Grant Vortex VTXBH1521 User guide

UK | DOC 0116 | Rev 1.1 | November 2017
Grant Vortex
Boiler House Floor Standing Condensing Oil
Boiler Range
Installation and Servicing Instructions

GRANT ENGINEERING (UK) LIMITED
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU
Tel: [phone] Fax: [phone]
Email: [email protected] www.grantuk.com
This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.
However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the
author or others involved in its publication.
All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
© Grant Engineering (UK) Limited. No part of this manual may be reproduced by any means without prior written consent.
IMPORTANT NOTE FOR INSTALLERS
These instructions are intended to guide Installers on the
installation, commissioning and servicing of the Grant Vortex oil
boiler. After installing the boiler, leave these instructions with the
user.
A user handbook is available to guide users in the operation of the
oil boiler.
SPECIAL TEXT FORMATS
The following special text formats are used in these instructions
for the purposes listed below:
! WARNING !
Warning of possible human injury as a consequence of not
following the instructions in the warning.
! CAUTION !
Caution concerning likely damage to equipment or tools
as a consequence of not following the instructions in the
caution.
! NOTE !
Used for emphasis or information not directly concerned
with the surrounding text but of importance to the reader.
PRODUCT CODES COVERED
These instructions cover the following product codes:
VTXBH1521, VTXBH2126, VTXBH2635, VTXBH3646,
VTXBH4658 and VTXBH5870.
SERVICING
The boiler should be serviced at least every twelve months and
the details entered in the Service Log in the user handbook.
Page 2
FUEL TYPE
All Grant Vortex boilers are suitable for use with Class C2
Kerosene. To use Bio-Kerosene (B30K), refer to the information
below:
OPERATION ON BIO-FUEL
All Grant Vortex condensing boilers manufactured since May
2011 are suitable for for operation on both standard Kerosene
(Class C2 to BS 2869) and also bio-kerosene - up to a 30% blend
(B30K).
All burner settings and nozzle sizes (as detailed in Section 2.2 of
these instructions) are correct for both standard kerosene and bio-
kerosene (B30K).
In order to operate this boiler on bio-kerosene, it will be necessary
to take the following actions:
• Useabio-kerosene(B30K)compatibleexibleoillinein
place of the oil line supplied with the boiler.
• Have the oil storage tank and oil supply line (including all
pipework,sightgauges,lters,isolatingvalves,revalves,
de-aeration devices, etc.) checked for their compatibility with
bio-kerosene (B30K).
Where necessary, some or all of these items may have to be
replaced with a bio-kerosene compatible alternative.
• CheckthesuitabilityoftheuesystemwithGrantUK.
• Use only bio-kerosne (B30K) that conforms to OPS24.
IMPORTANT:
Under no circumstances, should the boiler be used with
bio-kerosene without the above actions being taken rst.

1 INTRODUCTION 4
1.1 How a condensing boiler operates 4
1.2 Boiler description 4
1.3 Flue options 4
1.4 Boiler components 5
2 TECHNICAL DATA 6
2.1 Boiler technical data 6
2.2 Burner settings 7
2.3 Flue gas analysis 7
2.4 Water connections 7
2.5 Boiler dimensions 8
3 OIL STORAGE AND SUPPLY SYSTEM 10
3.1 Fuel supply 10
3.2 Burner oil connection 12
3.3 Fitting the burner 13
4 BOILER INSTALLATION INFORMATION 14
4.1 Introduction 14
4.2 Boiler location 14
4.3 Regulations compliance 14
4.4 Heating system design 14
considerations
4.5 Pipework materials 15
4.6 Connections 15
4.7 Preparation for installation 15
4.8 Installing the boiler 15
4.9 Before you commission 15
5 PIPE CONNECTIONS 16
5.1 General 16
5.2 15/21, 21/26 and 26/35 models 16
5.3 36/46 model only 16
5.4 46/58 and 58/70 models 17
5.5 Fitting the dual thermostat 17
6 CONDENSATE DISPOSAL 18
6.1 General requirements 18
6.2 Connections 18
6.3 Pipework 18
6.4 External pipework 18
6.5 Condensate soakaway 19
6.6 Condensate trap 19
6.7 Condensate disposal pipework 19
6.8 Inspection and cleaning of trap 19
7 SEALED SYSTEMS 20
7.1 Sealed system requirements 20
7.2 Filling the sealed system 21
7.3 Venting the pump 21
7.3 Pressure relief (safety) valve 21
operation
Contents Page 3
8 ELECTRICAL 22
8.1 General 22
8.2 Connecting the power supply 22
8.3 Frost protection 22
8.4 Wiring diagrams 22
9 FLUE SYSTEM AND AIR SUPPLY 25
9.1 Air supply 25
 9.2 Conventionaluesystems  25
 9.3 Connectingaconventionalue 28
 9.4 Balanceduesystems  28
9.5 Flue clearances 32
9.6 Prepare the wall 33
10 COMMISSIONING 34
10.1 Before switching on 34
10.2 Air adjuster disc - 15/21 only 35
10.3 Combustion head adjustment - 35
58/70 only
10.4 Switching on 35
10.5 Running the boiler 36
10.6 Balancing the system 36
10.7 Completion 36
11 BOILER SERVICING 37
11.1 General 37
11.2 Checks before servicing 37
11.3 Dismantling prior to servicing 37
11.4 Cleaning the boiler 37
11.5 Cleaning the burner 39
12 FAULT FINDING 40
 12.1 Boilerfaultnding   40
 12.2 Burnerfaultnding-RielloRDB 41
13 SPARE PARTS 42
13.1 Riello RDB 2.2 burners 42
(15/21, 21/26, 26/35 and 36/46)
13.2 Riello RDB 3.2 burners 44
(46/58 and 58/70)
13.3 Boiler Parts List 46
14 DECLARATION OF CONFORMITY 47
15 HEALTH AND SAFETY INFORMATION 48
15.1 Insulation materials 48
15.2 Sealant and adhesive 48
15.3 Kerosene and Gas Oil fuels 48
16 END OF LIFE INFORMATION 49
17 PRODUCT FICHE 50
CONTENTS

Section 1: IntroductionPage 4
1.1 HOW A CONDENSING BOILER
OPERATES
During the combustion process, hydrogen and oxygen combine
to produce heat and water vapour. The water vapour produced
is in the form of superheated steam in the heat exchanger. This
superheated steam contains sensible heat (available heat) and
latentheat(heatlockedupintheuegas).Aconventionalboiler
cannot recover any of the latent heat and this energy is lost to the
atmospherethroughtheue.
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uegases
to below 90°C, thus extracting more sensible heat and some of
thelatentheat.Thisisachievedbycoolingtheuegasestotheir
dew point (approximately 55°C).
Toensuremaximumefciency,theboilerreturntemperature
should be 55°C or less, this will enable the latent heat to be
condensedoutoftheuegases.
• Theboilerwillachievenetthermalefciencies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ow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efcienciesevenwhenitisnotincondensingmodeand
thereforeissuitableforttingtoanexistingheatingsystem
without alteration to the radiator sizes. The boiler is capable of a
maximumowtemperatureof75°C.
1.2 BOILER DESCRIPTION
The Grant Vortex Boiler House 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.
The boilers are supplied with a separate burner and dual
thermostat (15/21, 21/26, 26/35 and 36/46 models only).
Thedualthermostatissuppliedfactoryttedonthe46/58,58/70
models.
1.3 FLUE OPTIONS
Theboilerscanbeconnectedtoeitheraconventionaluesystem
orabalanceduesystem,asrequired.
1.3.1 FOR CONVENTIONAL FLUE APPLICATIONS
Where a chimney is to be lined - Grant recommends the use
oftheGrant‘Orange’uesystem,specicallydesignedforthe
Vortex range of condensing boilers. Refer to Section 9.2 for
further details.
Wherearigidconventionalue-eitherinternalorexternal-is
required, Grant recommends the use of the Grant ‘Green’ and
‘Orange’uesystemcomponents.Asnoueadaptorissupplied
with the boiler it will be necessary to purchase the Grant CF
adaptor kit in order to correctly connect this system to the boiler.
Flue adaptor kit (Grant product code: CFA15/70) is used for all
models as they all use the 100 mm ‘Green’ and ‘Orange’ system
componentstoconstructaueofmaximumverticalheight19
metres.
! NOTE !
The ue system materials and construction MUST be
suitable for use with oil-red condensing boilers. Failure
to t a suitable conventional ue may invalidate the
guarantee on the boiler.
1.3.2 FOR BALANCED FLUE APPLICATIONS
ThefollowinguekitsareavailablefromGrantUK.Referto
Section 9.4.
Yellow system
Standardlowlevelconcentricbalancedue-components
available:
• Lowlevelconcentricbalancedueshort
• Extensions 225 mm, 450 mm and 675 mm
• 90° extension elbow
• 45° extension elbow
• 45° elbow
• Plume diverter kits
Green system
Standardexternalhighlevel/verticaluestarterkit(roomsealed)-
components available:
• Externalhighlevel/verticaluestarterkitshort(roomsealed)
• Extensions 150 mm, 250 mm, 450 mm, 950 mm
• Adjustable extension 195 to 270 mm
• 45° elbow
• High level terminal
• Vertical terminal
White system
Highlevelandverticalconcentricbalanceduekit-components
available:
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable 275 to 450 mm
• Verticalconcentricbalanceduekit
• Extensions 225 mm, 450 mm, 950 mm
• Adjustable extension 275 to 450 mm
• 45° elbow
Red system (15/21 and 21/26 only)
Aexibleverticalbalanceduesystemdesignedtobettedinside
an existing masonry chimney.
Consisting of three sections:
•Concentricwhitepainteduepipeconnectedtotheboiler
•Verticalconcentricexibleue(exiblestainlesssteelueliner
insideaexibleplasticairinletliner)
•Terminalassemblyforchimneytopmounting
Flue extensions and 45° elbows from the White system may be
used.
Fitting instructions for the Low level, High level and Vertical
balanceduesystemsaresuppliedwiththekits.
1 INTRODUCTION

Section 1: Introduction Page 5
1.4 BOILER COMPONENTS
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
exiblefuellineand3/8ʺto1/4ʺBSPmaleadaptorsuppliedwith
the boiler.
Ifrequired,anadditionalexiblefuelline(600mm)and3/8”to
1/4”BSPmaleadaptorareavailabletopurchasefromGrantUK,
for two-pipe oil supply systems (Grant product code: RBS104).
The temperature of the water leaving the boiler to heat the
radiators and hot water cylinder is user adjustable.
Theboileristtedwithanoverheatthermostat(whichallows
it to be used on a sealed central heating system) which will
automatically switch off the boiler if the heat exchanger exceeds a
pre-set temperature of 110°C ± 3°C.
TheBoilerHousedualthermostat,ontopoftheboiler,istted
with a boiler thermostat control knob and the manual reset button
for the overheat thermostat.
The controls are shown in Figure 1.2.
Figure 1-1: Boiler components (model shown: 26/35kW)
Figure 1-2: Dual thermostat

2.1 BOILER TECHNICAL DATA
Table 2-1: Boiler technical data
Units 15/21 21/26 26/35 36/46 46/58 58/70
Water content litre 13 13 19 21 50 50
gal 2.9 2.9 4.2 4.7 11 11
Weight (dry)* kg 125 125 143 145 257 301
lb 276 276 315 320 567 664
Maximum heat output (Kerosene) kW 21.5 26.3 35.4 46.0 58.0 70.0
Btu/h 73,400 89,800 120,000 157,000 197,900 238,840
Minimumowrate(∆T=10°C) l/h 1,780 2,200 2,980 4,000 5,200 6,000
Minimumowrate(∆T=20°C) l/h 890 1,100 1,490 2,000 2,600 3,000
Condensate connection 22 mm (only connection plastic pipe)
Flue diameter (conventional) 100 mm 100 mm 100 mm 100 mm 125 mm** 125 mm**
Watersideresistance∆T=10°C mbar 28.5 26.0
Watersideresistance∆T=20°C mbar 10 9.5
Maximum static head m 28
Minimum circulating head m 1
Boiler thermostat range °C 50±5 to 75±4
Limit (safety) thermostat shut off temperature °C 110 ± 3
Maximum hearth temperature °C Less than 50
Electricity supply ~230 1ph 50Hz 5A fused
Burner motor power Watts 90 150
Absorbed motor power kW 0.16
Starting current Amps 4.2 6.4
Running current Amps 0.85 1.2
Oil connection ¼ʺBSPmale(onendofexiblefuelhose)
Conventionaluedraught mbar Minimum: 0.087 - Maximum: 0.37
in wg Minimum: 0.035 - Maximum: 0.15
Maximum operating pressure - sealed/open system bar 2.5
Maximum operating pressure - pressure relief valve bar 2.5
Boiler type ON/OFF
*Weightincludesburnerbutexcludesue
**125mmdiameterrequiredforexibleueliner(orangesystem).Forrigiduesystems,e.g.greensystem,100mmdiameteruerequired.RefertoSection9
for further details.
Section 2: Technical DataPage 6
2 TECHNICAL DATA

2.2 BURNER SETTINGS
Table 2-2: Burner settings
Boiler models
(burner type)
Heat output
Nozzle
Oil
pressure
(bar)
Smoke
No.
Burner
head
type
Burner head/
disc setting
Fuel
ow rate
(kg/h)
Flue gas
temp.
(°C)
CO2
(%)
(kW) (Btu/h)
VTXBH1521
(RDB2.2)
15.5 52,900 0.50/80°EH 7.0 0 - 1 T1 Disc setting B 1.29 55 - 75 11 - 12
18.5* 63,15 0 0.55/80°EH 7. 5 0 - 1 T1 Disc setting C 1.53 55 - 75 11 - 12
21.5 73,400 0.60/80°EH 8.5 0 - 1 T1 Disc setting C 1.78 55 - 75 11 - 12
VTXBH2126
(RDB2.2)
21.5 73,400 0.60/80°EH 8.5 0 - 1 T1 Fixed 1.78 55 - 75 11 - 12
23.5* 80,200 0.65/80°EH 8.5 0 - 1 T2 Fixed 1.95 55 - 75 11 - 12
26.3 89,800 0.75/80°EH 8.0 0 - 1 T2 Fixed 2.19 55 - 75 11 - 12
VTXBH2635
(RDB2.2)
26.3 89,800 0.75/80°EH 8.0 0 - 1 T2 Fixed 2.19 55 - 75 11 - 12
31.9* 108,800 0.85/80°EH 9.1 0 - 1 T3 Fixed 2.65 55 - 75 11 - 12
35.4 120,000 1.00/80°EH 8.0 0 - 1 T3 Fixed 2.93 55 - 75 11 - 12
VTXBH3646
(RDB2.2)
36.0 123,000 1.00/80°EH 9.0 0 - 1 T5 Fixed 3.01 55 - 75 12.0
41.5* 142,000 1.20/80°S 8.0 0 - 1 T5 Fixed 3.56 55 - 75 12.0
46.0 157,000 1.25/80°S 8.0 0 - 1 T5 Fixed 3.90 55 - 75 12.0
VTXBH4658
(RDB3.2)
46.0 157,000 1.25/80°S 8.0 0 - 1 GIB Head setting 0 4.01 55 - 75 12.0
52.0* 177,400 1.35/80°S 9.5 0 - 1 GIB Head setting 0 4.47 55 - 75 12.0
58.0 197,900 1.65/80°S 8.0 0 - 1 GIB Head setting 0 5.05 55 - 75 12.0
VTXBH5870
(RDB3.2)
58.0 198,000 1.65/80°S 8.0 0 - 1 GIB Head setting 0 5.05 55 - 75 12.0
64.0* 218,400 1.65/80°S 9.5 0 - 1 GIB Head setting 0 5.58 55 - 75 12.0
70.0 238,840 1.75/80°S 9.5 0 - 1 GIB Head setting 4 6.01 55 - 75 12.0
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 Grant Vortex boiler range
4. Theuegastemperaturesgivenaboveare±10%.
5. When commissioning, the air damper must be adjusted to obtain the correct CO2level.
6. * Factory settings: 15/21 - 18.5kW, 21/26 - 23.5kW, 26/35 - 31.9kW, 36/46 - 41.5kW, 58/70 - 52.0kW, 58/70 - 64.0kW
7. The combustion door test point may be used for CO2andsmokereadingsonly.Donotusethistestpointfortemperatureorefciencyreadings.
8. When setting the 15/21 to 15.5kW and the 58/70 to 70.0kW, the burner air adjuster disc requires repositioning. Refer to Section 6 (Commissioning).
When setting the 58/70 to 70.0kW, the burner air adjuster disc requires repositioning. Refer to Section 6 (Commissioning).
When setting the 21/26 to 21.5kW output, the combustion head must be changed. Refer to Section 11.4 (Cleaning the burner).
When setting the 26/35 to 26.3kW output, the combustion head must be changed. Refer to Section 11.4 (Cleaning the burner).
9. The installer must amend the boiler data label if the output is changed.
2.3 FLUE GAS ANALYSIS
To allow the boiler to be commissioned and serviced, the boiler is supplied with a combustion test point on the front cleaning door.
When this test point is used please note the following:
• The test point is for CO2and smoke readings only.
• Theboilerefciencyandtemperaturemustbetakenfromtheuetestpointonhighlevel,verticalandconventionalueadaptors.
• Concentriclowleveluesdonotcontainatestpoint.Thetemperatureandefciencyreadingsmustbetakenfromtheueterminal.
2.4 WATER CONNECTIONS
Table 2-3: Water connections
Boiler model Flow connection Return connection
Size Fitting Supplied Size Fitting Supplied
15/21 1ʺBSP BSP female Fitted 1ʺBSP BSP female Fitted
21/26 1ʺBSP BSP female Fitted 1ʺBSP BSP female Fitted
26/35 1ʺBSP BSP female Fitted 1ʺBSP BSP female Fitted
36/46 28mm pipe* Compression Inttingskit* 1ʺBSP BSP female Fitted
46/58 1¼ʺBSP BSP female Fitted 1¼ʺBSP BSP female Fitted
58/70 1¼ʺBSP BSP female Fitted 1¼ʺBSP BSP female Fitted
*Thepipeandcompressionttingareplacedundertheblankingplatethatcoverstheowconnection.
Section 2: Technical Data Page 7

2.5 BOILER DIMENSIONS
Section 2: Technical DataPage 8
DWG NO: REV:
BOILERHOUSE 15-35kW 04/07/17 22620
DATE:
JOB TITLE:
BOILERHOUSE SERIES 2
DRAWING TITLE: REV DISCRIPTION: REV DATE:
714
892
431
194
329
215
597
87
32
33
28
467
PLAN VIEW
REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW
106
629
591
CONDENSATE
DRAIN
FLOW
RETURN
114
Figure 2-4: 15/21, 21/26 and 26/35 dimensions
Figure 2-5: 36-46 dimensions
DWG NO: REV:
BOILERHOUSE 26-46kW 04/07/17 22621
DATE:
JOB TITLE:
BOILERHO USE SERIES 2
DRAWING TITLE: REV DISCRIPTION: REV DATE:
PLAN VIEW
REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW
456
703
880
592
458
27
228
193
28
88
323
108
556
RETURN
FLOW
CONDENSATE
DRAIN
114
* Condensate drain:
Upper opening: 15/21 and 21/26 models
Lower opening: 26/35 model only
*

Section 2: Technical Data Page 9
Figure 2-6: 46/58 and 58/70 dimensions
DWG NO: REV:
BOILERHOUSE 46-70kW 04/07/17 22622
DATE:
JOB TITLE:
BOILERHOUSE SERIES 2
DRAWING TITLE: REV DISCRIPTION: REV DATE:
PLAN VIEW
REAR VIEW
LEFT SIDE VIEW RIGHT SIDE VIEW
271
411
111
443
430
28
1078
1024
586
768542
287
CONDENSATE
DRAIN
836
FLOW
AIR VENT
924
RETURN
114

3.1 FUEL SUPPLY
3.1.1 FUEL STORAGE
The tank should be positioned in accordance with the
recommendations given in BS 5410-1 (Code of Practice for
Oil Firing - Installations up to 45kW output capacity for space
heating and hot water supply purposes). This gives details of the
requirements for suitable oil tank construction, tank installation,
tankbases,reprotectionandsecondarycontainment.
For installations of greater than 45kW output capacity, the tank
should be installed accordance with BS 5410-2.
Oil storage tanks should comply with the following standards:
• Plastic tanks OFT T100
• Steel tanks OFT T200
! CAUTION !
A galvanised tank must not be used.
! NOTE !
Plastic tanks should be stood on a rm non-combustible
base that adequately and uniformly supports the weight of
the tank over its entire base area.
The tank capacity should be selected to suit the appliance rated
output. Refer to BS5410-1 for guidance.
3.1.2 FUEL PIPES
Fuel supply pipes should be either copper or steel. Galvanised
pipesorttingsshouldnotbeused.
Plastic oil supply pipe conforming to BS EN 14125 can be used
for underground pipe runs, but must not be used above ground.
All soft copper pipe connections should preferably be made using
aredttings.Ifcompressionttingsaretobeused,asuitable
pipeinsertmustbettedintothepipeend.
Soft soldered connections must NOT be used on oil supply
pipework.
Fuel supply pipework should be of a suitable diameter, depending
on the type of oil supply system being used. Refer to information
given in sections 3.1.3, 3.1.4 or 3.1.5.
Run pipes as level as possible to prevent air being trapped. Take
the most direct route possible from tank to burner whilst locating
the pipe where it will be protected from damage.
Pipes should be supported to prevent sagging and sleeved where
they pass through a wall.
Ametalbodyfuellterofnobetterthan70μm(micron)mustbe
ttedintheoilsupplypipeclosetothetank.Thisshouldbetted
withsufcientclearancearoundandbelowittoalloweasyaccess
for maintenance.
Anisolatingvalveshouldalsobettedatthetank,beforethelter,
toallowtheoilsupplytobeshutofffortheltertobeserviced.
Asecondlter(15μmforKerosene)mustbelocatedclosertothe
burner to protect the burner pump and nozzle from contamination.
Refer to Figures 3-1 to 3-3.
Aremotesensingrevalvemustbeinstalledinthefuelsupply
line in accordance with BS540-1.
Afusiblewheelheadtypecombinedisolating/revalveMUST
NOTbeusedinplaceofaremotesensingrevalve.
Therevalvemustbelocatedoutside;justbeforetheoilline
entersthebuilding,withtherevalvesensorlocatedabovethe
burner.
A spring clip for mounting the sensor is provided with the boiler.
Thisshouldbexedwiththescrewprovided,usingthesmallhole
in the front panel of the boiler.
Therevalveshouldbelocatedafterthesecond(15micron)lter,
i.e.betweenthelterandthepointatwhichtheoillineentersthe
building. Refer to Figures 3-1 to 3-3.
Therevalvemusthaveanoperatingtemperatureofbetween
65 and 72°C to avoid unnecessary nuisance shut-offs to the oil
supply.
Aexiblefuelhoseand¼ʺisolatingvalvearesuppliedlosewith
the boiler, to make the final connection to the burner.
If a two-pipe system or deaerator is to be used, the following
additional items will be required:
• Flexiblefuelhose⅜ʺmalex¼ʺfemale,900mmlong
(product code: RBS36)
• ⅜ʺx¼ʺBSPadaptor(productcode:RBS35)
• ¼ʺisolatingvalve(productcode:ISOLATION1/4)
These are available to purchase from Grant UK.
Metal braided flexible fuel hoses should be replaced ANNUALLY
when the boiler is serviced.
Long life flexible fuel hoses should be inspected annually and
replaced, if necessary, or after a maximum five years service life.
3.1.3 SINGLE PIPE (GRAVITY) SYSTEM -
(REFER TO FIGURE 3-1)
Head A (m) Maximum pipe run (m)
10 mm OD pipe 12 mm OD pipe
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
If the storage tank outlet is at least 300 mm above the level of the
level of the burner oil pump, a single pipe (gravity) system should
be used.
The maximum height of the oil level above the burner oil pump
when the tank is full, must not exceed four metres. If this height
isexceeded,apressurereducingvalvemustbettedintheoil
supply pipe between the tank and the burner oil pump.
The maximum length of pipe run from the tank to the burner is
limited by the minimum head of oil (the height of the tank tank
outlet above the burner oil pump).
3.1.4 TWO PIPE SYSTEM -
(REFER TO FIGURE 3-2)
Head A (m) Maximum pipe run (m)
10 mm OD pipe 12 mm OD pipe
0 35 100
0.5 30 100
1.0 25 100
1.5 20 90
2.0 15 70
3.0 8 30
3.5 6 20
If the storage tank outlet is below the level of the burner oil pump,
a two pipe (sub gravity) system can be used.
The return pipe should be at the same level as the tank outlet,
between 75 to 100 mm above the base of the tank. The return
pipeshouldbeasufcientdistancefromthetankoutletsoasto
prevent any sediment disturbed by the return entering the supply
pipe from the tank.
Anon-returnvalveshouldbettedinthesupplypipe,alongwith
arevalveandlters(refertosection3.1.2-fuelpipes).Anon-
returnvalveshouldalsobettedinthereturnpipeifthetopofthe
tank is above the burner oil pump.
The maximum suction height (from the tank outlet to the level of
the burner oil pump), must not exceed 3.5 metres.
The pump vacuum should not exceed 0.4 bar. Beyond this limit,
gas is released from the oil.
Section 3: Oil Storage and Supply SystemPage 10
3 OIL STORAGE AND SUPPLY SYSTEM

Section 3: Oil Storage and Supply System Page 11
Figure 3-1: Single pipe (gravity) system
Figure 3-2: Two pipe system
Figure 3-3: De-aeration device system
1
23
2
6
12
9
7
4
8
5
10
3.5m Max
150mm
10
1
2
3
2
6
12
9
7
4
8
5
4m Max
300mm
Min
Min
123
2
6
12
9
7
4
8
5
11
3.5m Max
10
Key to oil supply diagrams
1 Oil tank 5 External wall 9 Burner
2 Isolating valve 6 Oillter(15μmmax.ltrationsize) 10 Non-return valve
3 Oil strainer 7 Fire valve sensor 11 De-aerator*
4 Fire valve to BS5410 8 Oil pump 12 Appliance isolation valves
* Position of de-aeration device must be level with or above the oil pump

Section 3: Oil Storage and Supply SystemPage 12
For guidance on the installation of top outlet fuel tanks and
suction oil supply pipe sizing, refer to OFTEC Technical Book 3:
Storage and Supply, available for purchase from OFTEC.
If a two-pipe system is to be used, the following additional items
will be required:
• Flexiblefuelhose⅜ʺmalex¼ʺfemale,900mmlong
(product code: RBS36)
• ⅜ʺx¼ʺBSPadaptor(productcode:RBS35)
• ¼ʺisolatingvalve(productcode:ISOLATION1/4)
These are available to purchase from Grant UK.
3.1.5 SINGLE PIPE (SUCTION) SYSTEM WITH
DEAERATOR - (REFER TO FIGURE 3-3)
If the storage tank outlet is below the level of the burner oil pump,
an alternative to the two pipe (sub gravity) system is the single
pipe (suction) system using a deaerator, e.g. a ‘Tiger Loop’
device.
The deaerator creates a loop with the burner oil pump, with the oil
being circulated through the pump out to the deaerator and back
to the pump. Any air in the single pipe lift from the tank is removed
from the oil, collected in the deaerator and then discharged to
outside.
! WARNING !
To prevent any fuel vapour being discharged within
the building, the deaerator must be tted outside, in
accordance with BS 5410-1, unless it is specically
designed to be installed inside.
The de-aerator must be mounted vertically at the same level as
(or above) the burner oil pump. Refer to Figure 3-3.
1/4" BSP female
connections
Tiger Loop
SUPPLY
TO PUMP
RETURN
FROM PUMP
SUPPLY
FROM TANK
Figure 3-4: Tiger loop de-aeration device
Anexternaldeaeratormustnotbettedwithin500mmofaue
terminal.
Always follow the manufacturers installation instructions supplied
with the deaerator.
To use a de-aertor, the following additional items will be required:
• Flexiblefuelhose⅜ʺmalex¼ʺfemale,900mmlong
(product code: RBS36)
• ⅜ʺx¼ʺBSPadaptor(productcode:RBS35)
• ¼ʺisolatingvalve(productcode:ISOLATION1/4)
These are available to purchase from Grant UK.
3.2 BURNER OIL CONNECTION
! WARNING !
The blanking plug supplied in the inlet (suction) port is
plastic and will not provide an oil tight seal when the pump
is running.
Ensure that the supply from the tank is connected to this
port and that the plastic plug is discarded.
The burner fuel pump is supplied factory set for use with a single
pipe (gravity) oil supply system.
For ease of access to the burner oil pump connections, the burner
should be removed from the boiler as follows:
1. Remove the red plastic burner cover.
• 15/21, 21/26, 26/35 and 36/46 models:
Unscrew and remove the TWO fixing screws from the
red burner cover and remove the cover from the burner.
• 46/58 and 58/70 models:
Unscrew and remove the THREE fixing screws from the
red burner cover and remove the cover from the burner.
2. Unscrew and remove the single burner fixing nut from the
stud on the burner flange (at the top of the burner) using a 13
mm spanner. Retain the fixing nut for re-fitting the burner.
3. Carefully withdraw the burner from the boiler.
3.2.1 SINGLE PIPE (GRAVITY) CONNECTION -
REFER TO FIGURE 3-5
Connect the oil supply to the burner oil pump as follows:
1. Unscrew and remove the plastic blanking plug from the
suction port of the burner oil pump and discard it.
2. Fitthenutoftheelbowconnectionontheexiblefuelhose
(supplied with the boiler) into the suction port and tighten.
3. Fitthe¼ʺisolatingvalve(suppliedwiththeboiler)totheend
oftherigidoilsupplypipeusingattingtosuitthepipesize
and type (not supplied).
4. Connecttheotherendoftheexiblefuelhosetotheisolating
valveusingthe⅜ʺx¼ʺBSPadaptor(suppliedwiththe
boiler).
5. Re-ttheburnertotheboiler.RefertoSection3.3.
2
1
3
4
5
6
7
8
Figure 3-5: Riello RDB pump
Figure 3-6: Key to Riello RDB pump
Item Description
1 Inlet (suction) port
2 Return port
3 By-pass screw
4 Pressure gauge port
5 Pressure adjustment
6 Vacuum gauge port
7 Solenoid
8 Auxiliary pressure test point

3.3 FITTING THE BURNER
With all Grant Boiler House models, the burner and boiler are
supplied together but in separate cartons.
Fit the burner to the boiler as follows:
1. Removeandretainthexingnutfromthestudontheburner
angeonthefrontoftheboiler.
• Leave the small nut in position on the threaded stud.
Check that this nut is fully tightened against the burner
mountingange.
• Donotremovetheburnermountingangefromthe
boiler.
2. Check that the ‘O’ ring around the collar of the burner
combustion head is in position.
3. Fit the burner on the boiler by sliding the combustion head
intotheholeinthecentreofthemountingange.Locatethe
xinglug(onthetopoftheburner)ontothexingstud.
4. With the burner level and correctly located into the mounting
ange,tthenut(previouslyremoved)ontothexingstud
and tighten to secure using a 13 mm spanner.
MAIN BURNER COMPONENTS
Figure 3-9: Key to Riello RDB burner components
Item Description
1 Reset button with lock-out lamp
2 Photoresistance
3 Snorkel (BF)
4 Blast tube
5 Control box
6 Pump pressure adjustment screw
7 Pressure gauge connection
8 Oil pump
9 Flange with gasket (do not remove from boiler)
10 Air damper adjustment screw
Section 3: Oil Storage and Supply System Page 13
8
9
3
10
5
1
6
7
2
4
Figure 3-7: Riello RDB burner components (15/21, 21/26, 26/35 and 36/46kW)
8
9
3
10
5
1
6
7
24
Figure 3-8: Riello RDB burner components (46/58 and 58/70kW)
3.2.2 TWO PIPE CONNECTION
For either a two pipe (sub gravity) or a single pipe (suction)
system with a deaerator, the following additional items will be
required:
• Flexiblefuelhose⅜ʺmalex¼ʺfemale,900mmlong
(product code: RBS36)
• ⅜ʺx¼ʺBSPadaptor(productcode:RBS35)
• ¼ʺisolatingvalve(productcode:ISOLATION1/4)
These are available to purchase from Grant UK.
Connect the oil supply to the burner oil pump as follows:
1. Fittheexiblefuelhose(suppliedwiththeboiler)tothe
suction port of the burner oil pump, as detailed in Section
3.2.1.
With either a two pipe (sub gravity) system or a single pipe
(suction) system with a deaerator, the by-pass screw (supplied
withtheboiler)mustbettedtotheburneroilpumpasfollows:
1. Unscrew and remove the blanking plug from the return port
on the burner oil pump and discard it.
2. Fit the by-pass screw into the threaded hole (inside the return
port) and fully screw it in using an allen key.
3. Fitthenutoftheelbowconnectionontheexiblefuelhose
into the return port and tighten.
4. Fitthe¼ʺisolatingvalve(notsupplied)totheendoftherigid
oilreturnpipe(tothedeaeratororoiltank)usingattingto
suit the pipe size and type (not supplied).
5. Connecttheotherendoftheexiblefuelhose(notsupplied)
totheisolatingvalveusinga⅜ʺx¼ʺBSPadaptor(not
supplied).
6. Re-ttheburnertotheboiler.RefertoSection3.3.

Section 4: Boiler Installation InformationPage 14
4.1 INTRODUCTION
GrantVortexBoilerHousemodelsaresuppliedintwocartons;
one containing the boiler and the other the burner, condensate
drain trap and dual thermostat (15/21, 21/26, 26/35 and 36/46
only).Thedualthermostatisfactoryttedtotheboilersonthe
46/58and58/70models.Theowpipeandpushtconnectorare
supplied with the 36/46 model (under the removable cover).
4.2 BOILER LOCATION
Theboilermuststandonarm,levelandnon-combustible
surface capable of supporting the boiler when full of water. Refer
to Section 2.1 for weights.
Sufcientclearancemustbeallowedatthefrontoftheboilerto
removetheburnerandbafesforservicing.
4.3 REGULATIONS COMPLIANCE
! NOTE !
Failure to install and commission appliances correctly may
invalidate the boiler guarantee.
Installation of a Grant Vortex boiler must be in accordance with
the following recommendations:
• Building Regulations for England and Wales, 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.
• National Building Regulations and any local Byelaws.
• Model Byelaws and the Water Supply Regulations.
• The following OFTEC requirements:
• OFS T100 Polythene oil storage tanks for distillate fuels.
• OFS T200 Fuel oil storage tanks and tank bunds for use
with distillate fuels, lubrication oils and waste oils.
Further information may be obtained from the
OFTEC Technical Book 3 (Installation requirements
for oil storage tanks) and OFTEC Technical Book 4
(Installationrequirementsforoilredboilers).
The installation should also be in accordance with the latest
edition of the following British Standard Codes of Practice (and
any relevant amendments):
• BS5410-1(Codeofpracticeforoilring.Installationsup
to 45 kW output capacity for space heating and hot water
supply purposes)
• BS EN 12828 (Heating systems in buildings. Design for
water-based heating systems)
• BS EN 12831-1 (Energy performance of buildings. Method
for calculation of the design heat load)
• BS EN 14336 (Heating systems in buildings. Installation and
commissioning of water based heating systems)
• BS 7593 (Code of Practice for treatment of water in domestic
hot water central heating systems)
• BS 7671 (Requirements for Electrical installations, IET Wiring
Regulations)
• BS7291(Thermoplasticspipeandttingsystemsforhotand
cold water for domestic purposes and heating installations in
buildings. General requirements)
• BS 7074-1 (Application, selection and installation of
expansion vessels and ancillary equipment for sealed water
systems. Code of practice for domestic heating and hot water
supply)
• BS 2869 (Fuel oils for agricultural, domestic and industrial
enginesandboilers.Specication)
4.4 HEATING SYSTEM DESIGN
CONSIDERATIONS
! WARNING !
Before starting any work on the boiler or fuel supply,
please read the Health and Safety information given in
Section 15.
ToachievethemaximumefciencypossiblefromtheGrantVortex
boiler, the heating system should be designed to the following
parameters:
RADIATORS:
• Flow temperature 70°C
• Return temperature 50°C
• Differential 20°C
Size radiators with a mean water temperature of 60°C.
Design system controls with programmable room thermostats
or use weather compensating controls to maintain return
temperatures below 55°C.
! NOTE !
The boiler should not be allowed to operate with return
temperatures of less than 40°C when the system is up to
temperature.
The use of a pipe thermostat is recommended to control the return
temperature when using weather compensating controls.
UNDERFLOOR:
• Flow temperature 50°C
• Return temperature 40°C
• Differential 10°C
Inunderoorsystems,itisessentialthatthereturntemperature
must be maintained at or above 40°C to prevent internal corrosion
of the boiler water ‘primary’ jacket.
Refer to Section 2.5 for the size and type of the connections and
Section 5 for the position of the connections.
OPEN VENTED SYSTEMS:
! NOTE !
The presence of ‘pumping over’ in an open vented heating
system connected to the Grant Vortex boiler will invalidate
the product guarantee.
Open vented systems must be correctly designed and installed.
The open safety vent pipe must be positioned to prevent ‘pumping
over’ (i.e. the discharge of water from the open safety vent pipe
into the feed and expansion cistern under the pressure created
by the circulator).For detailed information on the correct design of
open vented heating systems, and the correct location of the open
safety vent pipe, refer to the CIBSE Domestic Heating Design
Guide and OFTEC Technical Book 4 (Installation).
4 BOILER INSTALLATION INFORMATION

Section 4: Boiler Installation Information Page 15
4.5 PIPEWORK MATERIALS
The Grant Vortex boiler is compatible with both copper and plastic
pipe. Where plastic pipe is used it must be of the oxygen barrier
type and be the correct class (to BS 7291-1) for the application
concerned.
Oneithersealedoropen-ventedsystems;whereplasticpipeis
used a minimum of ONE metre of copper pipe (or as per pipe
manufacturers instructions) MUST be connected between both
theboilerowandreturnconnectionsandtheplasticpipe.
! NOTE !
Do not connect plastic pipe directly to the boiler.
Grant UK does not accept any responsibility for any damage,
howevercaused,toplasticpipingorttings.
SEALED SYSTEMS
If plastic pipe is to be used, the installer must check with the
plastic pipe manufacturer that the pipe to be used is suitable for
the temperature and pressures concerned.
Plastic pipe must be Class S to BS 7291-1.
! WARNING !
When plastic pipe is used, the system MUST incorporate
a low level pressure switch to shut off power to the boiler
if the system pressure drops below 0.2 bar. A suitable low
pressure switch kit is available to purchase from Grant UK
(product code: MPCBS62).
UNDERFLOOR PIPEWORK
Plasticpipemaybeusedonunderooroorsystemswherethe
plasticpipeisttedafterthethermostaticmixingvalve.Copper
tubemustbeusedforatleasttherstmetreofowandreturn
primarypipeworkbetweentheboilerandtheunderoormixing/
blending valves.
4.6 CONNECTIONS
4.6.1 FLOW AND RETURN CONNECTIONS
Refer to Section 5.
4.6.2 CONDENSATE CONNECTION
The condensate trap is supplied loose in the burner box and
needstobettedasshowninFigure6-2.
Refer to Section 6 for details of the condensate disposal pipework.
4.6.3 DRAIN COCK
A drain cock is supplied in the accessories pack and should be
ttedatthebottomonthefrontoftheboilertoallowtheboilerto
be drained.
To enable draining of the system, a suitable drain cock must be
ttedatthelowestpointoftheheatingsystem.
4.7 PREPARATION FOR
INSTALLATION
1. Grant Vortex Boiler House models are supplied in two
separatecartons;onecontainingtheboilerandtheother
containing the burner and condensate drain trap. The dual
thermostat (15/21, 21/26, 26/35, 36/46 models) are also
included with the burner.
Thedualthermostatisfactoryttedonthe46/58and58/70
models.
Theowpipeandpushtconnectoraresuppliedwiththe
36/46 model (under the removable cover).
2. Carefully remove the packaging from the boiler and unpack
the carton containing the remaining items.
4.8 INSTALLING THE BOILER
1. Having decided upon the position of the boiler and type of
ue,preparethewallasdescribedinSection9.Ensure
thattheueterminalpositioncomplieswiththenecessary
clearances.
2. Make the water connections as described in Section 5. If
access will be restricted, make any connections to the boiler
beforeplacingitinitsnalposition.RefertoSection7ifthe
boiler is to be used on a sealed system.
! NOTE !
If using a balanced ue system - install the balanced ue
system before connecting the heating system pipework to
the boiler. Once the ue system is tted then complete the
water connections and ll the heating system.
3. Ensure the requirements are met for the disposal of
condensate as described in Section 6.
4. Connect the power supply as described in Section 8.
5. Connecttheueandensurethereisanadequateairsupply
as described in Section 9.
4.9 BEFORE YOU COMMISSION
To avoid the danger of dirt and foreign matter entering the boiler
thecompleteheatingsystemshouldbethoroughlyushed
out – both before the boiler is connected and then again after
the system has been heated and is still hot. This is especially
important where the boiler is to be installed on an older system.
For optimum performance after installation, the boiler and the
associatedheatingsystemmustbeushedinaccordancewith
the guidelines given in BS 7593 (Treatment of water in domestic
hot water central heating systems). This must involve the use
of a proprietary cleaner, such as Sentinel X300 (new systems),
Sentinel X400 (existing systems), or Fernox Restorer.
After cleaning, it is vitally important that all traces of the cleaner
arethoroughlyushedfromthesystem.
For long term protection against corrosion and scale, after
cleaning/ushingasuitableinhibitorshouldbeaddedtothe
system water, such as Sentinel X100 or Fernox MB-1, in
accordance with the manufacturers’ instructions.
Failure to follow the above will invalidate the guarantee.
If the boiler is installed in a garage or out house, in order to
provide further protection should there be a power failure in cold
weather, a combined anti-freeze and corrosion inhibitor can
be used such as Sentinel X500 or Fernox Alphi-11. Follow the
manufacturers’ instructions supplied to achieve the level of anti-
freeze protection required.
For details of the Sentinel Products visit www.sentinel-solutions.
net and for Fernox products visit www.fernox.com.
Grant UK strongly recommends that a Grant Mag One in-line
magneticlter/s(orequivalent*)isttedintheheatingsystem
pipework. This should be installed and regularly serviced in
accordancewiththeltermanufacturer’sinstructions.
*Asmeasuredbygauss.TheMagOnemagneticlterhasagauss
value of 12000.
4.10 COMPLETION
Following installation of the boiler, instruct the user in the
operation of the boiler, the boiler controls, the heating controls and
the safety devices.
Please ensure that the OFTEC CD/10 installation completion
report (provided with the boiler) is completed in full, leaving the
top copy with the user and retain the carbon copy for your own
records.
Ensure that the User Handbook (supplied with the boiler) is
handed over to the user.

5.1 GENERAL
Theowandreturnpipeworkcanberoutedtoeithersideofthe
boiler,dependantonthetypeanddirectionoftheuesystem
used.
For condensate disposal pipework refer to Section 6.
A drain cock is supplied in the accessories pack and should be
ttedatthebottomonthefrontoftheboilertoallowtheboilerto
be drained.
Key to diagrams
Key
F Flow
FP Flow pipe
FC Flow connection
R Return
MB Mounting bracket
DS Dual stat
CP Removable cover plate
P Pockets
SP Split pin
5.2 15/21, 21/26 AND 26/35 MODELS
FLOW CONNECTION
A1ʺBSPsocketisprovidedfortheboilerowconnection.Thisis
located on the top of the boiler towards the right hand side. Refer
to Figure 5-1.
Theowpipefromtheboilerwillneedtobeventedasitisthe
highest point on the primary heat exchanger.
RETURN CONNECTION
Asecond1ʺBSPsocketisprovidedfortheboilerreturn
connection. This is located on the top of the boiler towards the
front on the right hand side. Refer to Figure 5-1.
The return pipe to the boiler will also need to be vented as it is the
highest point on the secondary heat exchanger.
Figure 5-1: 15/21, 21/26 and 26/35 models - dual stat/mounting
bracket,owandreturnconnectionsandremovablecoverplate
5.3 36/46 MODEL ONLY
FLOW CONNECTION
A28mmcompressionconnectionissuppliedfortheboilerow
connection. This is located on the right hand side of the boiler
behind a removable cover plate. To gain access to the connection,
unscrewandremovethetwoscrewsfromthetopangeofthe
cover plate and remove cover plate from boiler. Refer to Figure
5-2.
Figure 5-2:36/46model-dualstat/mountingbracket,owand
return connections and removable cover plate
Abent28mmowpipe,withtwothermostatpockets,issupplied
withtheboilertobettedintotheowconnection,asfollows:
1. With the cover plate removed, loosen the compression nut
andtthelongerlegofthebentowpipeintotheconnection.
2. Ensure that the pipe is vertical and fully pushed into the
connection.
3. Withtheopenendoftheowpipepointingintherequired
direction (see below), fully tighten the compression nut. Refer
to Figure 5-3.
4. Replace cover plate and secure with the two screws
previously removed.
Figure 5-3:36/46model-owpipetted(coverplateremoved)
Thedirectionofthebentowpipewilldependontheuesystem
being used with the boiler.
IfaGrantlowlevelbalancedue(YellowSystem)orexternal
balanceduesystem(GreenSystem)isused,theowpipemust
be positioned as follows:
• Iftheuepointstowardstherightoftheboiler(viewedfrom
thefront),theowpipemustbesettopointeithertotheright
ortothefrontoftheboilertoavoidclashingwiththeue.
• Iftheuepointstowardstherearoftheboiler,theowpipe
must be set to point either to the rear, to the right or to the
frontoftheboilertoavoidclashingwiththeue.
• Iftheuepointstowardstheleftoftheboiler(viewedfrom
thefront),theowpipemustbesettopointeithertotherear,
to the right or to the front of the boiler to avoid clashing with
theue.
Section 5: Pipe ConnectionsPage 16
5 PIPE CONNECTIONS

A28mmpush-tstraightconnectorisprovidedformakingthe
connectiontotheopenendofthebentowpipe.
Theowpipefromtheboilerwillneedtobeventedasitisthe
highest point on the primary heat exchanger.
! NOTE !
The pipe to be tted into the push-t connector provided
should be cut using a pipe slicer or pipe cutter, to leave the
end with a slight radius and free from any burrs or sharp
edges. It must NOT be cut using a hacksaw.
RETURN CONNECTION
A1”BSPsocketisprovidedfortheboilerreturnconnection.This
is located on the top of the boiler towards the front on the right
hand side. Refer to Figure 5-2.
The return pipe to the boiler will also need to be vented as it is the
highest point on the secondary heat exchanger.
5.4 46/58 AND 58/70 MODELS
FLOW CONNECTION
A1¼ʺBSPsocketisprovidedfortheboilerowconnection.This
is located in the right hand side of the boiler. Refer to Figure 5-4.
Theowpipefromtheboilerwillneedtobeventedasitisthe
highest point on the primary heat exchanger.
Figure 5-4:46/58and58/70models-dualstatandowand
return connections
RETURN CONNECTION
Asecond1¼ʺBSPsocketisprovidedfortheboilerreturn
connection. This is located on the top of the boiler towards the
front on the right hand side. Refer to Figure 5-4.
The return pipe to the boiler will also need to be vented as it is the
highest point on the secondary heat exchanger.
5.5 FITTING THE DUAL THERMOSTAT
Refer to Section 8 for the dual thermostat electrical connection
details.
Thedualthermostatissuppliedfactoryttedonthe46/58and
58/70 Vortex Boiler House models. Refer to Figure 5-4.
On all other models the dual thermostat is supplied on a mounting
bracketforttingontotheboilercasingbytheinstalleronsite.It
is to be located on the top of the boiler, at the front, towards the
right hand side. Refer to Figures 5-1 and 5-2.
Totthedualthermostat/mountingbracket:
1. Unscrewandremovethetwoxingscrewsfromthetopof
the boiler casing.
2. Position the dual thermostat/mounting bracket such that the
twoholesintheangealignwiththetwoxingholesinthe
top of the boiler casing.
3. Secure the dual thermostat/mounting bracket using the two
xingscrewspreviouslyremoved.
15/21, 21/26 AND 26/35 MODELS
Totthedualthermostatcapillaryphialsintotheirpocketsonthe
boiler:
1. Remove the cover plate located at the top of the boiler right
hand side panel.
To do this, unscrew and remove the two screws from the top
angeofthecoverplateandremoveitfromtheboiler.Refer
to Figure 5-5.
Figure 5-5: 15/21, 21/26 and 26/35 models - cover plate
(removed) and dual stat pockets
2. Unwind the thermostat capillaries taking care not to kink or
break them.
3. Locate the two capillary phials in the two pockets on the side
of the boiler, ensuring that the capillaries pass through the
small cut-out in the top casing panel.
4. Retthecoverplateandsecureinpositionusingthetwo
xingscrewspreviouslyremoved.
36/46 MODEL
On this model the two pockets for the dual thermostat capillary
phialsarelocatedonthebentowpipettedintotheboilerow
connection. Refer to Section 5.3.
1. Unwind the thermostat capillaries taking care not to kink or
break them.
2. Locate the two capillary phials in the two pockets on the side
oftheowpipe.
3. Securebothphialsinplacebyttingthesplitpinprovided
through the small holes at the top of the phial pockets. Refer
to Figure 5-6.
Figure 5-6:36/46model-dualstatphialsttedinpockets
Section 5: Pipe Connections Page 17

6.1 GENERAL REQUIREMENTS
When in condensing mode the Grant Vortex boilers produce
condensatefromthewatervapourintheuegases.
This condensate is moderately acidic with a pH value of around
3.27 (similar to orange juice).
Provision must be made for the safe and effective disposal of this
condensate.
Condensate can be disposed of using one of the following
methods of connection:
Internal connection (preferred option)
• into an internal domestic waste system (from kitchen sink,
washing machine, etc.)
• directly into the soil stack
External connection
• into an external soil stack
• into an external drain or gulley
• into a rainwater hopper (that is part of a combined system
where sewer carries both rainwater and foul water)
• purpose made soakaway
All condensate disposal pipes mustbettedwithatrap-whether
they are connected internally or externally to a domestic waste
system/soil stack or run externally to a gully, hopper or soakaway.
6.2 CONNECTIONS
Connections into a rainwater hopper, external drain or gulley
should be terminated inside the hopper/drain/gulley below the grid
level but above the water level.
! CAUTION !
Condensate disposal pipes must not be connected
directly into rainwater downpipes or to waste/soil systems
connected to septic tanks.
Condensate should not be discharged into ‘grey water’ systems
that re-use water used in the home (not including water from
toilets).
It should be noted that connection of a condensate pipe to the
drain may be subject to local Building Control requirements.
6.3 PIPEWORK
Condensate disposal pipework must be plastic (plastic waste or
overowpipeissuitable).
! NOTE !
Copper or steel pipe is NOT suitable and MUST NOT be
used.
Condensate disposal pipes should have a minimum ‘nominal’
diameterof22mm(¾ʺ)-e.g.use21.5mmODpolypropylene
overowpipe.
Condensatedisposalpipesmustbettedwithafall(awayfrom
the boiler) of at least 2.5° (~45 mm fall per metre run).
! NOTE !
Where it is not possible for the pipe to fall towards the
point of discharge - either internally into a waste system
or externally to a gulley (e.g. for boilers installed in a
basement), it will be necessary to use a condensate pump.
Condensate disposal pipes should be kept as short as possible
and the number of bends kept to a minimum.
Pipesshouldbeadequatelyxedtopreventsagging,i.e.atno
more than 0.5 metre intervals.
6.4 EXTERNAL PIPEWORK
Ideally, external pipework, or pipework in unheated areas, should
be avoided. If unavoidable, external pipework should be kept as
short as possible (less than 3 metres) and 32 mm waste pipe
used to minimise the risk of ice blocking the pipe in freezing
conditions.
Thenumberofbends,ttingsandjointsonexternalpipesshould
be kept to a minimum to reduce the risk of trapping condensate.
! NOTE !
For boilers installed in an unheated area such as a loft,
basement, outhouse or garage, all condensate pipework
should be as ‘external’.
The pipework should be insulated using suitable
waterproof and weather resistant insulation.
Section 6: Condensate DisposalPage 18
Ground level
32 mm waste pipe external to the building
Minimum 2.5 fall
O
25 mm
300 mm
400 mm
min.
Two rows of 3 x 12 mm
holes at 25 mm centres
and 50 mm from the bottom
of the tube. Holes facing
away from the property.
Cement seal
100 mm plastic tube Sealed end Backfill with 10 mm
limestone chippings
Figure 6-1: Purpose made condensate soakaway
6 CONDENSATE DISPOSAL

6.5 CONDENSATE SOAKAWAY
To keep external pipework to a minimum, locate the soakaway
as close as possible to the boiler but ensure it is at least 500 mm
from building foundations and away from other services, e.g. gas,
electricity, etc.
The condensate pipe may be run above or below ground level
and can enter either the top or side of the soakaway tube. Refer
to Figure 6-1.
Ensure that the drainage holes in the soakaway tube face away
from the building.
Backllboththesoakawaytube,andtheholearoundit,with10
mm limestone chippings.
Only use a soakaway where the soil is porous and drains easily.
Do not use in clay soils or where the soil is poorly drained.
! CAUTION !
Any damage due to condensate backing up into the boiler
due to a high water table, in the case of a soakaway, or
ooded drains when the condensate disposal is via a
gulley or soil stack, is not covered by the Grant product
guarantee.
6.6 CONDENSATE TRAP
Grant Vortex boilers are supplied with a condensate trap to
provide the required 75 mm water seal in the condensate
discharge pipe from the boiler.
The condensate trap for the Boiler House models is supplied
looseintheburnerboxandneedstobettedasshowninFigure
6-2.
Thistrapincorporatesaoat(whichwillcreateasealwhenthe
trapisempty)andanoverowwarningoutlet(ttedwithaplastic
sealing cap), see Figure 6-2.
Aexiblehoseconnectstheoutletofthecondensingheat
exchanger to the trap inlet. Ensure the elbow connector on the
hose is fully pushed onto the ‘top hat’ inlet connector of the trap.
If connecting the condensate discharge (either internally or
externally) into a waste system or soil stack - the sealing cap must
bettedinthetrapoutlet.
On external discharge systems to a hopper, gully or soakaway,
the sealing cap should be removed from the trap outlet.
Ifthereisanydischargeofcondensatefromtheoverowoutlet,
this could indicate a blockage (possibly due to freezing). Turn off
the boiler and investigate the cause. If necessary contact your
service engineer for assistance.
Careshouldbetakenwhensitingthetrapsuchthattheoverow
outletisreadilyvisibleandthatanycondensateoverowingfrom
the outlet cannot cause either a hazard to persons or damage to
surrounding property or equipment.
The condensate trap outlet is at an angle of 48° below the
horizontal. This is to automatically give a 3° fall on any ‘horizontal’
runs of condensate disposal pipe. Refer to Figure 6-2.
6.7 CONDENSATE DISPOSAL
PIPEWORK
The outlet of the trap will accept 21.5 mm to 23 mm OD
Polypropyleneoverowpipeforthecondensatedischargepipe.
! NOTE !
When connecting plastic discharge pipe, ensure that the
pipe is fully pushed into the outlet end on the exible hose
to prevent the possibility of leakage.
6.8 INSPECTION AND CLEANING OF
TRAP
The trap must be checked at regular intervals (e.g. on every
annual service) and cleaned as necessary to ensure that it is clear
and able to operate.
The bottom bowl can be unscrewed from the trap body for
inspection and cleaning.
To inspect and clean the trap:
1. Disconnectexiblecondensatehosefrominletconnector.
2. Unscrew the inlet connection nut.
3. Remove the inlet connector and nut from trap.
4. Remove trap from bracket.
5. Removeoatfromtrap–cleanifnecessary.
6. Inspect inside of trap and clean as necessary.
7. Re-assembletrap,re-ttoboilerandre-connectexible
hose. Ensure that hose is fully pushed onto the trap inlet
connector.
! CAUTION !
Failure to regularly check and clean the condensate trap
may result in damage to the boiler and will not be covered
by the product guarantee.
Section 6: Condensate Disposal Page 19
Condensate
drain from boiler
Minimum 2.5° fall
Overflow warning
outlet (with cap)
Condensate trap
Condensate
outlet to drain
Wall bracket
Figure 6-2: Condensate trap

Section 7: Sealed SystemsPage 20
All Grant Vortex Boiler House models are suitable for use with
sealed systems complying with the requirements of BS EN 12828,
BS EN 12831 and BS EN 14336.
The system must be provided with the following items:
• Diaphragm expansion vessel complying with BS EN 13831
• Pressure gauge
• Pressure relief (safety) valve
• Approvedmethodforllingthesystem
7.1.1 EXPANSION VESSEL
Theexpansionvesselshouldbettedinthereturnpipework
as shown in Figure 7-2. To reduce the operating temperature
of the expansion vessel, position it below the pipe to which it is
connected.
The expansion vessel may be positioned away from the system,
providing the connecting pipe is not less than 13 mm diameter. If
theexpansionvesselisconnectedviaaexiblehose,caremust
be taken to ensure that the hose is not twisted or kinked.
7.1 SEALED SYSTEM
REQUIREMENTS
Figure 7-1: Key to sealed system diagram
Key
1 Expansion vessel
2 Pressure gauge
3 Pressure relief valve
4 Tundish
5Removablellingloop
6 Double check valve
7 Automatic air vent
8 Thermostatic radiator valve
9 Automatic bypass
10 Drain point
Static head of system


  
 


Figure 7-2: Sealed system
7 SEALED SYSTEMS
Highest point of primary circuit
Centre of expansion vessel