Grant 50/70 Manual

USER, INSTALLATION
and
SERVICING INSTRUCTIONS
Vortex Condensing Oil Boilers
For use with Kerosene only
Part No. IRL 003 Rev. 02 May 2010
Indoor/Utility, System and Boiler House Models
with outputs up to 240,000 Btu/h
This appliance is deemed a controlled service and specific regional statutory
requirements may be applicable.
After installing the boiler leave these instructions with the User
IMPORTANT NOTICE
This appliance must be commissioned upon installation, the information recorded and returned to
Grant Engineering (Ireland) Ltd., using the form contained within the boiler passport provided.
Failure to do so may invalidate the warranty.
EFFICIEN T H EATING SOLUTIONS
GRANT

2Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
Subject PageSection
1 Introduction .............................................. 3
2 User instructions ...................................... 4
3 Boiler technical information .................... 7
4 General boiler information....................... 11
5 Condensate disposa; ................................. 27
6 Boiler installation ..................................... 30
7 Commissioning and Boiler passport ........ 35
8 Information for the user ........................... 38
9 Boiler servicing ........................................ 38
10 Wiring diagrams ....................................... 42
11 Fault finding ............................................. 46
12 Boiler spares ............................................ 48
13 Burner spares ........................................... 49
14 Health and safety information .................. 51
15 EC declaration of conformity .................. 52
LIST OF CONTENTS

3
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
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 nett 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
use of modulating circulating pumps (now widely
available) and effective control systems should be
considered.
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.
How a condensing boiler works
1.1 Heating system design considerations
1.2
To achieve the maximum efficiencies 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
Underfloor:-
Flow temperature 50° C
Return temperature 40° C
Differential 10° C
1 Size radiators with a mean water temperature of
60° C.
2 Design system controls with programmable room
thermostats or use weather compensating controls
to maintain return temperatures below 55° C.
The boiler should not be allowed to operate with
return temperatures of less than 40° C when the
system is up to operating temperature.
3 The use of a pipe stat is recommended to control
the return temperature when using weather
compensating controls.
1 - INTRODUCTION

4Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
2 - USER INSTRUCTIONS
The boiler is fully automatic once switched on, providing
central heating (and also heating your domestic hot water
if you have a hot water cylinder fitted).
A 'mains on' neon, see Fig. A, lights when the boiler is
switched on, but does not necessarily indicate the burner
is firing.
To gain acces to the controls, pull the front panel
forward at the top to disengage the fixing clips then lift
it up and off the boiler. To replace locate the bottom of
the panel over the fixing tags then push it towards the
boiler to engage the fixing clips.
Fig. A Boiler controls (Indoor/Utility model shown)
About your boiler
2.1
Boiler controls (see Fig. A)
2.2
1Ensure that - There is sufficient fuel, of the correct
type, in the supply tank and all fuel supply valves are
open. The water supply is on. The electricity supply
to the boiler is off. The boiler On/Off switch is set to
OFF. The room thermostat (if fitted) is at the desired
setting. The boiler thermostat is set to the required
setting (see Section 2.7).
2 Switch on the electricity supply to the boiler.
3 Set the On/Off switch to ON and, if fitted, the
programmer (CH or HW) to ON.
The boiler will now light automatically.
4 If you have a programmer fitted, refer to the
instructions supplied with the programmer and set the
programmer. Set the HW and CH functions to TIMED.
The boiler will now operate during the 'on' periods set
on the programmer.
Lighting your boiler (see Fig. A)
2.3
Pressure gauge
(System models only)
Boiler
thermostat
Overheat
thermostat
reset button
(under cover)
On/Off
switch
OVERHEAT
RESET
SYSTEM PRESSURE HEATING
TEMPERATURE OVERHEAT
RESET
BOILER
OFF
ON
HEATING
TEMPERATURE
ON
BOILER
OFF
Lock-out
button Front panel removed
(pull forward at top, then lift off)
Front panel
fixing clips
Front panel bottom locating tags
GRANT
Mains On
neon

5
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
For short periods - Set the On/Off to OFF.
To restart, simply set the switch to ON.
For long periods: Set the On/Off switch to OFF and
switch off the electricity supply to the boiler. If
required, the fuel supply valve may be closed and the
water and electricity supplies turned off at the mains.
To restart, refer to the full lighting instructions given
in Section 2.3.
1 Check that the boiler On/Off switch is ON.
2 Check that the programmer (if fitted) is working
and is in an 'on' period.
3 Check that all thermostats are set to the desired
setting and are calling for heat.
4 Check if the burner 'Lock-out' reset button (on the
burner) is lit. If it is, press it to start the burner. If
the burner fails to light and goes to 'Lock-out'
again, check that you have sufficient fuel in the
storage tank and that the fuel supply valve is open.
Check that the fire valve in the oil supply line has not
tripped
5 Ensure that a fuse has not blown or that the
electricity supply has not failed.
6 Check to see if the safety thermostat has operated
(see Section 2.7).
If the burner still fails to light after carrying out these
checks then a fault exists. Switch off the electricity
supply to the boiler and contact your Service engineer.
Grant Vortex boilers only operate on Class C2 Kerosene
to BS 2869:1998.
You should always quote this type of fuel when ordering
from your supplier.
Do not wait until the fuel runs out before you order
some more. Sludge in the bottom of the tank may be
drawn into the fuel lines. If it is possible, switch off the
boiler when the new supply is delivered and leave the
fuel to settle for an hour before restarting the boiler.
2 - USER INSTRUCTIONS
1 Boiler thermostat - This control allows the
temperature of the water leaving the boiler to heat
the radiators and domestic hot water to be adjusted.
Note: If you have a cylinder thermostat on your hot
water cylinder, this will control the temperature of
your domestic hot water. The boiler thermostat
setting must be equal to or above the cylinder
thermostat setting to enable the cylinder thermostat
to control the domestic hot water system.
2 Burner Lock-out reset button - If there is a
burner malfunction, a built-in safety circuit
switches the burner off and the 'Lock-out' reset
button (on the burner) will light. Usually such
malfunctions are short lived and pressing the reset
button will restore normal operation.
If the burner continually goes to 'Lock-out' a fault
exists or the fuel supply is low. If you have sufficient
fuel, you will need to call your Service engineer.
3 Safety thermostat - Your boiler is fitted with a safety
overheat thermostat which will automatically switch
off the boiler in the case of a control malfunction
causing overheating.
If your boiler goes off and you try to light it but
nothing happens and the 'Lock-out' reset button on the
burner is not lit, the overheat thermostat has probably
operated. The boiler will not light until the thermostat
is reset. To reset, unscrew the small plastic cap (see
Fig. A), press the button then replace the cap.
If this condition continually repeats, contact your
Service engineer.
4 Programmer (if fitted) - Refer to the instructions
supplied with the Programmer.
5 Ventilation - Always ensure that the boiler has
adequate ventilation. Any ventilation openings
provided by the Installer must not be obstructed.
Periodically check that they are clear.
Do not attempt to 'box in' the boiler or build a
compartment around it before consulting your
Installer.
Do not place any combustible material around or
on the boiler or flue pipe.
6 Flue terminal - The flue terminal on the outside
wall must not be obstructed or damaged.
In severe conditions check that the terminal does
not become blocked by snow.
Turning off your boiler (see Fig. A)
2.4
Points to check if burner fails to light
2.5
About your fuel
2.6
General notes and care of your system
2.7

6Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
7 Frost protection - Your Installer may have fitted a
frost thermostat. If not, and you are likely to be
away for a short time, leave the boiler on with the
boiler thermostat set at a low setting. For longer
periods the boiler and system should be drained.
Contact your Service engineer for draining and
filling the system.
8 Cleaning and servicing - Lightly wipe over the
case with a damp cloth and a little detergent. Do
not use abrasive pads or cleaners.
You must have your boiler serviced at least once a
year to ensure safe and efficient operation. Contact
your Service engineer for further details.
9 Failure of electricity supply - If the electricity
supply fails, the boiler will not operate. It should
relight automatically when the supply is restored.
If a programmer is fitted it will retain the time
settings for up to 24 hours and will not have to be
reset to the correct time of day when the supply is
restored (the display remains for up to 1 hour, but
will re-appear when the supply is restored).
The boiler requires a 230/240 V ~ 50 Hz supply. It
must be protected by a 5 Amp fuse.
Warning: This appliance must be earthed.
If your boiler is operating on a sealed heating system,
the installer will have pressurised the system and
should have told you (or set it on the pressure gauge)
the system pressure when cold (this is normally
between 0.5 and 1.0 bar, which will increase slightly
when hot). If the pressure (when cold) is below the set
pressure mentioned above, you can re-pressurise the
system. If the system requires frequent re-pressurising,
ask your Installer or Service engineer to check the
heating system for leaks and to check the expansion
vessel air charge.
The boiler or system will be fitted with an automatic air
vent to remove air from the system. Any air trapped in the
radiators should be removed by venting the radiators
using the vent screw at the top of each radiator. Only vent
a radiator if the top is cool and the bottom is hot.
Excessive venting will reduce the system pressure, so
only vent when necessary and check the system pressure
as mentioned above. Re-pressurise the system if necessary.
2 - USER INSTRUCTIONS
The boiler or system may be fitted with a safety valve
to release excess pressure from the system. If water or
steam is emitted from the end of the safety valve
discharge pipe, switch off the boiler and contact your
Installer or Service engineer.
The expansion vessel air charge must be checked
annually. Failure to maintain an adequate air
charge in the vessel may invalidate the warranty.
To re-pressurise the system by adding water:
1 Only add water to the system when it is cold and
the boiler is off. Do not overfill.
2 Ensure the flexible filling loop (see Fig. B) is
connected and that the shut off valve connecting it
to the boiler is open and the double check valve at
the front is closed.
A valve is open when the operating lever is in line with
the valve, and closed when it is at right angles to it.
3 Gradually open the double check valve on the front
of the filling loop until water is heard to flow.
When the black needle of the pressure gauge is
between 0.5 and 1 bar, close the valve.
4 Vent each radiator in turn, starting with the lowest
one in the system, to remove air.
5 Continue to fill the system until the pressure gauge
indicates between 0.5 and 1.0 bar. Close the fill
point valve.
6 Repeat steps 4 and 5 as required.
7 Close the valves either side of the filling loop and
disconnect the loop.
Electricity supply
2.8
Sealed central heating system
2.9
Sealed system filling loop arrangement - Fig. B

7
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
125 mm (5 in)**
150
6.4
1.2
22 mm (only connect plastic pipe)
26.0 mbar
9.5 mbar
28 m
1m
65 to 75° C
111° C ± 3° C
Less than 50° C
230/240 V ~ 50 Hz Fused at 5 Amp
¼" BSP Male (on end of flexible fuel hose)
Minimum flue draught - 8.7 N/m² (0.035 in wg)
Maximum flue draught - 37 N/m² (0.15 in wg)
2.5 bar
2.5 bar
90
2.6
0.85
125 mm (5 in)**100 mm (4 in) 100 mm (4 in)
Boiler technical data
3.1
3- BOILER TECHNICAL INFORMATION
Model
Water content litre
gal
* Weight (dry) kg
Max. heat output kW
(kerosene) Btu/h
Flow connection
Return connection
Min. flow rate (∆T=10°C) l/h
Min. flow rate (∆T=20°C) l/h
Condensate connection
Flue diameter (conventional)
Waterside resistance
Flow/Return temp. diff. of 10°C
Flow/Return temp. diff. of 20°C
Maximum static head
Minimum circulating head
Boiler thermostat range
Limit (safety) stat shut off temp
Max. hearth temperature
Electricity supply
Motor power Watts
Starting current Amps
Running current Amps
Oil connection
Conventional flue
Max operating press - sealed sys
Max operating press - open sys
*Weight includes burner but excludes flue.
** 125 mm diameter flue required for flexible flue liner (Orange system). Refer to Sections 4.1 and 4.7 for further details.
Indoor/Utility System
90
2.6
0.85
90
2.6
0.85
150
6.4
1.2
90
4.2
0.85
50/90
19
4.2
126.5
26
88,700
22 mm
22 mm
2,200
1,100
90/120
21
4.7
142
36
122,840
28 mm
28 mm
3,000
1,500
120/155
21
4.7
142
46
157,000
28 mm
28 mm
4,000
2,000
50/70
16.5
3.6
70
21
71,650
22 mm
22 mm
90
4.2
0.85
200/240
50
11
299
70
238,840
1¼"BSP
1¼"BSP
6,000
3,000
155/200
50
11
295
58
197,896
1¼"BSP
1¼"BSP
5,200
2,600
120/155
21
4.7
134
46
157,000
28 mm
28 mm
4,000
2,000
90
4.2
0.85
90/120
21
4.7
134
36
122,840
28 mm
28 mm
3,000
1,500
50/90
19
4.2
112
26
88,700
22 mm
22 mm
2,200
1,100
50/90
19
4.2
116
26
88,710
1"BSP
1"BSP
2,200
1,100
90/120
21
4.7
133
36
122,840
1"BSP
1"BSP
3,000
1,500
120/155
21
4.7
46
157,000
1"BSP
1"BSP
4,000
2,000
155/200
50
11
249
58
197,896
1¼"BSP
1¼"BSP
5,200
2,600
200/240
50
11
253
70
238,840
1¼"BSP
1¼"BSP
6,000
3,000
Boiler House
133
90
4.2
0.85

8Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
3 - BOILER TECHNICAL INFORMATION
Note: Grant Vortex boilers are only for use with kerosene.
Grant Vortex oil boilers using Class C2 kerosene
3.3
(kW)
15.0
18.3
21.0
15.0
20.0
23.0
26.0
26.0
31.5
36.0
36.0
41.5
46.0
46.0
52.0
58.0
58.0
64.0
70.0
(Btu/h)
51 200
62 400
71 650
51 180
68 240
78 475
88 700
88 700
107 500
123 000
123 000
142 000
157 000
156 952
177 424
197 896
197 896
218 368
238 840
Nozzle
0.50/80°EH
0.55/80°EH
0.60/80°EH
0.50/80°EH
0.60/80°EH
0.65/80°EH
0.75/80°EH
0.75/80°EH
0.85/80°EH
1.00/80°EH
1.00/80°EH
1.20/80°S
1.25/80°S
1.25/80°S
1.35/80°S
1.65/80°S
1.65/80°S
1.65/80°S
1.75/80°S
Oil
press.
(bar)
7.0
7.5
9.0
7.0
8.0
8.5
8.0
8.0
9.0
9.1
9.0
8.0
8.0
8.0
9.5
8.0
8.0
9.5
9.5
Smoke
No.
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
Fuel flow
rate
(kg/h)
1.29
1.56
1.83
1.25
1.67
1.94
2.16
2.18
2.57
3.01
3.01
3.56
3.90
4.01
4.47
5.05
5.05
5.58
6.01
Flue gas
temp.
(° C)
60 - 65
65 - 70
70 - 75
75 - 80
65 - 70
70 - 75
75 - 80
75 - 80
80 - 85
85 - 90
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
CO2
(%)
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
Burner
head type
T1
T1
T1
T1
T1
T2
T2
T3
T3
T3
T5
T5
T5
GIB
GIB
GIB
GIB
GIB
GIB
Heat Output
50/70
Riello RDB2.2
50/90
Riello RDB1
90/120
Riello RDB2
120/155
Riello RDB2.2
155/200
Riello RDB3.2
200/240
Riello RDB3.2
Model and
burner type
Sealed system data - System models (not 50/70, 155/200 and 200/240)
3.2
Heating system pressure (cold)
Operating pressure of pressure relief valve
Expansion vessel size (50/90)
Expansion vessel size (90/120)
Expansion vessel size (120/155)
Max heating system volume (including boiler) (50/90)*
Max heating system volume (including boiler) (90/120)*
Max heating system volume (including boiler) (120/155)*
Cold water mains connection
Pressure relief valve discharge connection
Maximum 1.0 bar, Minimum 0.5 bar
2.5 bar
10 litres (pre-charged at 1 bar)
12 litres (pre-charged at 1 bar)
16 litres (pre-charged at 1 bar)
106 litres (approximately)
128 litres (approximately)
170 litres (approximately)
15 mm copper pipe
15 mm copper pipe
* Based on vessel charge and system cold fill pressure of 0.5 bar
SEDBUK
efficiency
(%)
93
95.0
97.0
92.6
94.1
93.6
Disc setting B
Disc setting C
Disc setting C
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Head setting 0
Head setting 0
Head setting 0
Head setting 0
Head setting 0
Head setting 4
Burner
head/disc
setting
*
*
*
*
*
*
Notes:
1 The data given above is approximate only.
2 The above settings may have to be adjusted on site for the correct operation of the burner.
3 Gas Oil is not suitable for use with the Grant Vortex boiler range.
4 The net flue gas temperatures given above are ± 10%.
5 When commissioning the air damper must be adjusted to obtain the correct CO2level.
6* = Factory settings
7 The combustion door test point may be used for CO2and smoke readings only. Do not use this test point for temperature or efficiency readings.
8 When setting the 50/70 to 15 kW output the burner air adjuster disc requires repositioning. Refer to Section 7 Commissioning.
When setting the 50/90 to 15 or 20 kW output the combustion head must be changed. Refer to Section 9.4 Cleaning the burner.
When setting the 200/240 to 70 kW output the combustion head setting must be changed. Refer to Section 9.4 Cleaning the burner.
9 The installer must amend the boiler data label if the output is changed.
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:
1. The test point is for CO2and smoke readings only.
2. The boiler efficiency and temperature must be taken from the flue test point on high level and vertical flue adaptors.
3. Low level flues do not contain a test point. The temperature and efficiency readings must be taken from the flue terminal.

9
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
REAR
VIEW
348
21070
140
855
688
760
RIGHT SIDE
VIEW
200
19
47
25
125
594
766
805
704
17
R/H flow
R/H return
L/H flow
L/H return
LEFT SIDE
VIEW
111
566
Flue centre line
Alternative
condensate
drain outlets
3 - BOILER TECHNICAL INFORMATION
Fig. 1b - 50/90 Indoor/Utility and System dimensions
Fig. 1a - 50/70 Indoor/Utility dimensions
Boiler dimensions
3.4
Fig. 1c - 50/90 Boiler House dimensions
Alternative
condensate
drain outlets
FRONT VIEW
470
860
LEFT SIDE
VIEW
814
760
710
587
352
18
17
115
30 Flue centre line
RIGHT SIDE
VIEW
PLAN VIEW
603 110
Safety valve (System)
Cold fill (System)
Flow
170
Flue
spigot
Condensate
drain outlet
FRONT VIEW
PLAN VIEW
Return
RIGHT SIDE
VIEW
431
600
632
690
714
327
195
30
LEFT SIDE
VIEW
Condensate
drain
88
35
Flow

10 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
3 - BOILER TECHNICAL INFORMATION
FRONT VIEW
PLAN VIEW
Return
LEFT SIDE
VIEW
Flow
RIGHT SIDE
VIEW
Condensate
drain A
B
C
DE
F
G
H
J
Dimension
A
B
C
D
E
F
G
H
J
90/120, 120/155
705
460
600
560
605
191
30
330
90
155/200, 200/240
1022
540
868
835
938
285
30
415
115
Boiler House model
Fig. 1d - 90/120, 120/155, 155/200, 200/240 Boiler House dimensions
Fig. 1e - 90/120, 120/155 Indoor/Utility and System dimensions
Fig. 1f - 155/200, 200/240 Indoor/Utility dimensions
Safety valve (System)
Flow (System)
Cold fill
61
170
61
LEFT SIDE
VIEW
455
555
455
24
115
63 63
Flue centre line
RIGHT SIDE
VIEW
PLAN VIEW
603 150
FRONT VIEW
470
900
205
Flue
spigot
Alternative
condensate
drain outlets
Condensate
drain outlet
170
LEFT SIDE
VIEW
731
831
1024
25
30
109
250
Flue centre line
RIGHT SIDE
VIEW
PLAN VIEW
786 109
FRONT VIEW
563
1234
225
Flue
spigot
Alternative
condensate
drain outlets
Condensate
drain outlet

11
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4 - GENERAL BOILER INFORMATION
Boiler description
4.1 White system ...... High level and vertical concentric
balanced flue kit - components available:
Extensions 225 mm, 450 mm, 950 mm, adjustable
275 to 450 mm and 45° elbow
Vertical concentric balanced flue kit
Extensions 225 mm, 450 mm, 950 mm, adjustable
275 to 450 mm and 45° elbow
All burners are pre-set for use with kerosene and are
supplied ready to connect to a single pipe fuel supply
system with a loose flexible fuel line and 3/8" to 1/4" BSP
male adaptor supplied with the boiler.
If required, an additional flexible fuel line (600 mm) and
3/8" to 1/4" BSP male adaptor are available to purchase
from your local stockist, for two-pipe oil supply systems.
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
allowsittobeusedonasealedcentralheating system) which
will automatically switch off the boiler if the heat exchanger
exceeds a pre-set temperature of 111° 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.
Boiler components
4.2
The Grant Vortex 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.
See Section 4.13.
All models are supplied with the control panel and
burner factory fitted.
The boilers can be connected to either a conventional
flue system or a balanced flue system, as required.
For Conventional flue applications where a chimney is
to be lined - Grant recommends the use of the Grant
‘Orange’ flue system, specifically designed for the
Vortex range of condensing boilers. Refer to Section
4.7 for further details.
Important: The flue system materials and construction
MUST be suitable for use with oil-fired condensing
boilers. Failure to fit a suitable conventional flue may
invalidate the warranty on the boiler.
Fitting instructions for the Low level concentric, High level
and Vertical balanced flue kits are supplied with the kits.
Where a balanced flue system is required, the following
flue kits are available from your local stockist.
Refer to Section 4.8 for further details.
Yellow system ..... Standard low level concentric
balanced flue - components available:
Low level concentric balanced flue short
Extensions 225 mm, 450 mm and 675 mm
90° extension elbow
45° extension elbow
45° elbow
Where it is not possible to terminate the low level flue
at low level, a plume diverter kit is available for fitting
to the low level flue. The plume diverter kit diverts the
flue gases up and terminates at a higher level. When
fitting the plume diverter kit, follow the instructions
supplied with the kit. See Fig. 10b.

12 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
The installation should also be in accordance with the
latest edition of the following British Standard Codes
of Practice:-
BS 715 Metal flue pipes, fittings, terminals
and accessories.
BS 799:5 Oil storage tanks.
BS 1181 Clay flue linings and flue terminals.
BS 4543:3 Factory made insulated chimneys for
oil fired appliances.
BS 4876 Performance requirements for oil
burning appliances.
BS 5410:1 Codeof Practice for oil firing appliances.
BS 5449 Forced circulation hot water systems.
BS 7593 Code of Practice for treatment of
water in heating systems.
BS 7671 Requirements for electrical
installations, IEE Wiring Regulations.
Failure to install and commission appliances
correctly may invalidate the boiler warranty.
IMPORTANT
Before starting any work on the boiler, or fuel supply
please read the health and safety information given in
Section 14 on page 51.
4.4.1 Fuel storage
The tank should be positioned in accordance with the
recommendations given in BS 5410:1:1997, which gives
details of filling, maintenance and protection from fire.
A steel tank may be used and must be constructed to
BS 799:5:1987 and OFS T200.
A galvanised tank must not be used.
A plastic tank may be used and must comply with
OFS T100.
Note: Plastic tanks should be adequately and
uniformly supported on a smooth level surface, across
their entire base area.
Fuel supply
4.4
Installation of a Grant Vortex boiler must be in
accordance with the following recommendations:-
a Local Building Regulations and the Building
Standards issued by the Department of the
Environment and any local Byelaws etc.
b Model and local Water Undertaking Byelaws.
c Applicable Control of Pollution Regulations.
d The following OFTEC requirements:-
OFST 100 Polythene oil storage tanks for
distillate fuels.
OFST 200 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 Information Book 3
(Installation requirements for oil fired boilers
and oil storage tanks).
4 - GENERAL BOILER INFORMATION
Regulations to comply with
4.3
Regional statutory requirements may deem this appliance to be a 'controlled service'.
Where this is the case, it is a legal requirement that the appliance is installed and
commissioned either under the remit of building control or by a 'Competent person' such
as a suitably qualified Oftec registered technician.
Fig. 2 - System model (Also refer to Fig. 15)
SYSTEM PRESSURE
10508
HEATING
TEMPERATURE OVERHEAT
RESET
BOILER
OFF
Expansion
vessel Air supply
tube
Lock-out
button Burner
Pump
Pump
isolating
valves
Condensate
trap Drain tap

13
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4 - GENERAL BOILER INFORMATION
4.4.2 Fuel pipes
1 Fuel supply pipes should be of copper tubing with
an external diameter of at least 10 mm.
Galvanised pipe must not be used.
All pipe connections should preferably use flared
fittings. Soldered connections must not be used on
oil pipes.
2 Flexible hoses must not be used outside the boiler case.
3 A remote sensing fire valve must be installed in the
fuel supply line (outside) where it enters the building,
with the sensing head located above the burner.
Recommendations are given in BS 5410:1:1997.
4 A metal bowl type filter with a replaceable micronic
filter must be fitted in the fuel supply line adjacent to
the boiler. A shut-off valve should be fitted before the
filter, to allow the filter to be serviced.
5 A flexible fuel hose, adaptor and 1/4" BSP isolation
valve are supplied loose with the boiler for the final
connection to the burner. If a two pipe system or
'Tiger Loop' type de-aerator is used, an additional
flexible fuel hose (600 mm) and 3/8" to 1/4" BSP male
adaptor are available to purchase from your local
stockist.
6 Metal braided flexible hoses should be replaced
annually when the boiler is serviced. Long life
flexible hoses should be inspected annually and
replaced at least every 60 months.
4.4.3 Single pipe system - (See Fig. 3)
1 Where the storage tank outlet is above the burner
the single pipe system should be used. The height
of the tank above the burner limits the length of
pipe run from the tank to the burner.
2 As supplied the burner is suitable for a single pipe
system.
4.4.4 Two pipe system - (See Fig. 4)
1 When the storage tank outlet is below the burner,
the two pipe system should be used. The pipe runs
should be as shown in Fig. 4. The return pipe
should be at the same level in the tank as the
supply pipe, both being 75 to 100 mm above the
base of the tank. The pipe ends should be a
sufficient distance apart so as to prevent any
sediment disturbed by the return entering the
supply pipe.
2 Avoid the bottom of the tank being more than 3 m
below the burner.
3 A non-return valve should be fitted in the supply
pipe together with the filter and fire valve. A non-
return valve should be fitted in the return pipe if
the top of the tank is above the burner.
4 To be used with a two-pipe system, the burner
must be fitted with an additional flexible fuel hose
(a flexible fuel hose (600 mm) and 3/8" to 1/4" BSP
male adaptor are available to purchase from your
local stockist. See Section 4.4.6.
5 The pump vacuum should not exceed 0.4 bar.
Beyond this limit gas is released from the oil.
For guidance on installation of top outlet fuel tanks and
suction oil supply sizing, see OFTEC booklet T1/139.
Available at www.oftec.org.uk.
Fig. 3 - Single pipe system
Filter
Fire
valve
Shut-off
valve
Shut-off
valve
A
Sludge
valve
Fill
pipe
Vent
pipe
Level
gauge
Fuel
storage
tank
Fire
valve
sensor
Pump
Head A
(m)
Maximum pipe run (m)
0.5
1.0
1.5
2.0
10mm OD pipe
10
20
40
60
12mm OD pipe
20
40
80
100

14 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
Fig. 5 - De-aeration device system
4.4.5 Tiger Loop system - (See Figs. 5 and 6)
1 WhenThe storage tankis below theburner, an alternative
toa two pipe system can be achieved using a'TigerLoop'
typeoil de-aerator. This effectively removes the air from
the oil supply on a single pipe lift.
2 The de-aerator is connected close to the boiler as a
two pipe system (omitting the non-return valve) as
shown in Fig. 5. Refer to the manufacturers
instructions supplied with the de-aerator.
The de-aerator must be mounted vertically and
external.
4 - GENERAL BOILER INFORMATION
Fig. 4 - Two pipe system
Note: To prevent any possibility of fuel fumes
entering the building, the de-aerator must be fitted
outside.
3 To be used with a de-aerator, the burner must be
fitted with an additional flexible fuel hose (a
flexible fuel hose (600 mm) and 3/8" to 1/4" BSP
male adaptor are available to purchase from yor
local stockist. See Section 4.4.6.
Filter
Fire
valve
Shut-off
valve
Shut-off valve
Shut-off
valve
See
section 4.4.6
A
Return
Supply
Head A
(m)
Maximum pipe run (m)
0
0.5
1.0
1.5
2.0
3.0
3.5
10mm OD pipe
35
30
25
20
15
8
6
12mm OD pipe
100
100
100
90
70
30
20
Non
return
valve
Fire
valve
sensor
Sludge
valve
Fill
pipe
Vent
pipe
Level
gauge
Fuel
storage
tank
Fire
valve
Tankmaster
See
section 4.4.6
Sludge
valve
Fill
pipe
Vent
pipe
Fuel
storage
tank
De-aeration device
e.g. Tiger Loop
See Fig. 6
Fire
valve
sensor
Return
Supply

15
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4.4.6 Two pipe oil supplies
Riello RDB burner - See Fig. 7
1 The fuel pump is supplied for use with a single
pipe fuel supply system. For use on a two pipe
system, it is necessary to fit the By-pass screw (see
Fig. 7) into the tapping in the return port.
2 The By-pass screw is supplied in the boiler
accessory pack.
3On all models except 155/200 and 200/240:
Remove the plastic burner cover (secured by two
screws).
On 155/200 and 200/240 models only:
Remove the plastic burner cover (secured by three
screws). For ease of access to the fuel pump, to fit the
by-pass screw and connect the oil lines, the burner can
be removed from the boiler. To do this, unscrew the
single nut at the top of the burner (using a 13 mm
spanner) and withdraw the burner from the boiler.
4 Remove and discard the blanking plug from the
return connection of the pump and fit the By-pass
screw using an hexagonal key.
5 Connect the return oil flexible fuel hose to the pump.
6 Connect the 3/8" to 1/4" BSP adaptor to the flexible
fuel hose.
7 Flexible fuel hoses and adaptors are available to
purchase from your local stockist.
Fig. 6 - Tiger loop 'de-aeration' device
4 - GENERAL BOILER INFORMATION
Fig. 7 - Riello RDB pump
1 Oil inlet connection
2 Return connection
3 By-pass screw
4 Pressure gauge connection
5 Pressure adjuster
6 Vacuum gauge connection
7 Solenoid
8 Supply to nozzle
1 A 230/240 V ~ 50 Hz mains supply is required.
The boiler must be earthed.
2 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.
3 A fused double pole switch or a fused three pin
plug and shuttered outlet socket should be used for
the connection.
4 The power supply cable should be at least 0.75 mm²
PVC as specified in BS 6500, Table 16.
5 All the wiring and supplementary earth bonding
external to the boiler must be in accordance with
the current I.E.E. Wiring Regulations.
6 Any room thermostat or frost thermostat used must
be suitable for use on mains voltage.
7 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 and Resistance to earth.
Electricity supply
4.5
1/4" BSP female
connections
Tiger Loop
SUPPLY
TO PUMP
RETURN
FROM PUMP
SUPPLY
FROM TANK
12
3
4
5
6
7
8

16 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
BOILER IN
ROOM
Conventional open flue
C
BOILER IN
COMPARTMENT
Conventional open flue
compartment ventilated from room
Conventional open flue
compartment ventilated from outside
CC
D
D
E
BOILER IN
ROOM
Room sealed balanced flue
no ventilation required to room
BOILER IN
COMPARTMENT
Room sealed balanced flue
compartment ventilated from room
Room sealed balanced flue
compartment ventilated from outside
B
B
A
A
Fig. 8 - Air supply for room sealed balanced flue boilers
4 - GENERAL BOILER INFORMATION
Fig. 9 - Air supply for conventional flue boilers
155/200
319 cm² (50 in²)
638 cm² (100 in²)
200/240
385 cm² (60 in²)
770 cm² (120 in²)
Model
Vent A
Vent B
50/70
116 cm² (18 in²)
232 cm² (36 in²)
90/120
198 cm² (31 in²)
396 cm² (62 in²)
Model
Vent A
Vent B
120/155
253 cm² (40 in²)
506 cm² (80 in²)
155/200
319 cm² (50 in²)
638 cm² (100 in²)
957 cm² (150 in²)
200/240
385 cm² (60 in²)
770 cm² (120 in²)
1155 cm² (180 in²)
Model
Vent C
Vent D
Vent E
50/70
116 cm² (18 in²)
232 cm² (36 in²)
348 cm² (54 in²)
90/120
198 cm² (31 in²)
396 cm² (62 in²)
594 cm² (93 in²)
Model
Vent C
Vent D
Vent E
120/155
253 cm² (40 in²)
506 cm² (80 in²)
759 cm² (120 in²)
Air supply
4.6
See Figs. 8 and 9
A sufficient permanent air supply to the boiler should
be provided:
a For proper combustion of fuel and effective
discharge of combustion products to the open air.
b For the ventilation of any confined space in
which the boiler is installed to prevent
overheating of the boiler any equipment in and
near the boiler.
50/90
143 cm² (23 in²)
286 cm² (46 in²)
429 cm² (69 in²)
50/90
143 cm² (23 in²)
286 cm² (46 in²)

17
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4 - GENERAL BOILER INFORMATION
It should be both the designer's and installer's concern
that the air required for these functions be introduced
so as to cause as little discomfort as possible to the
building occupants and thus to offer them the least
temptation to obstruct the ventilators.
Further details may be obtained from BS 5410:1:1997.
Notes:
For a boiler fitted in a compartment, which is
ventilated as shown, no additional allowance is
necessary.
Open flue - Extract fans, where needed, should
be in accordance with Section 4.4.7 in BS 5410
Part 1 1997.
All ventilation areas given are for domestic
applications. For all other cases refer to BS
5410 Part 2 1978.
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 warranty.
See Fig. 10a
General
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 (Orange system)
are available to purchase from your local stockist - see
Fig. 10a.
1 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.
2 The condensate may be allowed to run back into
the boiler. A condensate drain at the base of the
flue system is not required.
3 The flue terminal must be at least 600 mm from
any opening into the building, and 600 mm above
any vertical structure or wall less than a horizontal
distance of 750 mm from the terminal. See Fig. 11.
4 If an existing chimney is to be used, it must be lined
with a smooth bore stainless steel liner suitable for
use with oil fired condensing boilers. The top and
bottom of the annular space must be sealed.
The internal flue and liner diameter for all models up
to and including 120/155 must be 100 mm (4 in), for
the 155/200 and 200/240 models 125 mm (5 in).
Conventional flue system
4.7
Grant recommends the use of the Grant 'Orange'
flue system, specifically designed for the Vortex
range of condensing boilers. Refer to Section 4.7
for further details.
The maximum vertical height (from the top of the
boiler to the terminal) for the 'Orange' system is
19 metres.
Fig. 10a - Grant Orange flue system in a typical
brick chimney
Brick
chimney
Flaunching
Locking band
Rigid to flexi flue
connector (bottom)
This
component
must be installed
vertically
Note:
Extension
Boiler flue
connector
Boiler
Flexi pack
Terminal
Adjustable section 235/300mm
WXA250/100
WXA250/125
100mm dia.
125mm dia.
Locking band
C
45 elbow
O
Top plate
Clamp

18 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
5 Twin-wall flues are recommended for externally
run flues to reduce the possibility of the condensate
freezing in the flue.
6 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.
7 If the draught conditions are satisfactory, the flue
should terminate with a standard cowl.
8 Refer to the locally applicable Building
Regulations, BS 5410:1 and OFTEC Installation
Requirements (Books 2 and 3) for further guidance
on conventional flue systems.
It is important to ensure that the flue system is sealed
and that condensate cannot escape. Up to 1.5 l/h of
condensate can be produced in a conventional flue
system.
Only use flue systems suitable for oil fired condensing
boilers.
Do not use fire cement. The use of high temperature
silicone sealants is recommended.
Grant EZ-Fit Flexi Pack conventional flue system
(Orange System) - See Fig. 10a
A range of Flexi pack conventional flue lining kits are
available to purchase from your local stockist . The packs
have been specifically produced for Grant Vortex oil
fired condensing boilers.
Contents of Grant EZ-Fit Flexi Pack
The pack includes a terminal/top plate/flexi flue adaptor,
stainless steel smooth bore flexible flue liner, a rigid to flexi
adaptor and a boiler flue connector. Two diameters are
available, a 100 mm for models up to and including 120/155
and 125 mm for the 155/200 and 200/240 models.
4 - GENERAL BOILER INFORMATION
Part No.
WX 150/100
WX 150/125
WX 250/100
WX 250/125
WX 450/100
WX 450/125
WX 950/100
WX 950/125
Extensions (Orange System)
100 mm dia. x 150 mm
125 mm dia. x 150 mm
100 mm dia. x 250 mm
125 mm dia. x 250 mm
100 mm dia. x 450 mm
125 mm dia. x 450 mm
100 mm dia. x 950 mm
125 mm dia. x 950 mm
Part No.
GFKIT 6/100
GFKIT 6/125
GFKIT 8/100
GFKIT 8/125
GFKIT 10/100
GFKIT 10/125
GFKIT 11/100
Flexi Pack (Orange System)
100 mm dia. x 6 metre
125 mm dia. x 6 metre
100 mm dia. x 8 metre
125 mm dia. x 8 metre
100 mm dia. x 10 metre
125 mm dia. x 10 metre
100 mm dia. x 11 metre
Extensions
A range of white powder coated single wall extensions
are available to connect the boiler to the flexible liner.
The external diameter of the extensions is 100 mm or
125 mm (see Table below). Extensions are supplied
with locking bands.
Flue extensions cannot be cut.
An adjustable extension and 45° elbow are also
available. See Fig. 10a.
The rigid flue between the boiler and flexible flue liner
should incorporate an adjustable section to allow
inspection and cleaning of the flue system.

19
Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4 - GENERAL BOILER INFORMATION
Apart from a conventional flue, several balanced flue
options are available for use with the Grant Vortex
boilers. All are suitable for use with Class C2 kerosene.
Note: None of the flue sections in the following
system can be cut.
1 Low level horizontal balanced flue (Yellow system)
Available in Standard kits.
Extensions are available which extend the flue by
225 mm, 450 mm or 675 mm. 90° and 45° elbows
are also available.
The maximum flue length - from the centre of the
boiler flue outlet to the outer face of the wall - is 4
metres (with or without elbows included). No more
than 2 x 45° or 1 x 90° elbow should be fitted per
system.
2 High level (horizontal) balanced flue (White
system)
Allows the flue to rise vertically within the building
before exiting through the wall horizontally.
The maximum flue length - from the top of the
boiler flue outlet to the outer face of the wall - is 10
metres for all Vortex boilers.
Extensions are available which extend the flue by
225 mm, 450 mm or 950 mm. An adjustable
extension of 275 to 450 mm is also available.
A 45° elbow is also available. No more than 6 x 45°
elbows should be fitted per system. Each elbow reduces
the overall maximum length of the system by 1 metre.
3 Vertical balanced flue (White system)
Allows the flue to rise vertically from the boiler to
exit through the roof.
The maximum flue length - from the top of the
boiler flue outlet to the terminal - is 12 metres for
all Vortex boilers.
Extensions are available which extend the flue by
225 mm, 450 mm or 950 mm. An adjustable
extension of 275 to 450 mm is also available.
A 45° elbow is also available. No more than 6 x
45° elbows should be fitted per system. Each elbow
reduces the overall maximum length of the system
by 1 metre.
Balanced flue options
4.8
Where it is not possible to terminate the low level flue
at low level, a plume diverter kit is available for fitting
to the low level flue. The plume diverter kit diverts the
flue gases up and terminates at a higher level. When
fitting the plume diverter kit, follow the instructions
supplied with the kit. See Fig. 10b.
The minimum dimensions for locating the terminal
from building features (windows, doors, etc.) are
shown in Fig. 11.
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 fitted
centrally over the flue terminal and securely fixed to
the wall.
The low level balanced flue (Yellow system) is
supplied with a stainless steel guard. This must be
fitted in all circumstances to prevent objects from
entering the flue outlet.
The terminal must be positioned so as to avoid
products of combustion accumulating in stagnant
pockets around the buildings or entering into
buildings. Care should be taken that the plume from
condensed flue gases does not cause a nuisance.

20 Grant Vortex Indoor/Utility, System and Boiler House Oil Boilers
4 - GENERAL BOILER INFORMATION
Fig. 10b- Plume diverter
GPDA90 = 1240 - 2080 mm
GPDA200 = 1290 - 2140 mm
Self tapping
screw 3mm
(x2)
Locking band
(x2)
Telescopic
locking band
(x1)
Locking band
(x2)
Adjustable
wall bracket
(x2)
Terminal
elbow (x1)
Telescopic
flue pipe
1000mm long
(x2)
Starter elbow
(x1)
Plume diverter kit components
50/70, Indoor/Utility, 50/90 Indoor/Utility, System and Boiler House models
90/120, 120/155 Indoor/Utility, System and Boiler House models
155/200, 200/240 Indoor/Utility and Boiler House models
A = 768 mm
A = 780 mm
A = 1102 mm
A