Grant Vortex Eco Release note

Grant Vortex Eco
External Wall Hung Condensing Oil Boiler Range
Installation & Servicing Instructions
Part No. DOC 83. Rev 1. November 2008

Commissioning Report
2
Commissioning
Report
For use with Kerosene only.
After installing the boiler leave these
instructions with the User.
This appliance is deemed a controlled
service and specific regional statutory
requirements may be applicable.
Dat :
Commissioning ngin r: T l. No:
Boil r mod l/output: kW
Fu l typ : K ros n
Nozzl siz : Pump pr ssur :
Air s tting: Flu gas % CO2:
N t flu gas t mp: Smok No:
GRANT ENGINEERING (UK) LIMITED
Hopton Hous , Hopton Industrial Estat , D viz s, Wiltshir SN10 2EU
T l: 01380 736920 Fax: [phone]
Email: sal [email protected] www.grantuk.com
This manual is accurat at th dat of printing but will b sup rs d d and should b disr gard d if sp cifications and/or
app aranc s ar chang d in th int r sts of continu d product improv m nt.
All good sold ar subj ct to our official Conditions of Sal , a copy of which may b obtain d on application.
© Grant Engin ring (UK) Limit d 2008. No part of this manual may b r produc d by any m ans without prior writt n cons nt.

Contents
Contents
3
1Introduction 4
1.1 How a condensing boiler works 4
1.2 Boiler Description 4
1.3 Boiler Components 5
2T chnical Data 6
2.1 Boiler technical data –
Vortex Eco external wall-hung boilers 6
2.2 Sealed system data –
External models 6
2.3 Vortex boilers using Class C2 kerosene 7
2.4 Flue gas analysis 7
2.5 External boiler panel assembly 8
3Oil Storag & Supply Syst m 9
3.1 Fuel supply 9
3.2 Burner oil connection 11
4Boil r Installation Information 13
4.1 Introduction 13
4.2 Boiler location 13
4.3 Preparation for installation 13
4.4 Dismantling the boiler 13
4.5 Installing the boiler 15
4.6 Regulations compliance 16
4.7 Completion 17
4.8 Before you commission 17
4.9 Heating system design considerations 17
4.10 Underfloor heating systems 17
4.11 Pipework materials 17
4.12 Sealed systems 17
4.13 Underfloor pipework 17
5Pip Conn ctions 18
5.1 Water connections 18
5.2 Water connections –
System models 18
6Cond nsat Disposal 19
6.1 General requirements 19
6.2 Connections 19
6.3 Pipework 19
6.4 External pipework 19
6.5 Condensate soakaway 19
6.6 Condensate trap 20
6.7 Condensate disposal pipework 20
6.8 Inspection and cleaning of trap 20
7S al d Syst ms 21
7.1 Sealed system installation 21
7.2 System models 22
7.3 Fill the sealed system 23
8El ctrical 24
8.1 Connecting the power supply 24
8.2 Frost protection 24
8.3 Control system wiring diagrams 24
8.4 Boiler control panel wiring diagrams 26
9Flu Syst m & Air Supply 27
9.1 Air supply 27
9.2 Conventional flue systems 27
9.3 External conventional flue 27
9.4 Hybrid conventional flue system
(green to orange) 28
10 Commissioning 30
10.1 Before switching on 30
10.2 Switching on 30
10.3 Running the boiler 31
10.4 Balancing the system 31
10.5 Completion 31
11 Boil r S rvicing 32
11.1 Checking before servicing 32
11.2 Dismantling prior to servicing 32
11.3 Cleaning the boiler 32
11.4 Cleaning the burner 33
12 Fault Finding 34
12.1 Burner fault finding 34
12.2 Boiler fault finding 37
13 Spar Parts 38
14 H alth & Saf ty Information 40
14.1 Insulation materials 40
14.2 Kerosene and gas oil fuels (mineral oils) 40
15 EC D claration of Conformity 41

1Introduction
4
Introduction
This manual is intended to guide
engineers in the installation and
maintenance of Grant VORTEX Eco
External Wall Hung boilers. A User
Guide for the operation of this boiler is
attached to the reverse of this manual.
The following special text formats are
used in this manual for the purposes
listed below:
Warning of possible human injury as
a consequence of not following the
instructions in the warning.
1.1 How a Condensing
Boiler Works
During the combustion process,
hydrogen and oxygen combine to
produce heat and water vapour. The
water vapour produced is in the form of
superheated steam in the heat
exchanger. This superheated steam
contains sensible heat (available heat)
and latent heat (heat locked up in the
flue gas). A conventional boiler cannot
recover any of the latent heat and this
energy is lost to the atmosphere
through the flue.
The Grant VORTEX Eco External Wall
Hung 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 Eco External Wall
Hung 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.
1.2 Boiler Description
The Vortex Eco External Modules have
an insulated weatherproof 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 External
modules are part of the Grant range of
automatic pressure jet oil boilers, and
have been designed for use with a fully
pumped central heating system with
indirect domestic hot water cylinder.
They are not suitable for use with either
a direct cylinder or a 'primatic' cylinder
or gravity hot water.
The boilers are suitable for use on open
vented or sealed central heating
systems. All models are supplied with
the control panel and burner factory
fitted.
The boilers are supplied with a flue
terminal, but can be connected to a
conventional flue system.
An external conventional flue (Green)
system is available from Grant
Engineering (UK) Ltd. Refer to Chapter 9
for further details including the list of
available components of this system.
A hybrid flue (Green/Orange) system is
also available which allows the External
module to utilize an existing chimney
stack. Refer to Chapter 9 for further
detail including the list of available
components of this system.
Caution concerning likely damage to
equipment or tools as a
consequence of not following the
instructions in the caution.
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.
Note text. Used for emphasis or
information not directly concerned
with the surrounding text but of
importance to the reader.
!WARNING
!CAUTION
!NOTE
!NOTE

Introduction
5
1.3 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 two flexible fuel lines and
3/8"to1/4" BSP male adaptor supplied
with the boiler.
The temperature of the water leaving
the boiler to heat the radiators and hot
water cylinder is User adjustable.
The boiler is fitted with an overheat
thermostat (which allows it to be used
on a sealed central heating system)
which will automatically switch off the
boiler if the heat exchanger exceeds a
pre-set temperature of 111°C ± 3°C.
The 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, pull open the
front panel by turning the knob at the
base, pulling it out from the base and
sliding it from under the lip at the top, as
shown in Figure 1-1.
The controls are shown in Figure 1-3.
Figure 1-3: Boiler controls Figure 1-2: Boiler front panel removed
Figure 1-1: Front panel showing
access knob at base and overlap at top

2Technical Data
6
2.1 Boiler Technical Data – Vortex Eco External Wall-hung Boilers
External External System
odel 12/16 16/21 12/16 16/21
Water content Litres 11 11 11 11
Gal 2.4 2.4 2.4 2.4
Weight - complete boiler (dry) kg 85.7 92.2 85.7 92.2
lbs 189 203 189 203
Weight - boiler shell only (dry)* kg 56.0 56.0 56.0 56.0
lbs 123 123 123 123
Max heat input (kerosene) kW 17.0 21.0 17.0 21.0
Btu/h 58,000 71,650 58,000 71,650
Flow connection 22mm - push-fit Tectite connector (supplied fitted)
Return connection 22mm - push-fit Tectite connector (supplied fitted)
Min. flow rate ∆T=10°C l/h 1420 1740 1420 1740
Min. flow rate ∆T=20°C l/h 710 870 710 870
Condense connection Accepts 21.5mm Ø polypropylene overflow pipe
Flue diameter (conventional flue) mm 100mm
Waterside resistance ∆T=10°C mbar 28.5
Waterside resistance ∆T=20°C mbar 10
Maximum static head m 28
Minimum circulating head m1
Boiler thermostat range °C 65 to 75
Limit (safety) stat cut-off temperature °C 111 ± 3
Max casing temperature °C less than 50
Electricity supply 230V ~ 50Hz Fused at 5 Amp
Motor power Watts 75
Starting current Amps 2.25
Running current Amps 0.85
Oil connections 1/4" Male BSP
Conventional flue draught N/m2Min - 8.7
in.wg Max - 37
Max operating press - sealed system bar 2.5
Max operating pressure - open system bar 2.5
* Weight of shell - without baffles & clean-out door 45.7kg
12/16 & 16/21
Heating system pressure (cold) 0.5 bar Min - 1.0 bar Max
Pressure relief valve operating pressure 2.5 bar
Expansion vessel size 8 litres
Max heating system volume (including boiler)* 85 litres
Cold mains connection (for filling loop) 15mm compression (provided)
Pressure relief valve discharge connection 15mm compression (provided)
* Based on vessel charge and s stem pressure cold fill pressure of 0.5 bar
2.2 Sealed System Data – External Models
Technical Data

Technical Data
7
2.3 Vortex Boilers using Class C2 Kerosene
Heat Heat Oil Burner Fuel Flue
Input output SEDBUK Nozzle pressure Smoke head flow gas CO2
rate temp
odel kW Btu/h kW Btu/h
efficiency bar No. type kg/h °C %
13.0 44,350 12.7 43,300 94.9 0.35 80ºEH 70No.1 Fixed 1.09 60 - 65 11 - 12
12/16 14.5 49,470 *14.0 47,770 94.9 0.40 80ºEH 10 0 No.1 Fixed 1.21 65 - 69 11 - 12
17.0 58,000 16.5 56,300 94.9 0.50 80ºEH 70No.1 Fixed 1.43 65 - 69 11 - 12
17.0 58,000 16.5 56,300 93.8 0.50 80ºEH 70No.1 Fixed 1.43 65 - 69 11 - 12
16/21 19.3 65,850 *18.7 63,800 93.8 0.50 80ºEH 10 0 No.1 Fixed 1.61 70 - 75 11 - 12
21.0 71,650 20.3 69,270 93.8 0.60 80ºEH 80No.1 Fixed 1.82 75 - 79 11 - 12
Notes:
1. Data given is approximate only.
2. The above settings may have to be adjusted on site for correct operation of burner.
3. Gas oil is not suitable for use with the Grant VORTEX Eco Wall Hung boiler range.
4. The net flue gas temperatures given above are ± 10%.
5. When commissioning the air damper must be adjusted to obtain correct CO2level.
6. * Factory settings: 12/16 - 14kW 16/21 - 18.7kW
7. Combustion door test point may be used for CO2and 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.
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 that the test point is
for CO2and smoke readings only.
Insert combustion probe in to the end of
the flue terminal to measure the CO2level.
Do not use the test point in the
cleaning door.
To obtain the correct CO2level the final
flue gas reading must be taken with all
the casing panels fitted.
!NOTE

8
Technical Data
Figure 2-1: Grant VORTEX Eco External Wall Hung boiler panel assembly
16
33
620
193
133
46
Bottom Vi w
Oil supply
Condensate
PRV
Flow
Return
Cold mains
Condensate
Electricity
Flow
Return
Cold mains
Electricity
215
241
Top Vi w
634
122 375
220
620
258
222
187
152
118
83
120 12073
832
394
122
10290
Back Pan l
352 352
L ft Sid Vi w
634
833
Front Vi w Right Sid Vi w
2.5 External Boiler
Panel Assembly
All dimensions in the diagram above are in millimetres.

Oil Storage &
Supply System
9
3.1 Fuel Supply
Fuel Storage
The tank should be positioned in
accordance with the recommendations
given in BS 5410:1:1997, which gives
details of filling, maintenance and
protection from fire.
A steel tank may be used and must be
constructed to BS 799:5:1987 and OFS
T200.
A galvanized tank must not be used.
A plastic tank may be used and must
comply with OFS T100.
Plastic tanks should be adequately
and uniformly supported on a
smooth level surface, across their
entire load bearing base area, that is,
the area in contact with the ground.
Fuel Pipes
Fuel supply pipes should be of copper
tubing with an external diameter of at
least 10mm.
Galvanised pipe must not be used.
All pipe connections should preferably
use flared fittings. Soldered connections
must not be used on oil pipes.
Flexible pipes must not be used
outside the boiler case.
A remote sensing fire valve must be
installed in the fuel supply line, with the
sensing head located above the burner.
Recommendations are given in
BS 5410:1:1997.
A metal bowl type filter with a
replaceable micronic filter must be fitted
in the fuel supply line adjacent to the
boiler. A shut-off valve should be fitted
before the filter, to allow the filter to be
serviced.
Two flexible fuel lines, adaptor and 1/4"
BSP isolation valve are supplied loose
with the boiler for the final connection to
the burner, with a two pipe system or
'Tiger Loop' type de-aerator.
Metal braided flexible pipes should be
replaced annually when the boiler is
serviced. Long life flexible pipes should
be inspected annually and replaced at
least every 60 months.
!CAUTION
!CAUTION
!NOTE
3Oil Storage & Supply System

10
Oil Storage &
Supply System
Two Pipe System - (See Figure 3-1)
With the storage tank outlet below the
burner, a two pipe system should be
used. The pipe runs should be as shown
in Figure 3-1. The return pipe should be at
the same level in the tank as the supply
pipe, both being 75 to 100mm above the
base of the tank. The pipe ends should be
a sufficient distance apart so as to prevent
any sediment disturbed by the return
entering the supply pipe.
Avoid the bottom of the tank being
more than 3m below the burner.
A non-return valve should be fitted in
the supply pipe together with the filter
and fire valve. A non-return valve should
be fitted in the return pipe if the top of
the tank is above the burner.
The pump vacuum should not exceed
0.4 bar.
Beyond this limit gas is released from
the oil.
For guidance on installation of top
outlet fuel tanks and suction oil supply
sizing, see OFTEC Technical Information
Book 3. A ailable from OFTEC.
Filter
Fire valve
Fire valve
Shut-off valve
Shut-off valve
Supply
Supply
Return
Return
A
Fire valve sensor
Fire valve sensor
Level Gauge
Non return valve
Shut-off valve
See section 4.4
Vent pipe
Vent pipe
Fill pipe
Fill pipe
Fuel storage tank
Sludge
valve
Sludge
valve
H Pipe Length (m)
(m) ø 6mm ø 8mm ø 10mm
0.5 19 60 100
1 21 66 100
1.5 23 72 100
2 25 79 100
2.5 27 85 100
3 29 91 100
3.5 31 98 100
Figure 3-1: Two pipe system
Tiger Loop System -
(See Figures 3-2 and 3-3)
When The storage tank outlet is below
the burner, an alternative to a two pipe
system can be achieved using a 'Tiger
Loop' type oil deaerator. This effectively
removes the air from the oil supply on a
single pipe lift.
The de-aerator is connected close to the
boiler as a two pipe system (omitting the
non-return valve) as shown in Figure 3-2.
Refer to the manufacturers instructions
supplied with the de-aerator.
The de-aerator must be mounted
vertically, as shown in Figure 3-2.
To prevent any possibility of fuel
fumes entering the building, the
de-aerator must be fitted outside in
accordance with BS 5410:1:1997.
!WARNING
Tankmaster
Fuel
storage
tank
De-aeration device e.g
Tiger Loop see Figure 3-3
See section 4.4
Figure 3-2: De-aeration device system
Figure 3-3: Tiger loop de-aeration device
To burner
From burner
From tank

Oil Storage &
Supply System
11
3.2 Burner Oil Connection
The burner fuel pump is supplied for use
with a two-pipe fuel supply 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 3-5.
Figure 3-4: Burner components
Burner head (blast tube)
Combustion air inlet
Combustion
air adjuster
Lockout reset button
Motor
Control box
Oil pump
Ignition spark
generator
Photocell
Fan housing
Figure 3-5: Fitting/location of ‘horseshoe’ washer

12
Oil Storage &
Supply System
Main Burner Components
Remove the control panel (secured by
two screws). To gain access to the
burner. It may be necessary to remove
the burner from the boiler to access
connections in the fuel pump.
To do this, unscrew the single nut at the
top of the burner (using a 13mm
spanner) and rotate the burner
clockwise and withdraw the burner from
the boiler as shown in Figure 3-6.
Burner Connection
The procedure is as follows:
1. Remove and discard the blanking
plugs from the suction (inlet) and
return connections of the pump.
Refer to figure 3-7.
2. Connect the suction and return oil
flexible fuel lines to the pump.
3. Connect the 3/8"to1/4" BSP
adaptor to the flexible fuel line using
the adaptor supplied. The supply
enters through one of the holes in
the casing.
Item Description
01 Inlet (suction) port
02 Return port
03 Bleed and pressure gauge port
04 Vacuum gauge port
05 Pressure adjustment
06 Nozzle outlet
Figure 3-6: Burner removal
Burner fixing nut
01
Figure 3-7: Danfoss BFP11 R3 oil pump
05
06
04
02
03

Boiler Installation
In ormation
13
4Boiler Installation Information
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 must be installed externally,
fixed to an outdoor wall that is firm, flat
and vertical. It does not require any
special base 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 9-3, are achieved.
Adequate clearance must be left around
and in front of the Module for servicing.
The Eco external wall mounted boiler
must be installed with the flue terminal
terminating at least two metres above
ground level. (Refer to standard BS5410
part 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. See Section 9.
The flue terminal must be a minimum
distance of 1.8m 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.
Once the outdoor boiler is fixed
sufficient clearance must be allowed at
the front of and below the boiler to
remove the burner and baffles for
servicing.
4.3 Preparation or Installation
The following procedure must be
performed before you can begin
dismantling the boiler for installation:
1. With boiler on pallet, open carton,
remove packing and carton from
boiler.
2. Remove door - turn the handle
anticlockwise and lift door away
from boiler, carefully sliding out from
top flange.
3. Remove internal packaging from
within boiler casing.
4. Remove flue terminal, filling loop
and flexible oil hose packs from
within boiler.
4.4 Dismantling the Boiler
Dismantle the boiler as follows, keeping
all components, screws and washers for
re-assembly:
1. Remove screws securing top panel
and remove top casing panel from
boiler.
2. Disconnect burner electrical plug.
3. System model only – Disconnect
pump electrical plug.
4. Unscrew inlet connection to
condensate trap and remove trap
from boiler.
5. Remove thermostat phials from their
pocket (in right side of heat
exchanger – below return
connection).
6. System model only - Unscrew and
disconnect pressure gauge from
PRV body.
7. Remove screws securing right hand
side panel and remove side panel,
complete with control panel, pulling
it forward and away from boiler.
8. Remove screws securing left hand
side panel and remove side panel,
pulling it forward and away from
boiler.
9. Remove screws securing bottom
casing panel and remove bottom
panel from boiler.
10. System model only - Unscrew
expansion vessel hose from
connection on boiler shell and
remove expansion vessel from
boiler.
Figure 4-1: Condensate trap and
thermostat phial location
Figure 4-2: Removing thermostat phials

14
Boiler Installation
In ormation
16. Remove baffles from boiler shell.
14. 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.
15. Using 13mm spanner, unscrew the
two clean-out door retaining nuts
and remove door from front of boiler
shell.
21. Unscrew and remove the two transit
screws & nuts securing mounting
bracket and back panel to pallet.
17. Undo retaining screw and remove
transit bracket from top of boiler
shell.
18. Push boiler shell upwards to
disengage it from mounting bracket
on back panel of boiler.
19. Lift boiler shell away from back
panel and stand it upright on the
four feet.
Figure 4-5: Lifting boiler out
20. Carefully remove the foil-faced
insulation from the back panel.
Figure 4-6: Back panel showing
insulating foil
Figure 4-4: Baffle location
11. System model only - Unscrew upper
pump union and remove pump,
complete with flow pipe, from boiler.
12. Non-system model – Unscrew
compression connection on boiler
shell and remove flow pipe from
boiler.
13. Unscrew top right compression
connection and remove return pipe
from boiler.
Figure 4-3: Flow and Return
pipe location

Boiler Installation
In ormation
15
4. Remove the back panel from the
wall. Drill the holes for the mounting
bracket fixings and fit the wall plugs
provided. Drill all other necessary
holes. Re-mount the back panel on
the two keyhole slots.
5. Locate mounting bracket onto back
panel, aligning four holes in bracket
with those in back panel. Ensure
that mounting ‘hooks’ are pointing
upwards and secure using the
fixings supplied by Grant UK.
6. Carefully re-fit insulation into back
panel, passing mounting ‘hooks’
through the two slits in the
insulation.
7. Lift 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.
8. Re-fit 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.
9. 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.
10. 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.
11. 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.
12. Re-fit baffles into boiler shell –
ensuring they are in the correct
order (check marking on each baffle)
as shown below:
13. Locate clean-out door onto the two
studs, re-fit nuts and tighten to
secure door in place.
Figure 4-8: Re-fitting baffles into
boiler shell
4.5 Installing the Boiler
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 this distance is to be less than this,
Grant suggest using the Green system
to achieve a termination point of at
least 2 metres above ground level.
Figure 4-7 shows the position of holes
required to match those in the back
panel.
1. 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
holes for the two keyhole slots.
Remove the back panel on the wall.
2. Drill and fit wall fixing plugs
(not supplied) in the two holes.
Fit suitable screws and mount the
back panel on the wall using the
two keyhole slots. Check again
that back panel is level before
proceeding.
3. 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.
!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.
!NOTE
1
2
3
4
Figure 4-7: Back panel showing
fixing holes

16
Boiler Installation
In ormation
Failure to install and commission
appliances correctly may invalidate
the boiler warranty.
Before starting any work on the
boiler, or fuel supply please read the
health and safety information given in
Section 14.
!NOTE
!WARNING
14. Re-fit left hand casing panel and
secure in place with screws (with
washers).
15. Re-fit bottom casing panel and
secure in place with screws (with
washers).
16. Re-fit right hand casing panel
complete with control panel fitted.
17. Re-locate thermostat bulbs in
pocket at rear right hand side of
boiler shell.
18. System model only - Re-connect
pressure gauge to PRV and tighten.
19. Re-connect burner plug.
20. System model only - Re-connect
pump plug.
21. Re-fit condensate trap. Connect
condensate discharge pipe to outlet
of trap. See also ‘Condensate
Disposal’.
22. System model only - Re-fit
expansion vessel onto bracket
inside right hand side panel and re-
connect expansion vessel hose to
connection on front right hand side
of boiler shell. Ensure rubber sealing
washer is fitted.
23. Re-fit top casing panel and secure
in place with screws (with washers).
24. Fit flue terminal, carefully pushing it
through seal in hole in top panel.
Ensure that seal is fitted to 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.
25. Re-fit front casing panel – 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.
4.6 Regulations Compliance
Installation of a Grant VORTEX Eco
External Wall Hung boiler must be in
accordance with the following
recommendations:-
Building Regulations for England
and Wales, and the Building
Standards for Scotland issued by
the Department of the Environment
and any local Byelaws which you
must check with the local authority
for the area.
Model and local Water Undertaking
Byelaws.
Applicable Control of Pollution
Regulations.
The following OFTEC requirements:
- OFS T100 Polythene oil storage
tanks for distillate fuels.
- OFS T200 Fuel oil storage tanks
and tank bunds for use with
distillate fuels, lubrication oils and
waste oils.
Further information may be obtained
from the OFTEC Technical Information
Book 3 (Installation requirements for oil
fired boilers and oil storage tanks).
The installation should also be in
accordance with the latest edition of the
following British Standard Codes of
Practice:
BS 715 Metal flue pipes, fittings,
terminals and accessories.
BS 799:5 Oil storage tanks.
BS 1181 Clay flue linings and flue
terminals.
BS 4543:3 Factory made insulated
chimneys for oil fired appliances.
BS 4876 Performance requirements
for oil burning appliances.
BS 5410:1 Code of Practice for oil
firing appliances.
BS 5449 Forced circulation hot
water systems.
BS 7593 Code of Practice for
treatment of water in heating
systems.
BS 7671 Requirements for electrical
installations, IEE Wiring Regulations.

Boiler Installation
In ormation
17
4.11 Pipework Materials
Grant boilers are compatible with both
copper and plastic pipe. Where plastic
pipe is used it must be of the oxygen
barrier type and be of the correct class
(to BS 7291:Part 1:1990) for the
application concerned.
4.9 Heating System Design
Considerations
To achieve the maximum efficiency
possible from the Grant VORTEX Eco
External Wall Hung boiler, the heating
system should be designed to the
following parameters:
Radiators:-
Flow temperature 70°C
Return temperature 50°C
Differential 20°C
Underfloor:-
Flow temperature 50°C
Return temperature 40°C
Differential 10°C
Size radiators with a mean water
temperature of 60°C.
Design system controls with
programmable 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.
The use of a pipe stat is recommended
to control the return temperature when
using weather compensating controls.
4.10 Under loor Heating Systems
In underfloor systems it is essential
that the return temperature must be
maintained above 40°C to prevent
internal corrosion of the boiler water
jacket.
4.7 Completion
Please ensure that the OFTEC CD/10
installation completion report (provided
with the boiler) is completed in full.
Leave the top copy with the User.
Retain the carbon copy.
Ensure that the User Information pack
(supplied with the boiler) is handed over
to the Householder.
4.8 Be ore you Commission
To avoid the danger of dirt and foreign
matter entering the boiler the complete
heating system should be thoroughly
flushed out - before the boiler is
connected and then again after the
system has been heated and is still hot.
This is especially important where the
boiler is used on an old system.
For optimum performance after
installation, this boiler and its associated
central heating system must be flushed
in accordance with the guidelines given
in BS 7593:1992 'Treatment of water in
domestic hot water central heating
systems'.
This must involve the use of a
proprietary cleaner, such as
BetzDearborn's Sentinel X300 or X400,
or Fernox Restorer. Full instructions are
supplied with the products, but for more
details of BetzDearborn’s products, view
the website www.sentinel-solutions.net
and for more details of Fernox products
view the website www.fernox.com.
For Long term protection against
corrosion and scale, after flushing, it is
recommended that an inhibitor such as
Betzdearborn's Sentinel X100 or Fernox
MB-1 is dosed in accordance with the
guidelines given in BS 7593:1992.
Failure to implement these guidelines
will invalidate the warranty.
The system should 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
Engineering (UK) Limited, Part No.
PCBS 62.
4.13 Under loor Pipework
Plastic pipe may be used on Underfloor
systems where the plastic pipe is fitted
after the thermostatic mixing valve.
Copper tube must be used for at least
the first metre of flow and return primary
pipework between the boiler and the
underfloor mixing/blending valves.
The first metre of pipework
connected to both the heating flow
and return connections of the boiler
must be made in copper on all types
of system - sealed or open-vented.
4.12 Sealed Systems
If plastic pipe is used, the installer must
check with the plastic pipe
manufacturer that the pipe to be used is
suitable for the temperature and
pressures concerned.
Plastic pipe must be Class S to
BS 7291: Part 1:1990.
!NOTE
!WARNING

5Pipe Connections
18
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.
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.
5.2 Water Connections –
System Models
A 15mm discharge pipe must be
connected to the safety valve outlet
connection. This pipe must be
unrestricted, i.e. no valves. The discharge
pipe should be run vertically down
through an exit hole in the bottom of the
case, and then terminate so that it cannot
cause injury to persons or property. See
Figures 5-1 and 5-2 above.
A 15mm 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
condense 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
Figure 5-3: Grant Vortex Eco External boiler with front casing removed
Figure 5-2: System boiler flow and
return connections
!NOTE

Condensate
Disposal
19
6Condensate Disposal
6.1 General Requirements
When in condensing mode the Grant
Vortex Eco wall-hung boilers produce
condensate from the water vapour in the
flue gases. This condensate is slightly
acidic with a ph value of around 3
(similar to vinegar). Provision must be
made for the safe and effective disposal
of this condensate.
Condensate can be disposed of using
one of the following methods of
connection:
Internal Connection (preferred option):
Into an internal domestic waste
system (from kitchen sink, washing
machine, etc.).
Directly into the soil stack
External Connection:
Into an external soil stack
Into an external drain or gulley
Into a rainwater hopper (that is part
of a combined system where sewer
caries 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.
Condensate disposal pipes should not
be connected directly into rainwater
downpipes or to waste/soil systems
connected to septic tanks.
Condensate should not be discharged
into ’grey water’ systems that re-use
water used in the home (not including
water from toilets).
It should be noted that connection of a
condensate pipe to the drain may be
subject to local Building Control
requirement.
6.3 Pipework
Condensate disposal pipework must
be plastic (plastic waste or overflow
pipe is suitable).
Copper or steel pipe is not suitable
and must not be used.
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
1 metre from building foundations and
away from other services, for example,
gas, electricity, or other services.
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 the soakaway tube and the hole
around it with 10mm limestone chippings.
Only use a soakaway where the soil is
porous and drains easily.
Any damage due to condensate
backing up into the boiler due to a
high water table, in the case of a
soakaway, or flooded drains when
the condensate disposal is via a
gulley or soil stack, is not covered by
the Grant product warranty.
Do not use in clay soils or where the
soil is poorly drained.
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 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 32mm 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
!NOTE
!NOTE
!CAUTION
Figure 6-1: Purpose made condensate soakaway
32mm waste pipe
external to the building
Two rows of 3 x 12mm
holes at 25mm centres and
50mm from the bottom of
the tube. Holes facing away
from the property.
Backfill with
10mm limestone
chippings
Sealed
end
100mm
plastic tube
Cement seal
Ground level
2.5° fall
25mm
300mm
400mm min.
Condensate disposal pipes should
have a minimum ‘nominal’ diameter of
22mm (3/4”)- e.g. use 21.5mm OD
polypropylene overflow pipe.
Condensate disposal pipes must be
fitted with a fall (away from the boiler) of
at least 2.5° (~45mm fall per metre run).

20
Condensate
Disposal
6.7. Condensate Disposal
Pipework
The boiler is supplied with a flexible
plastic condense disposal pipe, factory-
fitted to the outlet of the trap.
This flexible discharge pipe must be
routed through the boiler to exit via one
of the pre-cut ‘knock-outs’ in the
bottom flange of the boiler back panel -
at the right rear of the bottom casing.
Push out the ‘knock-out’ from the hole
taking care not to distort the back panel
flange.
The outlet end of this flexible pipe will
accept 21.5mm OD to 23mm OD
Polypropylene overflow pipe for
connection of the condensate discharge
pipe below the boiler.
When connecting plastic discharge
pipe, ensure that the pipe is fully
pushed into the outlet end connector
on the flexible pipe to prevent the
possibility of leakage.
6.8 Inspection and Cleaning
o 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.
6.6. Condensate Trap
Grant Vortex Eco Wall-hung boilers are
supplied with a factory-fitted condensate
trap to provide the required 75mm water
seal in the condensate discharge pipe
from the boiler.
This trap incorporates a float (which will
create a seal when the trap is empty) and
an overflow warning outlet (fitted with a
plastic sealing cap), see Figure 6-2.
The trap is factory-fitted inside the boiler
casing – mounted on the outlet of the
condensing heat exchanger - in an
accessible position to allow for routine
maintenance. See Figure 6-3.
A ‘push-fit’ elbow connects the outlet of
the condensing heat exchanger to the
trap inlet. Ensure the elbow is fully
pushed onto the ‘top hat’ inlet
connector of the trap.
With the trap fitted inside the boiler
casing, the sealing cap must be fitted.
Figure 6-2: Condensate trap
Figure 6-3: Condensate trap in-situ
The bottom bowl is sealed to the trap
body and cannot be removed.
To inspect and clean the trap
1. Remove expansion vessel (system
models only) and hang on front of
boiler casing.
2. Leave inlet connector fitted to
connecting elbow.
3. Unscrew the inlet connection nut.
4. Separate trap from the ‘top hat’ inlet
connector and nut.
5. Unscrew outlet connection nut,
disconnect disposal pipe from trap.
6. Remove trap from boiler.
7. Remove float from trap – clean if
necessary.
8. Inspect inside of trap and clean as
necessary.
9. Re-assemble trap, re-fit to boiler
and re-connect inlet connection.
Ensure that elbow is fully pushed
onto the ‘top hat’ inlet connector
and disposal pipe is correctly
connected to trap outlet.
!NOTE
Failure to regularly check and clean
the condensate trap may result in
damage to the boiler and will not be
covered by the Product Warranty.
!NOTE
!CAUTION