will be two flexible hoses connected to the burner. Identify (mark if necessary) which is the inlet and return if they are to be disconnected.

! WARNING !

Before servicing, set the boiler On/Off switch to OFF, isolate the electricity supply and close the fuel supply valve.
The data label on the inside of the case side panel will indicate the fuel used and the nozzle fitted.

Section 11: Servicing

Page 37

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 Figure 11-1.

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 22mm 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. 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.
! NOTE !
The condensate trap and condensate outlet must be checked on every service and cleaned as necessary.

11.4 CLEANING THE BURNER
With the burner removed from the boiler:
1. Remove the burner head. Refer to Figure 10-3. Loosen the two fixing screws (1) and remove head (2) from burner.
2. Clean the burner head.
3. Remove the diffuser/electrode assembly. Refer to Figure 103.
· Using a 3mm Allen key, loosen the diffuser fixing screw (3) on the diffuser/electrode assembly (5).
· Lift the diffuser/electrode assembly up and off the nozzle holder (6).
· Disconnect both ignition leads (4) from the electrodes.
4. Refer to figure 10-3. Replace the nozzle (7). The nozzle should always be replaced on an annual service. Refer to Table 2-3 for the correct nozzle size and type for the required boiler output. Do NOT attempt to clean the nozzle.
Use a 16 mm spanner to remove/re-fit the nozzle, whilst holding the nozzle holder using another 16 mm spanner.

Figure 11-1: Removing the baffles 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 and
replace if necessary. 6. Replace the baffles, ensuring they are correctly fitted. Refer
to Figure 11-1. 7. Pull out the spiral turbulators from the heat exchanger tubes.
(Refer to Figure 11-2).
Position in vertical plane
IMPORTANT: The ends of the turbulators must be vertical

! CAUTION !
The use of an ill-fitting spanner will damage the nozzle and could lead to an incorrect flame pattern and poor combustion.
! NOTE !
Ensure that the nozzle is securely tightened so that it does not leak but DO NOT OVER TIGHTEN!
5. Inspect the ignition electrodes ­ remove the electrode fixing screw and withdraw the electrode assembly. Wipe clean and check for any cracks on the insulation. Replace if necessary.
6. Re-fit the diffuser/electrode assembly. Refer to Figure 10-3. · Re-connect ignition leads (4) to electrodes. · Re-fit the diffuser/electrode assembly (5) onto the nozzle holder (6) lining up the fixing screw (3) with the recess in the nozzle holder. · Ensure diffuser/electrode assembly is fitted down hard onto the shoulder on the nozzle holder. · Tighten the fixing screw (3) to secure the diffuser/ electrode assembly (5) in place on the nozzle holder (6).
! NOTE !

Figure 11-2: Turbulators

Do not overtighten the fixing screw as this may damage the electrode insulator.

Page 38

Section 11: Servicing

7. Check/adjust the electrode setting. Refer to Figure 10-4.
Always check the electrode settings after replacing the nozzle.
8. Re-fit the burner head. Refer to Figure 10-3.
· Locate the head fixing screws in the countersunk slots in the burner collar (1).
· Check/adjust the electrode setting. Refer to Figure 10-4.
· As the head will only fit one way, rotate the head until the two screws align with the slots.
· Tighten the two screws to secure the head (2) in position on the burner.
9. Adjust the diffuser position. Refer to Figure 10-5.
! NOTE !
The distance between the end of the burner head and the front face of the diffuser (D) MUST be correctly set for the burner to operate correctly.
· Refer to Table 2-3 for the required distance (diffuser setting) for the boiler output required. This is the distance from the front face of the nozzle to the internal shoulder of the burner head. Refer to Figure 10-5.
· Check the distance using the gauge supplied with the burner.
· The three possible boiler output settings are stamped on three of the legs of the gauge.
· To use the gauge:
– Identify the correct leg of the gauge that matches the required boiler output.
– Position the gauge on the internal shoulder of the burner head so the leg for the required output is pointing towards the nozzle.
– Check that the gauge is at 90°to the internal shoulder of the burner head and across the full diameter.
– If the diffuser setting is correct, the tip of the gauge leg will just touch the front face of the nozzle, with the gauge still in contact with the internal shoulder of the burner head on BOTH sides. Refer to Figure 10-5.
– If the gauge leg is in contact with the nozzle face but the gauge is NOT in contact with the internal shoulder of the burner head on BOTH sides, the diffuser must be opened’ (see below). – If the gauge leg does not reach the nozzle with the gauge in contact with the internal shoulder of the burner head on BOTH sides, the diffuser must be closed’ (see below).
· To adjust the diffuser position:
– If necessary, adjust the diffuser position by rotating the adjustment screw, located on the front of the burner, using a 4mm Allen key. Refer to Section 11.7. Re-check the diffuser setting using the gauge, as described above.
– To increase the distance between the nozzle face and internal shoulder of the burner head (to open the diffuser): rotate the adjusting screw clockwise.
– To decrease the distance between the nozzle face and internal shoulder of the burner head (to close the diffuser): rotate the adjusting screw anticlockwise.

! NOTE !
It is essential that the final position of the diffuser is checked, using the gauge provided with the boiler, and the diffuser adjusted as necessary to achieve the required position.
10. Continue cleaning the other burner components as detailed in Section 11.5
11.5 CLEANING THE BURNER: OTHER COMPONENTS
Photocell The photocell is a push-fit in the front of the burner body. 1. Holding the body of the photocell and NOT the cable,
carefully pull the photocell out of the burner. 2. Clean the sensor end of the photocell. 3. Replace photocell back in the burner and check that it is fully
pushed in. Burner air inlet This is located on the right hand side of the burner. Refer to Section 11.7. 1. Using a 4mm Allen key, unscrew and remove the two screws
and remove the air inlet from the burner. 2. Check inside and remove any debris, leaves, hair, fluff, etc.
from the air inlet housing and air damper. Burner fan housing This is located over the fan impeller. Refer to Section 11.7. With the burner air inlet already removed: 1. Using a 4mm Allen key, unscrew and remove the four screws
and remove the fan housing from the burner. 2. Check and clean the fan impeller and remove any debris,
leaves, hair, fluff, etc. 3. Check the fan housing is clean and clean as required. 4. Check the rubber seal around the fan housing. Replace if
damaged or missing. 5. Re-fit the fan housing to the burner and secure with the four
screws. 6. Re-fit the burner air inlet to the burner and secure with the
two screws. Oil pump filter This is located under the end cover on the oil pump. Refer to Section 11.7. 1. Using a 4mm Allen key, unscrew and remove the four cap
screws securing the pump end cover. Remove end cover from pump. 2. Remove the filter and wash in kerosene. 3. Check the O-ring seal around the end cover. Replace if damaged. 4. Refit the filter and end cover. 5. Re-fit the four cap screws, tighten evenly, to secure the end cover.
11.6 RECOMMISSIONING
! WARNING !

! NOTE !
One full rotation of the adjuster screw is approximately 1mm of diffuser (and nozzle) movement.

To ensure safe and efficient operation of the boiler it is important that re- commissioning is carried out, especially
combustion checks (%CO2 level, flue gas temperature and smoke number) after the boiler has been serviced. Refer to
the Commissioning instructions in Section 10.

Section 11: Servicing

Page 39

11.7 BURNER COMPONENTS (ECOFLAM MAX 1 LN)

3

10

9

2

8

5
6

4 7
6
11
Item 1 2 3 4 5 6 7 8

15
Description Oil pump
Air damper adjustment screw Reset / “lockout” button Photocell Control box
Pump pressure adjustment screw Pressure gauge connection point
Combustion head

16
1
12
Item 9 10 11 12 13 14 15 16

13 14
Description Mounting flange
Air inlet Motor Motor ignition capacitor Fuel suction line Fuel return line Diffuser adjustment screw Solenoid coil

Page 40

Section 11: Servicing

12 FAULT FINDING

12.1 BOILER FAULT FINDING
Always isolate the electricity supply to the boiler before working on the boiler.

Table 12-1: Boiler fault finding Fault Boiler will not start: No fuel supply.
No electricity supply. Burner not starting – fuel and electricity supplies present. Burner lights but goes to lock-out. Boiler works but: 1. Visible smoke from flue or high smoke number.
2. Burner pulses.
3. Flame slow to stabilise during start up.
4. Water temperature low. 5. Boiler operating on overheat thermostat. 6. Fumes and puffing during starting (conventional flue) 7. Oil odours. 8. Combustion fumes smell.

Remedies
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. Check that the fire valve has not operated to shut off the oil supply.
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.
Insufficient air supply – check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 9.1. 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 room ventilation is adequate, see Section 9.1. Check the nozzle size and type.
Insufficient air supply – check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 9.1. 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.
Undersized 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 the condition of the chimney, ensure it is not blocked and is high enough to produce the required draught. Check that there is an adequate air supply near the burner and that a kitchen fan is not drawing products out of the burner.
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.

! NOTE !
For an overview of the fault diagnostic capabilities built into the circulating pump that comes installed in the sealed system boiler models, please refer to Appendix A1 at the back of this installation and servicing manual.

Section 12: Fault Finding

Page 41

12.2 BURNER FAULT FINDING CHARTS 12.2.1 BURNER FAILS TO START, NO FLAME, NO LOCK OUT

Symptoms

Possible causes

Actions

Motor fails to run Lock-out light not lit

No electrical supply to boiler Fuse has blown

Check ON/OFF switch is ON – mains neon is lit
Check or replace fuse If fuse has blown – check reason for failure

Boiler thermostat not calling

Adjust boiler thermostat to call for heat

Heating controls are not calling

Adjust programmer and room thermostat to call

Overheat thermostat has operated

Check and reset overheat thermostat if required If operated – check reason for operation

No power to burner

Check for 230 volts at control box mains terminals

Control box faulty

Replace faulty control box

12.2.2 BURNER FAILS TO START, NO FLAME, GOES TO LOCKOUT

Symptoms

Possible causes

Actions

Motor fails to run Burner lockout

No power to burner motor Burner motor capacitor faulty

Check for 230 volts at motor plug terminals Check and replace if necessary

Burner motor faulty

Replace burner motor

Burner motor stalled Seized oil pump

Check and replace faulty oil pump

Page 42

Section 12: Fault Finding

12.2.3 BURNER STARTS, NO FLAME, GOES TO LOCKOUT

Symptoms

Possible causes

Actions

Motor runs Burner pre-purges Burner does not fire Burner lock-out

Flame instability Carbon / soot on combustion head No oil pressure
Low oil pressure Excessive combustion air Excessive flue draught (CF only)

Clean blast tube Check pump drive coupling – replace if failed Check oil pump pressure is correct Adjust air damper setting Rectify condition

False light

Check photocell is not sensing ambient light

No ignition spark

Check HT lead connections are sound Check ignition electrode gap is correct Check for 230 volts at ignition transformer Check transformer – replace if faulty

No oil at nozzle

Check for sufficient fuel in tank Check fire valve has not tripped Check all oil supply valves are open Check oil line and pump is not air-locked Check operation of solenoid valve Check pump drive coupling – replace if failed Check fuel pump – replace if seized

Restriction in oil supply

Check filters, valves and oil lines and rectify

Fuel contamination (water in tank)

Check tank, filters and oil line for water

12.2.4 BURNER FIRES, GOES TO LOCKOUT

Symptoms

Possible causes

Motor runs Burner pre-purges Burner fires Burner lockout

Flame instability Carbon / soot on combustion head Fuel contamination (water in tank)
Low oil pressure Excessive combustion air Excessive flue draught (CF only)

Photocell not sensing light

Photocell failed

Defective nozzle

Actions
Clean combustion head Check tank, filters and oil line for water Check oil pump pressure and adjust if necessary Adjust air damper setting Rectify condition Check photocell is clean and unobstructed Replace faulty photocell Replace nozzle

Section 12: Fault Finding

Page 43

12.2.5 DELAYED IGNITION, BURNER STARTS VIOLENTLY

Symptoms

Possible causes

Actions

Burner pulsates on start up

Excessive combustion air

Recommission burner – adjust air setting

Low oil pressure

Check and recommission burner

Partially blocked nozzle

Replace nozzle

Fuel contamination (water in tank)

Check tank, filters and oil line for water

Fan slipping on shaft

Check and re-tighten

Pump coupling loose or worn

Check and replace

Burner starts violently

Delayed ignition

Check electrode settings Check electrodes for damage Check HT lead connections are sound Check HT leads for damage or arcing

12.2.6 BURNER CYCLES ON AND OFF

Symptoms

Possible causes

Burner firing Burner stops firing Pre-purge starts Burner fires Burner stops firing

Restriction in oil supply Fuel contamination (water in tank) Partially blocked nozzle Vitiated combustion air (balanced flue only)

Boiler thermostat hunting

Actions Check filters, valves and oil lines and rectify
Check tank, filters and oil line for water
Replace nozzle
Disconnect snorkel tube and check operation Check flue terminal for obstructions and rectify Check flue system for leaks and rectify
Replace faulty thermostat

Page 44

Section 12: Fault Finding

13 SPARE PARTS
13.1 BOILER PARTS LIST
Table 13-1: Boiler parts list Description
Cleaning door nut and washer set Double pole switch
Baffle set (complete) – all Wall Hung models Turbulator baffle – all Wall Hung models Combustion Door – all Wall Hung models
Cleaning door rope seal – all Wall Hung models Limit thermostat (110°C) c/w Earth wire
Control thermostat (50 – 75°C) c/w Earth wire Wilo Yonos Para RKS HE circulating pump (7 m head) – all models
between April 2015 and November 2019 WIlo Para SC HE circulating pump (7m head) –
all models from November 2019 Automatic Air Vent
Low Pressure Switch Upgrade Kit (Wall Hung External models)
13.2 SEALED SYSTEM PARTS LIST
Table 13-2: Sealed system parts list Description
Expansion vessel (8 litre) – all Wall Hung models Water pressure gauge
Pressure relief valve (3.0 bar) Pressure relief valve with pressure gauge port (3.0 bar)
Expansion vessel flexible hose Filling Loop Kit

Grant UK product code EFBS14 EFBS19 WBS03 WBS01 WBS04 WBS05 VBS147 VBS146 VBS126
VBS159 MPCBS29 MPCBS63/A
Grant UK product code WBS07 VBS08
MPCBS123 MPCBS124
WBS08 VBS35

Section 13: Spare Parts

Page 45

13.3 ECOFLAM MAX 1 LN BURNER
This section gives exploded views of the Ecoflam Max 1 low NOx yellow flame burners in the Grant Vortex Eco Wall Hung boilers, and parts lists associated with them.

0170 0290

0270 0120

0140

Figure 13-1: Ecoflam Max 1 low NOx yellow flame burner exploded diagram

0150

0030 0090 0080 0130 0310 0100 0110

0180 0260 0250 0160

0300 0020 0010 0050

0200 0280 0220 0190 0210 0240 0230

Page 46

Section 13: Spare Parts

Page 47

Section 13: Spare Parts

Table 13-3: Ecoflam Max 1 low NOx burner parts list

Key No.

Description

0010

Oil pump (Danfoss BFP11 R3

0020

Coil (Danfoss BFP T85)

0030

Coupling

0050

Hoses

0080

Motor

0090

Capacitor (4 F)

0100

Ignition transformer

0110

Control box with cables

0120

Photoresistor

0130

Support

0140

Plug and cable

0150

Fan

0160

O-ring

0170

Cover air inlet

0180

Cables

0190

Electrodes

0200

Combustion head (16-21)

0210

Nozzle holder

0220

Diffuser (16-21)

0230

Conveyor

0240

Rod

0250

Flange

0260

Gasket

0270

Oil pipe

0280

Nozzle – 0.50/80°EH Nozzle – 0.60/80°EH

0290

Ring

0300

Set filter and seal

0310

Gauge

Ecoflam product code 65322968 65327293 65322920 65327402 65326747 13011117 65323257 65327403 65327404 65327405 65327406 65323826 65321066 65327407 65320934 65327306 65327409 65327410 65327412 65327413 65327414 65320975 65321089 65327415 65320513 65325684 65327489

Grant product code EBS65322968 EBS65327293 EBS65322920 EBS65327402 EBS65326747 EBS13011117 EBS65323257 EBS65327403 EBS65327404 EBS65327405 EBS65327406 EBS65323826 EBS65321066 EBS65327407 EBS65320934 EBS65327306 EBS65327409 EBS65327410 EBS65327412 EBS65327413 EBS65327414 EBS65320975 EBS65321089 EBS65327415 M1BS27/46 M1BS27/31 EBS65320513 EBS65325684 EBS 65327489

14 DECLARATION OF CONFORMITY

EC DECLARATION OF CONFORMITY
In accordance with BS EN ISO/IEC 17050-1:2004

We:

Grant Engineering (UK) Limited

Of:
Telephone: Fax: Email: Website:

Frankland Road Blagrove Industrial Estate Swindon SN5 8YG +44 (0)1380 736920 +44 (0)1380 736991 [email protected] www.grantuk.com

Declare that: Equipment: Model Name/Number:

Domestic oil boilers Grant Vortex Eco Wall Hung External 16-21 Grant Vortex Eco Wall Hung External System 16-21

Note: All Grant system variants are supplied with glandless high efficiency integrated circulators

In accordance with the following Directives:

2006/95/EEC

Conforms with the safety objectives of the Low Voltage Directive and its amending directives.

2004/108/EC

Conforms with the essential protection requirements of the Electromagnetic Compatibility Directive and its amending directives.

92/42/EC

Conforms with the requirements of the Boiler Efficiency Directive.

2010/30/EU

Conforms with the Labeling of Energy related products to EU (no) 811/2013

2009/125/EC

Conforms with the Ecodesign of Energy related products to EU (no) 813/2013

I hereby declare that the equipment named above has been tested and found to comply with the relevant sections of the above referenced specifications. The unit complies with all essential requirements of the Directives.

Responsible Person: Position: Signature:

Neil Sawers Technical Manager

Date:

April 2022

Page 48

Section 14: Declaration of Conformity

15 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:
15.1 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.

15.3 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.

15.2 SEALANT AND ADHESIVE
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.

Section 15: Health and Safety Information

Page 49

16 END OF LIFE INFORMATION

GENERAL
Grant oil boilers incorporate components manufactured from a variety of different materials. The majority of these materials can be recycled whilst the smaller remainder cannot.
Materials that cannot be recycled must be disposed of according to local regulations using appropriate waste collection and/or disposal services.

DISASSEMBLY
There is little risk to those involved in the disassembly of this product. Please refer to and follow the Health and Safety Information given in the Installation & Servicing Instructions provided with the boiler. For guidance on the disassembly of the boiler refer to the information given in the Servicing section of the Installation & Servicing Instructions provided with the boiler.

RECYCLING

Many of the materials used in Grant oil boilers can be recycled, these are listed in the table below:

COMPONENT

MATERIAL

Outer casing panels

Mild steel (polyester powder coated)

Primary heat exchanger and baffles

Mild steel

Secondary heat exchanger

Stainless steel

Secondary heat exchanger spirals

Aluminium alloy

Pipework

Copper

Burner body/flange

Aluminium alloy

Burner oil pump

Aluminium alloy/steel

Riello oil burner cover

Plastic

Electrical wiring

Copper/plastic

Thermostats

Copper/plastic

Printed Circuit boards

Copper/plastic

DISPOSAL
All materials other than those listed above must be disposed of responsibly as general waste.

Neil Sawers Technical Manager

Page 50

Section 16: End of Life Information

17 PRODUCT FICHE
Product fiche concerning the COMMISSION DELEGATED REGULATIONS (EU) No 811/2013 of 18 February 2013 (EU) No 813/2013 of 2 August 2013

Vortex Eco Wall Hung External

Symbols

Unit

Condensing boiler Low temperature boiler B1 boiler Combination heater Rated heat output Useful heat output At rated heat output and high temperature regime At 30% of rated heat output and low temperature regime Auxiliary electricity consumption At full load At part load In standby mode Useful efficiency Seasonal space heating energy efficiency At rated heat output and high temperature regime At 30% of rated heat output and low temperature regime Other items Standby heat loss Ignition burner power consumption Annual energy consumption Sound power level indoors Emissions of nitrogen oxides Emission class Daily fuel consumption Annual fuel consumption

Prated
P4 P1
elmax elmin PSB
s 4 1
Pstby Pign QHE LWA NOX
Qfuel AFC

kW
kW kW
kW kW kW
% % %
kW kW kWh dB mg/ kWh
kWh GJ

Yes No No No 21
21
6.3
0.150 0.07
0
90.52 90.8
96.9
0.236 0 52
<120 2 –

16-21 System 16-21

Yes No No No 21
21
6.3
0.150 0.07
0
90.52 90.8
96.9
0.236 0 52
<120 2 –

Section 17: Product Fiche

Page 51

18 GUARANTEE

You are now the proud owner of a Grant Vortex condensing boiler from Grant Engineering (UK) Limited which has been designed to give years of reliable, trouble free operation.
Grant Engineering (UK) Limited guarantees the manufacture of the boiler including all electrical and mechanical components for a period of twelve months from the date of installation4, provided that the boiler has been installed in full accordance with the installation and servicing instructions issued.
This will be extended to a total period of two years if the boiler is registered with Grant Engineering (UK) Limited within thirty days of installation and it is serviced at twelve month intervals3. See main Terms and Conditions below.
Registering the product with Grant Engineering (UK) Limited Please register your Grant Vortex condensing bo

References

• Award Winning HVO compatible boilers, air source heat pumps & renewable heating from Grant UK
• Register Your Product For Its Grant Guarantee - Warranty Registration Grant UK

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