Grant Vortex Outdoor Module Manual

USER, INSTALLATION
and
SERVICING INSTRUCTIONS
GRANT VORTEX
Condensing Oil Boiler range
For use with Kerosene only
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
Part No. DOC 52 Rev. 00 October 2004
Outdoor Modules
with outputs up to 46 kW

2Grant Vortex Outdoor Module
Subject PageSection
1 Introduction.............................................. 3
2 User instructions ...................................... 4
3 Boiler technical information .................... 7
4 General boiler information....................... 10
5 Boiler installation..................................... 20
6 Commissioning......................................... 27
7 Information for the user ........................... 29
8 Boiler servicing ........................................ 30
9 Wiring diagrams....................................... 33
10 Fault finding ............................................. 35
11 Boiler spares ............................................ 37
12 Burner spares ........................................... 38
13 Health and safety information.................. 39
14 EC declaration of conformity .................. 40
Date % CO2Net flue gas
temp. SmokeNo. Service engineer/Tel. No.
Date:..............................
Commissioningengineer:.............................................................................. Tel. No: ....................................
Boiler model/output: ........................................kW Fuel type: Kerosene
Nozzle size: .................................... Pump pressure: .................... Air setting: ...........................
Flue gas % CO2: ............................. Net flue gas temp:................ Smoke No:...........................
It is recommended that the boiler should be regularly serviced, at least once a year, and the details entered below by the
serviceengineer.
COMMISSIONING REPORT
SERVICE LOG
LIST OF CONTENTS

3
Grant Vortex Outdoor Module
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 80° C.
1 - INTRODUCTION
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.

4Grant Vortex Outdoor Module
2 - USER INSTRUCTIONS
The boiler will provide domestic hot water and central
heating and is fully automatic once switched on. An
illuminated On/Off switch, see Fig. A, is fitted to the
Outdoormodules,whichlightswhentheboilerisswitched
on, but does not necessarily indicate the burner is firing.
ToaccesstheOutdoormodulecontrols,removethefront
panelby turning the handle and withdrawing it forwards
at the bottom.
Controls for Outdoor modules - Fig. A
1 Ensure that - There is sufficient fuel, of the correct
type,inthesupplytank 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 neon in the switch is not alight). The Test
switch is set to Off. The room thermostat (if fitted) is
at the desired setting. The boiler thermostat is set to
the required setting.
2Switch on the electricity supply to the boiler.
3Set the Boiler On/Off switch to on. A neon in the
switch lights when it is in the on position.
The boiler will now light automatically.
About your boiler
2.1
Boiler controls (see Fig. A)
2.2
Lighting your boiler (see Fig. A)
2.3

5
Grant Vortex Outdoor Module
For short periods - Set the boiler switch to OFF.
To restart, set the switch to ON.
For long periods - Set the boiler switch to OFF. If
required, the fuel supply valve may be closed and the
water and electricity supplies turned off at the mains.
Note: If the electricity, fuel and water supplies are
turned off, the built-in frost thermostat will not
operate.
1Check that the boiler switch is ON.
2Check that any remote programmer (if fitted) is
working and is in an 'on' period.
3Check that all thermostats are set to the desired
setting and are calling for heat.
4Check if the burner 'Lock-out' reset button is lit. If it
is,pressittostarttheburner.Iftheburnerfailstolight
and goes to 'Lock-out' again, check that you have
sufficient fuel in the storage tank and that the fuel
supply valve is open.
5Ensure that a fuse has not blown or that the
electricity supply has not failed.
6Check 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.
The Vortex Outdoor modules operate on Class C2
Keroseneonly.Youshouldalwaysquotethetypeoffuel
you require 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.
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.
The boiler thermostat has an operating range of 65
to 80°C. The following settings are recommended:-
a Heating and hot water in Winter 75°C
b Hot water only in Summer 65°C
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 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 Ventilation - Always ensure that the boiler has
adequate ventilation. Any ventilation openings
must not be obstructed. Periodically check that
they are clear.
Do not attempt to 'box in' the boiler or build a
compartment around.
Do not place any combustible material around or
on the boiler or flue pipe.
Do not place anything against the door of the
Outdoor modules that might obstruct the
ventilationopenings.
2 - USER INSTRUCTIONS
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 Outdoor Module
6 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.
The control panel of the Outdoor modules includes
a built-in frost thermostat factory set to 5°C.
Note: For Vortex Outdoor modules we recommend
that a combined antifreeze and corrosion inhibitor
be used in the primary water system.
7 Cleaning and servicing - Lightly wipe over the
case with a damp cloth and a little detergent. Do
not use abrasive pads or cleaners.
You should have your boiler serviced at least once
a year to ensure safe and efficient operation.
Contact your Service engineer for further details.
Warning note - External equipment operated at
230 volts should not be serviced or repaired
under adverse weather conditions.
8 Failure of electricity supply - If the electricity
supply fails, the boiler will not operate. It should
relight automatically 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 0.8 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.
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.
Avalveisopenwhentheoperatingleverisinlinewith
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.
4 Vent each radiator in turn, starting with the lowest
one in the system, to remove air.
7 Continue to fill the system until the pressure gauge
indicates 1.0 bar. Close the fill point valve.
9 Close the valves either side of the filling loop and
disconnect the loop.
2 - USER INSTRUCTIONS
Electricity supply
2.8
Sealed central heating system
2.9
Sealed system filling loop arrangement - Fig. B

7
Grant Vortex Outdoor Module
22 mm plastic pipe
28 m
1m
65 to 80°C
111°C ± 3°C
Less than 50°C
230/240 V ~ 50 Hz Fused at 5 Amp
90 W max.
2.6 Amp
0.85 Amp
¼" BSP Male (on end of flexible fuel line)
2.5 bar
2.5 bar
Boiler technical data
3.1
3 - BOILER TECHNICAL INFORMATION
Model
Water content litre
gal
* Weight (dry) kg
lb
Max. heat output kW
(kerosene) Btu/h
Flow connection
Return connection
Condensate connection
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
Starting current
Running current
Oil connection
Max operating press - sealed sys
Max operating press - open sys
*Weight includes burner but excludes flue.
Vortex Outdoor Module
All Heating Return connections are in stainless steel pipe - compression fittings must be used.
36/46
21
4.7
174
384
46
157 000
28 mm
28 mm
26.0 mbar
9.5 mbar
15/26
19
4.2
157
346
26
88 700
22 mm
22 mm
28.5 mbar
10.0 mbar
26/36
21
4.7
174
384
36
122 840
28 mm
28 mm
26.0 mbar
9.5 mbar

8Grant Vortex Outdoor Module
3 - BOILER TECHNICAL INFORMATION
Note: Grant Vortex boilers are only for use with kerosene.
Grant Vortex oil boilers using Class C2 kerosene
3.3
Heating system pressure (cold)
Operating pressure of pressure relief valve
Expansion vessel size (15/26)
Expansion vessel size (26,36 and 36/46)
Max heating system volume (including boiler) (15/26)
Max heating system volume (including boiler) (26/36 and 36/46)
Cold water mains connection
Pressure relief valve discharge connection
Circulating pump (15/26)
Circulating pump (26/36 and 36/46)
Maximum 1.0 bar, Minimum 0.5 bar
2.5 bar
12 litres (pre-charged at 1 bar)
16 litres (pre-charged at 1 bar)
75 litres (approximately)
120 litres (approximately)
15 mm copper pipe
15 mm copper pipe
6 m Head
7 m Head
Sealed system data
3.2
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 * Net thermal efficiency.
5 The net flue gas temperatures given above are ± 10%.
6 When commissioning the air damper must be adjusted to obtain the correct CO2level.
7 ** Factory settings: 15/26 - 23 kW, 26/36 - 31.5 kW, 36/46 - 41.5 kW.
8 ThecombustiondoortestpointmaybeusedforCO2andsmokereadingsonly.Donotusethistestpointfortemperature
or efficiency readings.
9 When setting the 15/26 to 15 or 20 kW the combustion head must be 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. Lowlevelfluesdonotcontainatestpoint.Thetemperatureandefficiencyreadingsmustbetakenfromtheflueterminal.
(kW)
15.0
20.0
23.0
26.0
26.0
31.5
36.0
36.0
41.5
46.0
(Btu/h)
51 180
68 240
78 475
88 700
88 700
107 500
123 000
123 000
142 000
157 000
100.4
101.0
101.0
101.5
101.5
101.5
101.5
101.5
98.5
97.0
Nozzle
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
Oil
press.
(bar)
7.0
8.0
8.5
8.0
8.0
9.0
9.1
9.0
8.0
8.0
Smoke
No.
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)
1.25
1.67
1.94
2.18
2.18
2.57
3.01
3.01
3.56
3.90
Flue gas
temp.
(°C)
60 - 65
65 - 70
70 - 75
68
68
70
78
78
80
88
CO2
(%)
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
Burner
head
T1
T1
T2
T2
T3
T3
T3
T3
T5
T5
Heat Output Net
eff *
(%)
15/26
26/36
36/46
Model
**
**
**

9
Grant Vortex Outdoor Module
3 - BOILER TECHNICAL INFORMATION
Boiler dimensions
3.4
Fig 1a - 15/26 dimensions
Fig 1b - 26/36 and 36/46 dimensions

10 Grant Vortex Outdoor Module
The Vortex Outdoor Modules have an insulated
weatherproof enclosure made of galvanised steel with
a powder coated finish, and are designed for external
installation, either against a wall or free standing some
distance away from the property, as required.
The Vortex Outdoor modules are part of the Grant range
of automatic pressure jet oil boilers have been designed
for use with a fully pumped central heating system with
indirectdomestichotwatercylinder.Theyarenotsuitable
forusewitheitheradirectcylinderora'primatic'cylinder
or gravity hot water..
The boilers are suitable for use on sealed central
heatingsystems.
All models are supplied with the control panel and
burner factory fitted.
The factory fitted low level discharge flue system can
be adjusted on site for either rear, left hand or right
hand flue outlet position, as required.
A conventional flue (Green) system is also available
from Grant UK. Refer to Section 5.3 for further details.
Green system......Standard external high level/
vertical flue starter elbow with test point -
components available:
Extensions 150 mm, 250 mm, 450 mm, 950 mm
and adjustable 195 to 270 mm
45° elbow
High level terminal
Vertical terminal
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 and 3/8" to 1/4"
BSP male adaptor are available from Grant Engineering
(UK) Limited, 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
allows it to be used on a sealed central heating system)
which will automatically switch off the boiler if the heat
exchangerexceedsapre-settemperatureof111°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 description
4.1
Boiler components
4.2
4 - GENERAL BOILER INFORMATION
Installation of a Grant Vortex boiler must be in
accordance with the following recommendations:-
a Building Regulations for England and Wales,
and the Building Standards for Scotland 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:-
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 CodeofPracticeforoilfiringappliances.
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 13 on page 39.
Regulations to comply with
4.3

11
Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
4 A metal bowl type filter with a replaceable
micronic filter must be fitted in the fuel supply line.
A shut-off valve should be fitted before the filter,
to allow the filter to be serviced.
5 A flexible fuel line, 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 system is used, an additional flexible
fuel line and 3/8" to 1/4" BSP male adaptor are
available from Grant Engineering (UK) Limited.
6 Flexible pipes should be inspected annually when
the boiler is serviced and replaced every two years.
4.4.3 Single pipe system - (See Fig. 2)
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.
4.4.1 Fuel storage
The tank should be positioned in accordance with the
recommendationsgiveninBS5410:1:1997,whichgives
details of filling, maintenance and protection from fire.
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.
4.4.2 Fuel pipes
1 Fuel supply pipes should be of copper tubing with
an internal diameter of at least 8 mm.
Galvanised pipe must not be used.
2 Flexible pipes must not be used outside the boiler case.
3 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.
Fuel supply
4.4
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 - Single pipe system

12 Grant Vortex Outdoor Module
4.4.5 Tiger Loop system - (See Figs. 4 and 5)
1 When The storage tank is below the burner, an
alternativetoatwopipesystemcanbeachievedusing
theTigerLoopoildeaerator.Thiseffectivelyremoves
the air from the oil supply on a single pipe lift.
2 The Tiger Loop is connected close to the boiler as
a two pipe system (omitting the non-return valve)
as shown in Fig. 4. Refer to the manufacturers
instructions supplied with the Tiger Loop.
The Tiger Loop must be mounted vertically.
3 To be used with a Tiger Loop system, the burner
must be fitted with an additional flexible fuel line.
See Section 4.4.6.
Flexible fuel lines and adaptors are available from
Grant Engineering (UK) Ltd.
4.4.4 Two pipe system - (See Fig. 3)
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. 3. 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 line
(a flexible fuel line and 3/8" to 1/4" BSP male
adaptor are available from Grant Engineering (UK)
Limited). 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
4 - GENERAL BOILER INFORMATION
Fig. 3 - Two pipe system

13
Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
4.4.6 Two pipe oil supplies
Riello RDB burner - See Fig. 6
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. 6) into the tapping in the return port.
2 The By-pass screw is supplied in the boiler
accessory pack.
3 Remove the plastic burner cover (two screws).
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 line to the pump.
6 Connect the 3/8" to 1/4" BSP adaptor to the flexible
fuel line.
7 Flexible fuel lines and adaptors are available from
Grant Engineering (UK) Ltd.
Fig. 4 - Tiger loop system
1/4" BSP female
connections
Tiger Loop
SUPPLY
TO PUMP
RETURN
FROM PUMP
SUPPLY
FROM TANK
Fig. 5 - Tiger loop
Fig. 6 - 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
12
3
4
5
6
7
8

14 Grant Vortex Outdoor Module
See Fig. 6
If a two pipe system is to be used refer to Section 4.4.6.
1 Remove the oil inlet plug from the fuel pump and
connect the elbow of the flexible fuel line supplied
with the boiler.
2 Connect the flexible fuel line to the rigid supply
using the adaptor supplied. The supply enters
through one of the holes in the underside of the
side casing panels.
1 A 230/240 V ~ 50 Hz mains supply is required.
The boiler must be earthed.
2 The electrical supply to the boiler and control
system should be fed from a single separate 5 Amp
circuit breaker with earth leakage protection,
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 external to the boiler must be in
accordancewiththecurrentI.E.E.WiringRegulations.
6 Any room thermostat or frost thermostat used must
be suitable for use on mains voltage.
7 The boiler requires a permanent mains supply, do
not interrupt it with any external time control.
8 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.
1 Outdoor Modules are supplied with a factory fitted
frost protection thermostat, located inside the
boiler control panel. This is pre-wired to the boiler
electrical system and factory set to 5°C.
2 For total system protection against freezing,
particularly during extended periods without
electrical power, Grant recommend the use of a
combined heating system antifreeze and corrosion
inhibitor, used in accordance with the
manufacturer'sinstructions.
4 - GENERAL BOILER INFORMATION
1 The Outdoor Module must stand on a solid, level
surfacecapableofsupportingtheweightoftheboiler
whenfullofwater,e.g. aprepared concretestanding,
pavingslabsbeddeddownonsand/cement,orsimilar.
2 The Module can be installed either against the
building or 'free standing' some distance away from
the building.
3 The Module must be positioned such that the
required clearances from the low level flue outlet,
as shown in Fig. 7, are achieved.
4 Adequate clearance must be left around the
Module for servicing. In particular, a minimum
clearance of 600 mm above the Module for
removal of the top panel and 600 mm at the
opposite end to the flue outlet for access to the
burner.
5 The flue terminal must be a minimum distance of
1.8 m 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.
General - Grant boilers are compatible with both
copper and plastic pipe. Where plastic pipe is used it
must be of an oxygen barrier type. The first metre of
pipe connected to the boiler must be made in copper.
Sealed systems - Where a sealed heating system is
fitted to the boiler only copper tube may be used.
Underfloor systems - 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 the primary pipework between the boiler and
the underfloor mixing/blending valves.
Connect the fuel supply
4.5
Electricity supply
4.6
Frost protection
4.7
Boiler location
4.8
Pipework materials
4.9

15
Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
Flue terminal locations
4.10
Fig. 7 - Flue terminal
positions
K
D
FAJ
B
L
G
C
C
I
H
E
Distances measured to rim of terminal.
Clearances recommended by Grant
Engineering (UK) Limited in accordance with
British Standards and Building Regulations.
Notes:1 An opening means an openable
element, such as an openable
window, or a permanent opening
such as a permanently open air vent.
2 Notwithstanding the dimensions
given, a terminal should be at least
300 mm from combustible material,
e.g. a window frame.
3 A way of providing protection of
combustible material would be to fit
a heat shield at least 750 mm wide.
Notes: * 75 mm with protection.
** 300 mm British Standards.
A Below gutters, eaves or balconies (with protection)
B Horizontally from a door, window or air vent
C Above ground, flat roof or balcony level
D Below gutters, eaves or balconies (without protection)
E From an external corner
F From a terminal facing the terminal
G From a surface facing the terminal
H Vertically from a terminal on the same wall
I Horizontally from a terminal on the same wall
J Directly below an opening, air brick, window, etc.
K From a vertical drain pipe or soil pipe
L From an internal corner
*600
600
**300
*600
300
1200
600
1500
750
600
300
300
Terminal position Min. distance
The minimum dimensions for positioning the flue
terminal are shown in Fig. 7.
The terminal should be positioned so as to avoid
products of combustion accumulating in
stagnant pockets around the building or
entering into buildings. Care should also be
taken that the plume from the condensed flue
gases does not cause a nuisance.

16 Grant Vortex Outdoor Module
Flow connection - All models
A 22 mm (28 mm 26/36 and 36/46 models) Tectite
push-fit elbow connection is provided for the heating
flow. The flow and return pipework can exit the boiler
enclosure either through the openings provided in both
sides (under the movable cover plates) and through the
wall when installed against the building, or down and
through the openings provided in the base of the
enclosure for 'free standing' installations.
Returnconnection(seealsoSection5.4)-Allmodelshave
astainlesssteelpipeonthelefthandside(whenviewedfrom
the back) for the return connection - 22 mm for the 15/26
models or 28 mm for the 26/36 and 36/46 models.
Compressionfittingsmustbeusedforthereturnconnection.
All water connections have been temporarily sealed
with plastic caps to prevent any residual water (from
factory pressure testing) leaking from the boiler during
storage and transit. All the caps must be removed
before connecting any fittings.
Plug all unused connections.
Fit drain cocks in the central heating and domestic hot
water systems to allow the complete system to be fully
drained.
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
associatedcentralheatingsystemmustbeflushedinaccordance
withtheguidelinesgiven inBS7593:1992'Treatmentofwater
indomestic 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 immediate information, please
contact BetzDearborn on 0151 4209563 or Fernox on
0179 9550811.
For Long term protection against corrosion and scale,
afterflushing,itisrecommendedthataninhibitorsuchas
Betzdearborn's Sentinel X100 or Fernox MB-1 is dosed
inaccordancewiththeguidelinesgiveninBS7593:1992.
Failure to implement the guidelines will invalidate the
warranty.
4 - GENERAL BOILER INFORMATION
Water connections
4.11 Boiler components 4.12
Fig. 8 - Top view
Fig. 9 - Rear view

17
Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
See Fig. 10
Grant sealed system kits, incorporating circulating
pumps are available.
1 The boiler is only suitable for use with a sealed
systemcomplyingwiththerequirementsofBS5449.
The maximum temperature of the central heating
water is 80°C.
2 The system must be provided with the following
items:-
a Diaphragm expansion vessel complying with
BS 4814.
b Pressure gauge.
c Safety valve.
d Approved method for filling the system.
Refer to BS 7074:1 for further guidance.
3 The expansion vessel can be fitted in either the
return or flow pipework in any of the
recommended positions as shown in Fig. 10. To
reduce the operating temperature of the expansion
vessel diaphragm, position it below the pipe to
which it is connected. The expansion vessel may
be positioned away from the system, providing the
connecting pipe is not less than 13 mm diameter.
Sealed systems
4.13
4 The pressure gauge should have an operating range
of 0 to 4 bar.
5 The safety valve, set to operate at 2.5 bar, should
be fitted in the flow pipework near to the boiler.
The pipework between the safety valve and boiler
must be unrestricted, i.e. no valves. The safety
valve should be connected to a discharge pipe
which will allow the discharge to be seen, but
cannot cause injury to persons or property.
6 Provision should be made to replace water lost
from the system. This can be done manually. A
double check valve assembly must be used.
7 An automatic air vent should be fitted to the
highest point of the system.
8 All fittings used in the system must be able to
withstand pressures up to 3 bar.
9 Radiator valves must comply with the requirements
of BS 2767(10):1972.
10 One or more drain taps (to BS 2879) must be used
to allow the system to be completely drained.
11 For proprietary expansion vessel/valve/gauge
packs, refer to the manufacturers instructions for
the correct location on the heating system.
Fig. 10 - Sealed system

18 Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
See Fig. 11
On underfloor systems it is essential that the return is
pre-heated by mixing flow water into the return before
it enters the boiler. The return temperature must be
maintained above 40°C to prevent internal corrosion
of the boiler water jacket.
Fig. 11 - Underfloor system
Underfloor heating systems
4.14
Condensate disposal
4.15
The minimum diameter of the condensate drainage line
is 3/4". The drainage line may run into a soil stack or
waste pipe, an external gulley, hopper or soak-away,
see Fig. 13. Standard plastic overflow pipe (3/4" [19
mm] diameter) may be used to connect to the outlet of
the condensate trap.
It should be noted that the connection of a condensate
pipe to the drain may be subject to local building
control requirements.
Fig. 12 - Condensate trap
When in condensing mode the Grant Vortex boiler
produces condensate from the flue gases. Provision
must be made for the safe and effective removal of the
condensate. All Vortex boilers are supplied with a
float valve condensate trap (the float creates a seal
against flue gases), see Figs. 9 and 12, that
incorporates an overflow warning outlet. The bung
should be removed from the overflow outlet.
The trap must be located inside the casing in an
accessible position to allow for maintainance.
The mounting bracket (supplied) for the condensate
trap must be used.
Thetrap should be checked at regular intervals to ensure
thatitisoperatingcorrectlyandservicedatleastannually.
Ifthereisanydischargeofcondensatefromtheoverflow
outlet, turn off the boiler and contact a service engineer.
Thecondensatedrainage linemust beofasuitablematerial
such as plastic.
Steel or copper must not be used.

19
Grant Vortex Outdoor Module
4 - GENERAL BOILER INFORMATION
Fig. 13 - Purpose made condensate soakaway

20 Grant Vortex Outdoor Module
1 Carefully remove the packaging from the boiler
and lift it off the pallet.
2 The flue terminal guard is supplied loose inside the
boiler.
3 Remove the case top panel (four screws).
4 Thefluemayexitthecasingfromtheleft,rightorrear
ofthecasing.Thecasinghastworemovableblanking
panelsandaflueexitpanel.Fitthepanelwiththeflue
exit hole and seal in the required position.
5 Slacken the wing nuts holding the flue elbow and
rotate the elbow to the required direction for the
flue to exit the casing.
6 Push the end of the flue terminal section with the
red seal through the seal in the casing. The terminal
has been factory lubricated. Take care not to
dislodge or damage the red seals.
7 Carefullyinsert the terminal into the flue elbow until
the bend of the terminal contacts the outer casing,
then,pulltheterminalforwardapproximately25mm
and rotate the bend so that the outlet is horizontal.
Rear Exit - The flue must discharge away from the
building.
Side Exit - The flue should discharge towards the
rear of the casing to prevent flue gases re-entering
the boiler casing through the air inlet vents on the
casing front door.
The flue terminal must be fitted horizontally to
prevent dripping from the end of the terminal.
5 - BOILER INSTALLATION
Unpack the boiler
5.1
Fig. 14
8 Tightenthewingnuts holdingthe flueelbow andfit the
stainlesssteelflueguardusingthetwoscrewsprovided.
9 The top panel of the casing has been designed so that
it may be fitted to create a slight slope away from the
sidepositioned against the wall. To tilt the top panel,
loosen the four top panel casing screws, one at each
corner and push down on the side furthest from the
wall. Tighten the screws. See Fig. 14.
1 Iftheboileristobefittedagainstthewall,preparethe
wallto accept the heating system pipework. To mark
thewallfordrilling,refertoFig.1forthepositionsof
the pipework openings in the enclosure sides.
Note: Pipework should be insulated where it
passes through the wall into the boiler enclosure.
If the boiler is to be installed 'free standing' (i.e.
away from a wall) and the pipework run
underground, slide away the covers to open the two
pipe openings in the base of the boiler enclosure.
Using a sharp knife, cut through the polystyrene in
the base, around the edge of the holes, to allow the
flow and return pipes to enter the enclosure.
2 The electrical supply to the boiler should be routed
through the wall in a suitable conduit, such that it
enters the boiler enclosure via one of the unused
pipework openings. The cable can be routed to the
front of the boiler, for connection to the boiler
control panel, either over the top or beneath the
boiler heat exchanger. Heat resistant PVC cable, of
at least 1.0 mm² cross section should be used
within the boiler enclosure.
Preparations for installation
5.2