Grant Vortex 15/26 Manual

USER, INSTALLATION
and
SERVICING INSTRUCTIONS
GRANT VORTEX
Condensing Oil Boiler range
For use with Kerosene only
Part No. DOC 37 Rev. 12 September 2006
Kitchen, Kitchen System,
Utility and Utility System Models
with outputs up to 70 kW
Utilitymodel
Kitchen model
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

2Grant Vortex Oil Boilers
Subject PageSection
1 Introduction.............................................. 3
2 User instructions ...................................... 4
3 Boiler technical information .................... 7
4 General boiler information....................... 11
5 Boiler installation..................................... 28
6 Commissioning......................................... 34
7 Information for the user ........................... 36
8 Boiler servicing ........................................ 36
9 Wiring diagrams....................................... 40
10 Fault finding ............................................. 43
11 Burner spares ........................................... 45
12 Health and safety information.................. 47
13 EC declaration of conformity .................. 48
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 in the Boiler
Handbook by the service engineer.
COMMISSIONING REPORT
SERVICE LOG
LIST OF CONTENTS

3
Grant Vortex Oil Boilers
During the combustion process, hydrogen and oxygen
combine to produce heat and water vapour. The water
vapour produced is in the form of superheated steam in
the heat exchanger. This superheated steam contains
sensible heat (available heat) and latent heat (heat
locked up in the flue gas). A conventional boiler
cannot recover any of the latent heat and this energy is
lost to the atmosphere through the flue.
The Grant Vortex condensing boiler contains an extra
heat exchanger which is designed to recover the latent
heat normally lost by a conventional boiler. It does this
by cooling the flue gases to below 90° C, thus
extracting more sensible heat and some of the latent
heat. This is achieved by cooling the flue gases to their
dew point (approximately 55° C).
To ensure maximum efficiency, the boiler return
temperature should be 55° C or less, this will enable
the latent heat to be condensed out of the flue gases.
The boiler will achieve nett thermal efficiencies of
100%.
To achieve maximum performance from the Grant
Vortex boiler, it is recommended that the heating
system is designed so that a temperature differential of
20° C between the flow and return is maintained. The
use of modulating circulating pumps (now widely
available) and effective control systems should be
considered.
The Grant Vortex boiler will however still operate at
extremely high efficiencies even when it is not in
condensing mode and therefore is suitable for fitting to
an existing heating system without alteration to the
radiator sizes. The boiler is capable of a maximum
flow temperature of 75° C.
How a condensing boiler works
1.1 Heating system design considerations
1.2
To achieve the maximum efficiencies possible from
the Grant Vortex boiler, the heating system should be
designed to the following parameters:
Radiators:-
Flow temperature 70° C
Return temperature 50° C
Differential 20° C
Underfloor:-
Flow temperature 50° C
Return temperature 40° C
Differential 10° C
1 Size radiators with a mean water temperature of
60° C.
2 Design system controls with programmable room
thermostats or use weather compensating controls
to maintain return temperatures below 55° C.
The boiler should not be allowed to operate with
return temperatures of less than 40° C when the
system is up to operating temperature.
3 The use of a pipe stat is recommended to control
the return temperature when using weather
compensating controls.
1 - INTRODUCTION

4Grant Vortex Oil Boilers
2 - USER INSTRUCTIONS
The boiler will provide domestic hot water and central
heatingandisfullyautomaticonceswitchedon.Kitchen
models have a 'mains on' neon, see Fig. A, which lights
when the boiler is switched on, but does not necessarily
indicate the burner is firing.
If your model has a programmer fitted, it will provide
hot water and central heating during the periods set on
the programmer.
Kitchen and Kitchen System: To access the controls,
open the front door from the right (may be altered to
open from the left if required).
Utility and Utility System: Pull off the front access
panel.
Fig. A Boiler controls (Kitchen model shown)
About your boiler
2.1
Boiler controls (see Fig. A)
2.2
1Ensure that - There is sufficient fuel, of the correct
type,inthesupplytankandallfuelsupplyvalves are
open. The water supply is on. The electricity supply
to the boiler is off. The boiler On/Off switch is set to
OFF. The room thermostat (if fitted) is at the desired
setting. The boiler thermostat is set to the required
setting (see Section 2.7).
2 Switch on the electricity supply to the boiler.
3 Set the On/Off switch to ON and, if fitted, the
programmer (CH or HW) to ON.
The boiler will now light automatically.
4 If you have a programmer fitted in the control panel,
refertotheinstructionssuppliedwiththeprogrammer
andsettheprogrammer.SettheHWandCHfunctions
toTIMED.Theboilerwillnowoperateduringthe'on'
periods set on the programmer.
Lighting your boiler (see Fig. A)
2.3

5
Grant Vortex Oil Boilers
For short periods - Set the On/Off to OFF.
To restart, simply set the switch to ON.
For long periods: Set the On/Off switch to OFF and
switch off the electricity supply to the boiler. If
required, the fuel supply valve may be closed and the
water and electricity supplies turned off at the mains.
To restart, refer to the full lighting instructions given
in Section 2.3.
1 Check that the boiler On/Off switch is ON.
2 Check that the programmer (if fitted) is working
and is in an 'on' period.
3 Check that all thermostats are set to the desired
setting and are calling for heat.
4 Check if the burner 'Lock-out' reset button (on the
burner) is lit. If it is, press it to start the burner. If
the burner fails to light and goes to 'Lock-out'
again, check that you have sufficient fuel in the
storage tank and that the fuel supply valve is open.
Checkthat the fire valve in theoilsupply line has not
tripped
5 Ensure that a fuse has not blown or that the
electricity supply has not failed.
6 Check to see if the safety thermostat has operated
(see Section 2.7).
If the burner still fails to light after carrying out these
checks then a fault exists. Switch off the electricity
supply to the boiler and contact your Service engineer.
GrantVortexboilersonlyoperateonClassC2 Kerosene
to BS 2869:1998.
Youshould alwaysquotethis typeoffuel whenordering
from your supplier.
Do not wait until the fuel runs out before you order
some more. Sludge in the bottom of the tank may be
drawn into the fuel lines. If it is possible, switch off the
boiler when the new supply is delivered and leave the
fuel to settle for an hour before restarting the boiler.
2 - USER INSTRUCTIONS
1 Boiler thermostat - This control allows the
temperature of the water leaving the boiler to heat
the radiators and domestic hot water to be adjusted.
Note: If you have a cylinder thermostat on your hot
water cylinder, this will control the temperature of
your domestic hot water. The boiler thermostat
setting must be equal to or above the cylinder
thermostat setting to enable the cylinder thermostat
to control the domestic hot water system.
2 Burner Lock-out reset button - If there is a
burner malfunction, a built-in safety circuit
switches the burner off and the 'Lock-out' reset
button (on the burner) will light. On Kitchen
models a neon on the control panel also indicates a
burner lock-out (see Fig. A). 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
existsor thefuelsupply islow.If youhave sufficient
fuel, you will need to call your Service engineer.
3 Safetythermostat-Yourboilerisfittedwithasafety
overheatthermostat which will automatically switch
off the boiler in the case of a control malfunction
causing overheating. On Kitchen models a neon on
thecontrolpanelwillilluminatetoindicatetheoverheat
thermostat has operated (see Fig. A).
If your boiler goes off and you try to light it but
nothinghappensandthe'Lock-out'resetbuttononthe
burner (or the neon on the control panel) are not lit,
the overheat thermostat has probably operated. The
boiler will not light until the thermostat is reset. To
reset,unscrewthesmallplasticcap(seeFig.A),press
the button then replace the cap.
If this condition continually repeats, contact your
Service engineer.
4 Programmer (if fitted) - Refer to the instructions
supplied with the Programmer.
5 Ventilation - Always ensure that the boiler has
adequate ventilation. Any ventilation openings
provided by the Installer must not be obstructed.
Periodically check that they are clear.
Do not attempt to 'box in' the boiler or build a
compartment around it before consulting your
Installer.
Do not place any combustible material around or
on the boiler or flue pipe.
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 Oil Boilers
6 Flue terminal - The flue terminal on the outside
wall must not be obstructed or damaged.
In severe conditions check that the terminal does
not become blocked by snow.
7 Frost protection - Your Installer may have fitted a
frost thermostat. If not, and you are likely to be
away for a short time, leave the boiler on with the
boiler thermostat set at a low setting. For longer
periods the boiler and system should be drained.
Contact your Service engineer for draining and
filling the system.
8 Cleaning and servicing - Lightly wipe over the
case with a damp cloth and a little detergent. Do
not use abrasive pads or cleaners.
You must have your boiler serviced at least once a
year to ensure safe and efficient operation. Contact
your Service engineer for further details.
9 Failure of electricity supply - If the electricity
supply fails, the boiler will not operate. It should
relight automatically when the supply is restored.
If a programmer is fitted it will retain the time
settings for up to 24 hours and will not have to be
reset to the correct time of day when the supply is
restored (the display remains for up to 1 hour, but
will re-appear when the supply is restored).
The boiler requires a 230/240 V ~ 50 Hz supply. It
must be protected by a 5 Amp fuse.
Warning: This appliance must be earthed.
If your boiler is operating on a sealed heating system,
the installer will have pressurised the system and
should have told you (or set it on the pressure gauge)
the system pressure when cold (this is normally
between 0.5 and 1.0 bar, which will increase slightly
when hot). If the pressure (when cold) is below the set
pressure mentioned above, you can re-pressurise the
system. If the system requires frequent re-pressurising,
ask your Installer or Service engineer to check the
heating system for leaks and to check the expansion
vessel air charge.
2 - USER INSTRUCTIONS
The boiler or system will be fitted with an automatic air
venttoremoveairfromthesystem.Anyairtrappedinthe
radiators should be removed by venting the radiators
usingtheventscrewatthetopofeachradiator.Onlyvent
a radiator if the top is cool and the bottom is hot.
Excessive venting will reduce the system pressure, so
onlyvent whennecessaryand checkthe system pressure
asmentionedabove.Re-pressurisethesystemifnecessary.
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.
When the black needle of the pressure gauge is
between 0.5 and 1 bar, close the valve.
4 Vent each radiator in turn, starting with the lowest
one in the system, to remove air.
5 Continue to fill the system until the pressure gauge
indicates between 0.5 and 1.0 bar. Close the fill
point valve.
6 Repeat steps 4 and 5 as required.
7 Close the valves either side of the filling loop and
disconnect the loop.
Electricity supply
2.8
Sealed central heating system
2.9
Sealed system filling loop arrangement - Fig. B

7
Grant Vortex Oil Boilers
22 mm (only connect 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
¼" BSP Male (on end of flexible fuel line)
Minimum flue draught - 8.7 N/m² (0.035 in wg)
Maximum flue draught - 37 N/m² (0.15 in wg)
2.5 bar
2.5 bar
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
Min. flow rate (ΔT=10°C) l/h
Min. flow rate (ΔT=20°C) l/h
Condensate connection
Flue diameter (conventional)
Waterside resistance
Flow/Return temp. diff. of 10°C
Flow/Return temp. diff. of 20°C
Maximum static head
Minimum circulating head
Boiler thermostat range
Limit (safety) stat shut off temp
Max. hearth temperature
Electricity supply
Motor power Watts
Starting current Amps
Running current Amps
Oil connection
Conventional flue
Max operating press - sealed sys
Max operating press - open sys
*Weight includes burner but excludes flue.
** 125mmdiameterrequiredforflexibleflueliner(Orangesystem).Forrigidfluesystem(e.g.Greensystem)100mm
diameter flue required. Refer to Sections 4.1 and 4.7 for further details.
Kitchen System Utility Utility System
IMPORTANT: On all models except 46/58 and 58/70 Return connections are stainless steel pipe (see above for size).
Compression fitting MUST be used. Brass push-fit connectors are not suitable for use on stainless steel pipe.
Kitchen
90
2.6
0.85
90
4.2
0.85
90
2.6
0.85
150
6.4
1.2
15/26
19
4.2
119
262
26
88 700
22 mm
22 mm
2 200
1 100
15/26
19
4.2
127
280
26
88 700
22 mm
22 mm
2 200
1 100
15/26
19
4.2
112
246
26
88 700
22 mm
22 mm
2 200
1 100
26/36
21
4.7
134
295
36
122 840
28 mm
28 mm
3 000
1 500
36/46
21
4.7
134
295
46
157 000
28 mm
28 mm
4 000
2 000
46/58
50
11
295
649
58
197 896
1¼" BSP
1¼" BSP
5 200
2 600
58/70
50
11
299
658
70
238 840
1¼" BSP
1¼" BSP
6 000
3 000
90
4.2
0.85
26.0 mbar
9.5 mbar
28.5 mbar
10.0 mbar
100 mm (4 in) 100 mm (4 in)
26.0 mbar
9.5 mbar
125 mm (5 in)**
15/26
19
4.2
126.5
278
26
88 700
22 mm
22 mm
2 200
1 100
28.5mbar
10.0mbar
26/36
21
4.7
142
312
36
122 840
28 mm
28 mm
3 000
1 500
36/46
21
4.7
142
312
46
157 000
28 mm
28 mm
4 000
2 000

8Grant Vortex Oil Boilers
Notes:
1 The data given above is approximate only and is based on the boiler being used with a low level balanced flue.
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 When commissioning the air damper must be adjusted to obtain the correct CO2level.
5 * Factory settings.
6 The combustion door test point may be used for CO2and smoke readings only. Do not use this test point for temperature
or efficiency readings.
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, vertical and conventional
flue adaptors.
3. Concentric low level flues do not contain a test point. The temperature and efficiency readings must be taken from the
flue terminal.
3 - BOILER TECHNICAL INFORMATION
Note: Grant Vortex boilers are only for use with kerosene.
Grant Vortex oil boilers using Class C2 kerosene
3.3
(kW)
15.0
20.0
23.0
26.0
26.0
31.5
36.0
36.0
41.5
46.0
46.0
52.0
58.0
58.0
64.0
70.0
(Btu/h)
51 180
68 240
78 475
88 700
88 700
107 500
123 000
123 000
142 000
157 000
156 952
177 424
197 896
197 896
218 368
238 840
Nozzle
0.50/80°EH
0.60/80°EH
0.65/80°EH
0.75/80°EH
0.75/80°EH
0.85/80°EH
1.00/80°EH
1.00/80°EH
1.20/80°S
1.25/80°S
1.25/80°S
1.35/80°S
1.65/80°S
1.65/80°S
1.65/80°S
1.75/80°S
Oil
press.
(bar)
7.0
8.0
8.5
8.0
8.0
9.0
9.1
9.0
8.0
8.0
8.0
9.5
8.0
8.0
9.5
9.5
Smoke
No.
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
0 - 1
Fuel flow
rate
(kg/h)
1.25
1.67
1.94
2.16
2.18
2.57
3.01
3.01
3.56
3.90
4.01
4.47
5.05
5.05
5.58
6.01
Flue gas
temp.
(° C)
60 - 65
65 - 70
70 - 75
75 - 80
65 - 70
70 - 75
75 - 80
75 - 80
80 - 85
85 - 90
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
75 - 80
CO2
(%)
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
Burner
head type
T1
T1
T2
T2
T3
T3
T3
T5
T5
T5
GIB
GIB
GIB
GIB
GIB
GIB
Heat Output
15/26
Riello RDB1
26/36
Riello RDB2
36/46
Riello RDB2.2
46/58
Riello RDB3.2
58/70
Riello RDB3.2
Model and
burner type
*
*
Sealed system data - System models (not 46/58 and 58/70)
3.2
*
Heating system pressure (cold)
Operating pressure of pressure relief valve
Expansion vessel size (15/26)
Expansion vessel size (26/36)
Expansion vessel size (36/46)
Max heating system volume (including boiler) (15/26)*
Max heating system volume (including boiler) (26/36)*
Max heating system volume (including boiler) (36/46)*
Cold water mains connection
Pressure relief valve discharge connection
Maximum 1.0 bar, Minimum 0.5 bar
2.5 bar
10 litres (pre-charged at 1 bar)
12 litres (pre-charged at 1 bar)
16 litres (pre-charged at 1 bar)
106 litres (approximately)
128 litres (approximately)
170 litres (approximately)
15 mm copper pipe
15 mm copper pipe
* Based on vessel charge and system cold fill pressure of 0.5 bar
*
*
SEDBUK
efficiency
(%)
95.0
97.0
92.6
94.1
93.6
Burner
head setting
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
Fixed
0
0
0
0
0
4

9
Grant Vortex Oil Boilers
FRONT VIEW
470
860
LEFT SIDE VIEW
813
759
709
487
587
352
18
17
110
30 Flue centre line
RIGHT SIDE VIEW
631
59
PLAN VIEW
470
603
110
22mm condensate drain
Safety valve
Cold fill
Flow - 22mm push-fit
22mm stainless
return
170
Flue
spigot
3 - BOILER TECHNICAL INFORMATION
Boiler dimensions
3.4
Fig 1a - Kitchen and Kitchen System 15/26 dimensions
Fig. 1b - Utility and Utility System 15/26 dimensions

10 Grant Vortex Oil Boilers
3 - BOILER TECHNICAL INFORMATION
Fig. 1c - Utility and Utility System 26/36 and 36/46 dimensions
Fig. 1d - Utility 46/58 and 58/70 dimensions
Safety valve
Flow - 28mm push-fit
Cold fill
61
170 61
LEFT SIDE VIEW
455
555
599
311
24
115
63 63
Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
470
603
150
22mm condensate drain
FRONT VIEW
470
900
28mm stainless
return
205
Flue
spigot
170
LEFT SIDE VIEW
731
831
1024
25
30
44 Dia.
44 Dia.
109
250
Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
563
786
109
22mm condensate drain
FRONT VIEW
563
1234
225
Flue
spigot
Note: Cover plate on
each side slides
forwards to provide
opening for pipes.