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Grant Vortex Design, Installation And Servicing Instructions

Utility condensing oil boiler range
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Grant Vortex
Utility Condensing Oil Boiler Range
Installation and Servicing Instructions
IRL | DOC 0027 | Rev 01.00 | October 2022

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  • Page 1 Grant Vortex Utility Condensing Oil Boiler Range Installation and Servicing Instructions IRL | DOC 0027 | Rev 01.00 | October 2022...
  • Page 2 This manual is accurate at the date of printing but will be superseded and should be disregarded if specifi cations and/or appearances are changed in the interests of continued product improvement.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 (Ireland) ULC, the author or others involved in its publication.
  • Page 3 All Grant Vortex boilers are suitable for use with Class C2 Kerosene. This boiler IMPORTANT NOTE FOR INSTALLERS is not suitable for gas oil. To use Bio-Kerosene (B30K), refer to the information These instructions are intended to guide installers on the installation, below: commissioning and servicing of the Grant Vortex oil boiler.

  • Page 4: Table Of Contents

    Frost protection Sealed system data Control system wiring diagrams Burner settings Boiler control panel wiring diagrams Flue gas analysis System wiring using grant wiring centre EP001 27 Water connections Boiler dimensions FLUE SYSTEM AND AIR SUPPLY OIL STORAGE AND SUPPLY...
  • Page 5 12.1 Boiler fault fi nding 12.2 Burner fault fi nding - Riello RDB SPARE PARTS 13.1 Boiler parts list 13.2 Sealed system parts list 13.3 Riello RDB 2.2 burners (15/26, 26/36 and 36/46) 13.4 Riello RDB 3.2 burners (46/70) DECLARATION OF CONFORMITY HEALTH AND SAFETY INFORMATION...

  • Page 6: Introduction

    1.3.1 FOR CONVENTIONAL FLUE Plume Kit (15/26 models only) APPLICATIONS A fl exible vertical balanced fl ue system designed to be fi tted inside Where a chimney is to be lined - Grant recommends the use of the Page 6 Introduction...

  • Page 7: Boiler Components

    Figure 1-1: Boiler components thermostat control knob and the manual reset button for the overheat thermostat. Figure 1-1 shows the components in the Vortex Utility boilers and the position of the control panel. Figure 1-2 shows the details of the control panel.

  • Page 8: Technical Data

    TECHNICAL DATA BOILER TECHNICAL DATA Table 2-1: Boiler technical data Utility Units 15/26 26/36 36/46 46/70 litre Water content 1 12 Weight (dry) Maximum heat output (Kerosene) Btu/h 88,700 122,800 157,000 238,800 Minimum fl ow rate (ΔT=10°C) 2,200 3,000 4,000 6.000 Minimum fl...

  • Page 9: Burner Settings

    The data given above is approximate only and is based on the boiler being used with a low level balanced fl ue. The above settings may have to be adjusted on site for the correct operation of the burner. Gas Oil is NOT suitable for use with Grant Vortex boiler range The fl ue gas temperatures given above are ± 10%.

  • Page 10: Boiler Dimensions

    BOILER DIMENSIONS PLAN VIEW INTERNAL DRAIN TRAP EXIT (LEFT SIDE PANEL ONLY) REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW Figure 2-5: Vortex Utility 15/26 dimensions Page 10 Technical Data...
  • Page 11 PLAN VIEW INTERNAL DRAIN TRAP EXIT (LEFT SIDE PANEL ONLY) REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW Figure 2-6: Vortex Utility 26/36, 36/46 dimensions PLAN VIEW INTERNAL DRAIN TRAP EXIT (LEFT SIDE PANEL ONLY) REAR VIEW LEFT SIDE VIEW...

  • Page 12: Oil Storage And Supply System

    • 3/8x ¼” BSP adaptor (product code: 3005720) • Steel tanks OFT T200 These are available to purchase from Grant Ireland. Metal braided flexible fuel hoses should be replaced ANNUALLY when the boiler is serviced. A galvanised tank must not be used.
  • Page 13 Figure 3-1: Single pipe (gravity) system Figure 3-2: Two pipe system Figure 3-3: De-aeration device system Key to oil supply diagrams Oil tank External wall Burner Isolating valve Oil fi lter (15μm max. fi ltration size) Non-return valve Oil strainer Fire valve sensor De-aerator* Fire valve to BS5410...

  • Page 14: Burner Oil Connection

    • 3/8” x ¼” BSP adaptor (product code: 3005720) Remove the red plastic burner cover. These are available to purchase from Grant Ireland. • Unscrew and remove the TWO fixing screws from the red burner cover and remove the cover from the burner.
  • Page 15 Fit the nut of the elbow connection on the fl exible fuel hose (supplied with the boiler) into the suction port and tighten with These are available to purchase from Grant Ireland. a correct sized spanner. Connect the oil supply to the burner oil pump as follows: Fit the ¼”isolating valve (supplied with the boiler) to the end of...

  • Page 16: Installation

    REGULATIONS COMPLIANCE The boiler should not be allowed to operate with return temperatures of less than 40°C Installation of a Grant Vortex boiler must be in accordance with the when the system is up to temperature. following recommendations: • National Building Regulations and any local byelaws which NOTE you must check with the local authority for the area.

  • Page 17: Pipework Materials

    4.5 PIPEWORK MATERIALS has been heated and is still hot. This is especially important where The Grant Vortex boiler is compatible with both copper, aluminium the boiler is to be installed on an older system. and plastic pipe. Where plastic pipe or aluminium piping is used it...

  • Page 18: Pipe Connections

    Push out the ‘knock-out’ from the required holes, taking care not to distort the side panel. Figure 5-1: Vortex Utility 15/26 WATER CONNECTIONS  SYSTEM MODELS A 15 mm discharge pipe must be connected to the safety valve outlet connection.

  • Page 19: Condensate Disposal

    PIPEWORK GENERAL REQUIREMENTS Condensate disposal pipework must be plastic (plastic waste or When in condensing mode the Grant Vortex boilers produce overfl ow pipe is suitable). condensate from the water vapour in the fl ue gases. This condensate is moderately acidic with a pH value of around Copper or steel pipe is NOT suitable and MUST 3.27.

  • Page 20: Condensate Soakaway

    CONDENSATE TRAP This is to automatically gives a 3° fall on any ‘horizontal’ runs of Grant Vortex boilers are supplied with a condensate trap to provide condense disposal pipe. Refer to Figure 6-1 and see trap outlet/ the required water seal in the condensate discharge pipe from the pipe.

  • Page 21: External Condensate Trap Fitting

    Disconnect condensate discharge hose from heat exchanger and condensate trap and remove it from the boiler. The fl exible hose must fall continuously from Replace with condensate trap hose (Grant product codes: the outlet to the top of the trap. ZCONHOSE2646 (INT15-26,26-36/36-46KW) ZCONHOSE4670 (INT46-70KW).

  • Page 22: Sealed Systems

    Ensure that the expansion vessel used is of REQUIREMENTS suffi cient size for the system volume. All Grant Vortex models are suitable for use with sealed systems Refer to BS 7074-1 or The Domestic Heating complying with the requirements of BS EN 12828, BS EN 12831 Design Guide for sizing the required vessel.

  • Page 23: Filling The Sealed System

    undertaking) using an approved fi lling loop arrangement fi ll pressure (cold) should be 0.2 - 0.3 bar greater than the incorporating a double check valve assembly. vessel charge pressure – giving typical system fi ll pressures of approx 0.5 bar for a bungalow and 1.0 bar for a two storey The fi...

  • Page 24: Electrical System

    GENERAL Do not switch on the electricity supply at this stage. Grant Vortex models requires a ~230V 1ph 50Hz supply. It must be protected by a 5 Amp fuse. Refer to Figures 8-3 to 8-6 for typical control system wiring FROST PROTECTION diagrams for all models.

  • Page 25: Control System Wiring Diagrams

    CONTROL SYSTEM WIRING DIAGRAMS Burner Mains Supply: Use 2 pole isolator with power ‘ON’ indicator Boiler Terminal Block Boiler Control Limit On/Off Switch Thermostat Thermostat Br - Brown, Bl - Blue, R - Red, G/Y - Green/Yellow, Y - Yellow Colour code: Figure 8-1: Wiring diagram - utility models Burner...

  • Page 26: Boiler Control Panel Wiring Diagrams

    Grey Grey Blue Blue Motor Motor Orange 2-port 2-port Zone Valve Zone Valve Orange Green/Yellow 240 V 50 HZ Room Stat Cylinder Stat Pipe Wiring Centre Thermostat (if fitted) Frost Thermostat Pump Boiler Channel Terminal Block Programmer Remove link 1 to 4 when plug-in programmer is fitted Figure 8-4: Utility models with 2 X 2-port valve control system BOILER CONTROL PANEL WIRING DIAGRAMS...

  • Page 27: System Wiring Using Grant Wiring Centre Ep001

    SYSTEM WIRING USING GRANT WIRING CENTRE EP001 Electrical Page 27...

  • Page 28: Flue System And Air Supply

    Grant recommends the use of the Grant ‘Orange’ fl ue system, Figure 9-1: Air supply for room sealed balanced fl ue boilers specifi cally designed for the Vortex range of condensing boilers this fl exible liner should not be visible from outside the chimney stack..
  • Page 29 Grant CF A range of Flexi pack conventional fl ue lining kits are available from adaptor kit (product code: CFA15/70). Grant Ireland. The packs have been specifi cally produced for Grant NOTE Vortex oil fi red condensing boilers.
  • Page 30 Boiler flue connector (from CFA 15/70 kit) Boiler Boiler Figure 9-6: Grant Orange fl ue system in a typical brick chimney Figure 9-7: Hybrid fl ue system using Grant Orange and Green systems components Page 30 Flue System and Air Supply...

  • Page 31: Connecting A Conventional Flue

    All are suitable for use with Class C2 Kerosene. instructions supplied with the fl ue kit. If the Grant ‘Green’ system (100 mm rigid twin-wall fl ue) is to be fi tted to the boiler then the Grant CF adaptor kit (product code: None of the fl...
  • Page 32 The maximum fl ue length - from the top of the boiler fl ue outlet to the The following items are additionally available: outer face of the wall - is 10 metres for all Grant Vortex boilers. • Extensions to extend the fl ue by 225 mm, 450 mm or 950 mm.
  • Page 33 FLEXIBLE VERTICAL BALANCED FLUE (RED SYSTEM) The Grant Red system fl exible stainless steel liner is directional. The arrows marked on the liner MUST be pointing vertically upwards, following the direction of the fl ue gases. Failure to comply Terminal...
  • Page 34 Vertical terminal kit GTV90 (15 - 26 kW) GTV200 (26 - 70 kW) 45 elbow kit GE45/90 (15 - 26 kW) GE45/200 (26 - 70 kW) High level terminal kit GTH90 (15 - 26 kW) GTH200 (26 - 70 kW) Typical Flue Typical Extended wall bracket...

  • Page 35: Prepare The Wall

    PREPARE THE WALL 9.5.2 HIGH LEVEL AND VERTICAL BALANCED FLUE 9.5.1 LOW LEVEL BALANCED FLUE If the boiler is to be used with the high level balanced fl ue (White If the boiler is to be used with a low level balanced fl ue (Yellow system) make the hole in the wall as shown in Figure 9-17.

  • Page 36: Flue Clearances

    FLUE CLEARANCES Page 36 Flue System and Air Supply...
  • Page 37 Further guidance can be obtained from BS 5410-1:2014, OFTEC Book 4 (Installation) and Approved Document J. Grant Ireland fl ue products are fully compliant with the CE (Communauté Européenne/European Community) standards having undergone rigorous product testing. Flue System and Air Supply...

  • Page 38: Commissioning

    10 COMMISSIONING To ensure safe and effi cient operation, it is essential that a Grant Vortex boiler is commissioned as detailed in the following procedure. To access the controls, remove the front panel from the boiler (pull forward at the top and then lift off).

  • Page 39: Before Switching On

    The controls are shown in Figure 10-1. 10.2 BURNER SETTINGS: 10.1 BEFORE SWITCHING ON RDB2.2 BX BURNERS FOR 15/26, 26/36 AND 36/46 MODELS Ensure the boiler is isolated from the electrical supply and the boiler On/Off switch is set to OFF. With the burner removed from the boiler: Check that the high limit thermostat bulb and boiler thermostat On the 15/26 models - fi...
  • Page 40 DEPTH distance D. GAUGE NOTE 10. For Vortex 15/26 models only: Check the burner air adjuster disc is correctly set. Refer to Section 10.4. 1 1. On the 15/26 models - refi t the recirculation tube to the burner head and secure using the single fi xing screw.
  • Page 41 10.3 BURNER SETTINGS: + 0.5 RDB3.2 BURNERS FOR 46/58 AND 58/70 MODELS With the burner removed from the boiler: Figure 10-7: Ignition electrode settings Model Utility 46/70 • To adjust the diffuser position: Loosen the diffuser clamp screw. Slide diffuser along the nozzle holder to give the correct gap (A).

  • Page 42: Air Adjuster Disc

    8 for correct disc settings. If the disc is not correctly set it MUST Screw Slotted ring be re-positioned. Refer to step 7 below. If the burner is to be set to a different output than the factory setting, the air adjuster disc MUST be set to the required setting for that output.

  • Page 43: Running The Boiler

    To increase the CO₂%: After commissioning the Boiler Passport. • Turn the screw anti-clockwise. This will close down the Return the top copy to Grant Engineering, burner air damper and decrease the combustion air retain the middle copy for the engineers own entering the burner.

  • Page 44: Servicing

    11 SERVICING To ensure safe and effi cient operation it is essential that a Grant Unscrew and remove the two fi xing screws and remove the red Vortex boiler is serviced at regular intervals of no longer than 12 cover from the burner.
  • Page 45 Position in vertical plane IMPORTANT: The ends of the turbulators must be vertical Figure 11-1: Baffl es (15/26 models) Product code: BF-02 Figure 11-4: Turbulators Product codes: CA3360(INT15-26KW,26-36KW/36-46KW) CA3476 (INT-46-70KW). Figure 11-2: Baffl es (26/36 and 36/46 models) Product code: BF-03 Figure 11-3: Baffl...
  • Page 46 11.4 CLEANING THE BURNER: The distance between the end of the burner RDB2.2 BX BURNERS ONLY head and the front face of the diffuser (D) FOR 15/26, 26/36 AND 36/46 MODELS MUST be correctly set for the burner to operate With the burner removed from the boiler: correctly.

  • Page 47: Cleaning The Burner: All Models

    • Remove the diffuser/electrode assembly from the nozzle 11.6 CLEANING THE BURNER: holder. Refer to Figure 10-6. ALL MODELS • Disconnect both ignition leads from the electrodes. Photodiode Replace the nozzle (6). The nozzle should always be replaced The Photodiode is a push-fi t in the front of burner body. Refer to on an annual service.

  • Page 48: Burner Components

    11.9 BURNER COMPONENTS 11.9.1 UTILITY 15/26, 26/36, 36/46 (RIELLO RDB 2.2 BX) Item Description Item Description Oil pump Air inlet Air damper adjustment screw Motor Reset button with lockout lamp Motor ignition capacitor Photodiode Fuel suction line Control box Return line Pump pressure adjustment screw Combustion head adjustment handle Extension for gauge connection...

  • Page 49: Fault Finding

    FAULT FINDING 12.1 BOILER FAULT FINDING Always isolate the electricity supply to the boiler before working on the boiler. Figure 12-1: Boiler fault fi nding Fault Remedies Boiler will not start: Ensure that an adequate supply of fuel is available and that the fuel supply valve is open.
  • Page 50 12.2 BURNER FAULT FINDING  RIELLO BURNERS Page 50 Fault Finding...

  • Page 51: Spare Parts 13

    SPARE PARTS 13 13.1 BOILER PARTS LIST Table 13-1: Boiler parts list Description Grant IRL product code Double pole switch ZSWDPN Baffl e set (complete) - 15/26 BF-02 Baffl e set (complete) - 26/36 and 36/46 BF-03 Baffl e set (complete) - 46/70...

  • Page 52: Riello Rdb 2.2 Burners

    13.3 RIELLO RDB 2.2 BX BURNERS (15/26, 26/36 AND 36/46 MODELS) This section gives exploded views of the Riello burners in the Grant Vortex boilers, and parts lists associated with them. Page 52 Spare Parts...
  • Page 53 Spare Parts Page 53...
  • Page 54 Page 54 Spare Parts...

  • Page 55: Riello Rdb 3.2 Burners

    13.4 RIELLO RDB 3.2 BURNERS (46/70 MODELS) This section gives exploded views of the Riello burners in the Grant Vortex boilers, and parts lists associated with them. Spare Parts Page 55...
  • Page 56 Page 56 Spare Parts...

  • Page 57: Declaration Of Conformity

    In variants -Indoor, Outdoor Module & Boiler house. Grant Vortex Combi 26 & 36. In variants -Indoor & Outdoor Module. Note. All Grant Combi and System variants are supplied with glandless high Efficiency integrated circulators. In accordance with the following Directives: 2014/35/EC Conform with the safety objectives of the Low Voltage Directive.

  • Page 58: Health And Safety Information

    15 HEALTH AND SAFETY INFORMATION Under the Consumer Protection Act 2007 and Section 6 of the Skin Health & Safety at Work Act 2005, we are required to provide Wipe off and wash with soap and water. information on substances hazardous to health (COSHH Inhalation Regulations 2002).

  • Page 59: End Of Life Information

    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.

  • Page 60: Product Fiche

    17 PRODUCT FICHE Product fi che concerning the COMMISSION DELEGATED REGULATIONS (EU) No 81 1/2013 of 18 February 2013 (EU) No 813/2013 of 2 August 2013 Vortex Utility Symbols Unit Condensing boiler Low temperature boiler B1 boiler Combination heater Rated heat output...

  • Page 61: Guarantee

    GUARANTEE You are now the proud owner of a Grant Vortex condensing boiler Free of charge repairs on the burner(For the fi rst twelve from Grant Engineering (Ireland) ULC which has been designed to months) give years of reliable, trouble free operation.
  • Page 62 Terms of manufacturer’s guarantee include any consequential costs, such as the removal or • The Company shall mean Grant Engineering (Ireland) ULC. replacement of worktops, kitchen units, etc. • The boiler must be installed by a competent person and in full •...

  • Page 63: Remarks

    REMARKS Remarks Page 63...
  • Page 64 GRANT ENGINEERING (IRELAND) ULC Crinkle, Birr, Co. Off aly, R42 D788, Ireland Tel: +353 (0)57 91 20089 Email: info@grantengineering.ie www.grant.eu...

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