Grant Vortex Pro Installation & Servicing Instructions Manual

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[Page 1] Grant Vortex Pro

Part No. Doc 37 Rev.19 May 2012 D317 Grant Vortex Pro Kitchen/Utility, System and Boiler House Floor Standing Condensing Oil Boiler Range Installation & Servicing Instructions ...

[Page 2] Grant Vortex Pro

2 Commissioning Report Commissioning Report For use with Kerosene* only. After installing the boiler leave these instructions with the User. This appliance is deemed a controlled service and specific regional statutory requirements may be applica...

[Page 3] Grant Vortex Pro

3 1 Introduction 4 1.1 How a condensing boiler works 4 1.2 Boiler description 4 1.3 Boiler components 5 2 Technical Data 6 2.1 Boiler technical data 6 2.2 Sealed system data 6 2.3 Vortex boiler using Class C2 kerosene 7 ...

[Page 4] Grant Vortex Pro

4 This manual is intended to guide engineers in the installation and maintenance of Grant VORTEX Pro boilers. A User guide for the operation of this boiler is attached to the reverse of this manual. The following special text formats are used i...

[Page 5] Grant Vortex Pro

5 White system High level and vertical concentric balanced flue kit- components available: • Extensions 225 mm, 450 mm, 950 mm • Adjustable 275 to 450 mm • Vertical concentric balanced flue kit • Extensions 225 mm, 450 mm,...

[Page 6] Grant Vortex Pro

6 * Weight includes burner but excludes flue. ** 125 mm diameter required for flexible flue liner (Orange system). For rigid flue system (e.g. Green system) 100 mm diameter flue required. Refer to Section 9 Flue System and Air Supply for furt...

[Page 7] Grant Vortex Pro

7 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 Pro boiler range. 4 The net flue gas tempe...

[Page 8] Grant Vortex Pro

8 REAR VIEW 348 21070 140 855 688 760 RIGHT SIDE VIEW 200 19 47 25 125 594 766 805 704 17 R/H flow R/H return L/H flow L/H return LEFT SIDE VIEW 111 566 Flue centre line Alternative condensate drain outlets Alternative condensate drain outlets FRONT ...

[Page 9] Grant Vortex Pro

9 Safety valve Flow - 28mm push-fit Cold fill 61 170 61 LEFT SIDE VIEW 455 555 311 24 115 63 63 Flue centre line RIGHT SIDE VIEW PLAN VIEW 470 603 150 FRONT VIEW 470 900 205 Flue spigot Alternative condensate drain outlets 170 LEFT SIDE VIEW 731 831 ...

[Page 10] Grant Vortex Pro

10 3.1 Fuel Supply Fuel Storage The tank should be positioned in accordance with the recommendations given in BS 5410:1:1997, which gives details of filling, maintenance and protection from fire. A steel tank may be used and must be co...

[Page 11] Grant Vortex Pro

11 Oil Storage & Supply System Figure 3-3: De-aeration device system Figure 3-2: Two pipe system Filter Fire valve Shut-off valve Shut-off valve Shut-off valve See Section 3.2 A Return Supply Head A (m) Maximum pipe run (m) 0 0.5 1.0 1.5 2.0 3.0...

[Page 12] Grant Vortex Pro

12 Tiger Loop system - (See Figures 3-3 and 3-4) When The storage tank outlet is below the burner, an alternative to a two pipe system can be achieved using a 'Tiger Loop' type oil de-aerator. This effectively removes the air from the o...

[Page 13] Grant Vortex Pro

13 Figure 3-6: Riello RDB burner components Main Burner Components It may be necessary to remove the burner from Kitchen/Utility boilers to access connections in the fuel pump. On System models, carefully lift up and remove the expansion vessel fr...

[Page 14] Grant Vortex Pro

14 4.1 Introduction Kitchen/Utility models are supplied fully assembled in a carton. Boiler House models are supplied in two cartons, one containing the boiler and the other the burner and dual thermostat (26/36, 36/46 only). 4.2 Boiler location ...

[Page 15] Grant Vortex Pro

15 4.6 Completion Please ensure that the OFTEC CD/10 installation completion report (provided with the boiler) is completed in full. Leave the top copy with the User. Retain the carbon copy. Ensure that the User Information pack (supplied with the...

[Page 16] Grant Vortex Pro

16 5.1 Water Connections The Flow and Return pipework can be routed to either side of the boiler, dependant on the type and direction of the flue system used. For condensate disposal pipework refer to Section 6. A drain cock is fitted at the bo...

[Page 17] Grant Vortex Pro

17 Pipe Connections Flow pipe Figure 5-3: Fit flow pipe and remove screws Figure 5-4: Remove split pin and fit phials 5.3 Water Connections - Boiler House Models 26/36, 36/46 Flow connection: A 28 mm pipe is provided for the flow connection. Thi...

[Page 18] Grant Vortex Pro

18 6.1 General Requirements When in condensing mode the Grant VORTEX Pro boilers produce condensate from the water vapour in the flue gases. This condensate is slightly acidic with a ph value of around 3 (similar to vinegar). Pro...

[Page 19] Grant Vortex Pro

19 6.6 Condensate Trap Grant VORTEX Pro boilers are supplied with a factory-fitted 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 su...

[Page 20] Grant Vortex Pro

20 6. From the front of boiler, remove the straight connector end of the flexible hose from the top of the condensate trap. 7. Reverse the flexible hose and pass the straight connector end through the new hole in the left hand casing panel. ...

[Page 21] Grant Vortex Pro

21 7.1 Sealed System Installation See Figure 7-1 All Grant VORTEX Pro boilers are suitable for use with sealed systems complying with the requirements of BS 5449. The maximum temperature of the central heating water is 75°C. The system must be p...

[Page 22] Grant Vortex Pro

22 The air pressure in the vessel must be checked annually. The central heating system volume, using the expansion vessel as supplied, must not exceed the recommended value. Refer to Section 2.2. If the system volume is greater, an extra expansi...

[Page 23] Grant Vortex Pro

23 7. Continue to fill the system until the pressure gauge indicates between 0.5 and 1.0 bar. Close the fill point valve. 8. Repeat steps 4 and 5 as required. 9. Close the fill point and double check valves either side of the filling loop ...

[Page 24] Grant Vortex Pro

24 The VORTEX Pro boiler requires a 230/240 V ~ 50 Hz supply. It must be protected by a 5 Amp fuse. Refer to Figures 8-1 to 8-5 for typical control system wiring diagrams for all models. Refer to Figures 8-6 and 8-7 for wiring diagrams for all mo...

[Page 25] Grant Vortex Pro

25 7. Replace the back of control panel and complete the electrical connection procedure from paragraph 2 of Section 8.1. Refer to the User's Operating Instructions provided with the boiler for the operation and setting of ...

[Page 26] Grant Vortex Pro

26 Figure 8-2: Kitchen/Utility models with 2 X 2-port valve control system Electrical L N E 240 V 50 HZ Frost Thermostat Pipe Thermostat (if fitted) Wiring Centre 1 2 3 4 5 6 7 8 9 10 1 3 4 N L Cylinder Stat 1 C Room Stat 2 1 3 Pump E N L 2-port Zone...

[Page 27] Grant Vortex Pro

27 Figure 8-3: System models with 3-port valve control system Cylinder Stat 1 C 2 L N E 240 V 50 Hz Room Stat 2 1 3 3-Port Mid Position Zone Valve Blue Green/Yellow White Grey Orange Frost Thermostat Pipe Thermostat (if fitted) Wiring Centre 1 2 3 4 ...

[Page 28] Grant Vortex Pro

28 8.6 Boiler Control Panel Wiring Diagrams Electrical Figure 8-6: Wiring Diagram - Kitchen/Utility models R R Y G/Y CH OFF N L HW OFF CH ON HW ON Br Bl 2A 4B 1A Br Br 5B 1 Bl G/Y Br C C 2 G/Y Bl BOILER FEED 4321 DHW - ON CENTRAL HEATING 65 97 8 N L ...

[Page 29] Grant Vortex Pro

29 Figure 8-7: Wiring Diagram - System models Electrical Figure 8-8: Dual Thermostat Wiring Diagram - Boiler House models Overheat Thermostat Supply to Burner Mains Supply Control Thermostat L L E E N N Boiler Casing Earth Connector to link Neutral w...

[Page 30] Grant Vortex Pro

30 9.1 Air Supply A sufficient permanent air supply to the boiler should be provided for the following reasons: • For proper combustion of fuel and effective discharge of combustion products to the open air. • For the ventilation of an...

[Page 31] Grant Vortex Pro

31 9.2 Conventional Flue Systems Under no circumstances can Grant VORTEX Pro boilers be installed with existing flue systems. Only flue systems and components suitable for wet flues should be used. Failure to install the correct type of flue...

[Page 32] Grant Vortex Pro

32 Flue Lining Kits Grant EZ-Fit Flexi Pack conventional flue system (Orange System) A range of Flexi pack conventional flue lining kits are available from Grant UK. The packs have been specifically produced for Grant VORTEX oil fired conden...

[Page 33] Grant Vortex Pro

33 Flue System and Air Supply Figure 9-4: Hybrid flue system using Grant Orange and Green system components 9.3 Connecting a Conventional Flue 1 - 4 Kitchen/Utility models only. 1. Lift off upper rear casing panel. 2. Remove the insulation from th...

[Page 34] Grant Vortex Pro

34 6. Fit the flue adaptor (from the adaptor kit) into the boiler connector. Lubricate the seal on the adaptor using the lubricant provided before attempting to fit the flue adaptor. 7. Fit the first section of flue into the flue adaptor...

[Page 35] Grant Vortex Pro

35 Vertical balanced flue (White system) Allows the flue to rise vertically from the boiler to exit through the roof. The maximum flue length - from the top of the boiler flue outlet to the terminal - is 12 metres for all VORTEX boilers. The f...

[Page 36] Grant Vortex Pro

36 External balanced flue (Green system) Where it is not practical to use a low level (Yellow system) or internal high level/vertical (White system) balanced flue, the boiler can be fitted with an external vertical/high level flue (Green sys...

[Page 37] Grant Vortex Pro

37 Flue System and Air Supply Vertical terminal kit GTV90 (15 - 26 kW) GTV200 (26 - 70 kW) 45 elbow kit GE45/90 (15 - 26 kW) GE45/200 (26 - 70 kW) O Starter kit GK90 (15 - 26 kW) GK200 (26 - 70 kW) GK90S - short (15 - 26 kW) GK200S - short (26 - 70 ...

[Page 38] Grant Vortex Pro

38 Flue System and Air Supply Notes: * 75 mm with protection. ** Only applies if one or both terminals are balanced flues. B D D C C C E F H G M I J J B B D A EK L Distances measured to rim of terminal. Clearances recommended by Grant UK in acc...

[Page 39] Grant Vortex Pro

39 Flue System and Air Supply 9.5 Prepare the Wall If the boiler is to be used with a low level balanced flue (Yellow system) make the hole in the wall for the flue as shown in Figure 9-11. Dimension B given in Figure 9-11 includes an extra 10 ...

[Page 40] Grant Vortex Pro

40 It is important that the following commissioning procedure is carried out to ensure safe and efficient operation of the boiler. To access the controls, remove the front panel (pull forward at the top then lift off). The controls are shown in ...

[Page 41] Grant Vortex Pro

41 9. Ensure the automatic air vent on the condensing heat exchanger is open. 10. Check that all fuel line valves are open. 11. Remove the plastic burner cover if it was not previously removed. 12. Connect a combined vent manifold and pressure ga...

[Page 42] Grant Vortex Pro

42 If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained. Alternatively, a suitable antifreeze should be used. To allow the boiler to be commissioned and serviced correctly a c...

[Page 43] Grant Vortex Pro

43 To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general on...

[Page 44] Grant Vortex Pro

44 11.4 Cleaning the Burner 15/21, 15/26, 26/36, 36/46 models The procedure is as follows: 1. Combustion head: Loosen the two screws securing the combustion head and withdraw the head. 2. Clean the combustion head. 3. Inspect the ignition elect...

[Page 45] Grant Vortex Pro

45 Combustion head Combustion head fixing screw Electrode clamp screw Electrode leads Nozzle holder Diffuser clamp screw Burner flange Boiler Servicing 4 ± 0.3 mm 3 to 3.5 mm Clamp screw Figure 11-5: 15/21, 15/26, 26/36, 36/46 electrode settings ...

[Page 46] Grant Vortex Pro

46 12 Fault Finding Fault Finding 12.1 Boiler Fault Finding Always isolate the electricity supply to the boiler before working on the boiler. Fault Boiler will not start: Remedies 1 No fuel supply. 2 No electricity supply. 3 Burner not starting - ...

[Page 47] Grant Vortex Pro

47 Fault Finding 12.2 Burner Fault Finding - Riello RDB burners Motor/pump seized or tight Replace motor capacitor Burner motor runs Check L & N to control box Check boiler controls Motor gives 50 Volts to white wire * Replace burner motor Repair...

[Page 48] Grant Vortex Pro

48 13 Spare Parts Spare Parts This section gives exploded views of the Riello burners in the Grant VORTEX Pro boilers, and parts lists associated with them Figure 13-1: Riello RDB1, RDB2 and RDB2.2 burner components diagram 13.1 Riello RDB1, RDB2 ...

[Page 49] Grant Vortex Pro

49 Spare Parts Key No. Description Riello Part No. Grant Part No. 1 2 3 3 3 3 4 5 6 7 8 9 10 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Not applicable Flange Combustion head T1 - 15/21 kW Combustion head T2 - 15/26 Combustio...

[Page 50] Grant Vortex Pro

50 Figure 13-2: Riello RDB3.2 burner components diagram Spare Parts 13.2 Riello RDB3.2 burner ...

[Page 51] Grant Vortex Pro

51 Flange Combustion head Diffuser disc assembly Nozzle holder High voltage lead Collar Seal kit Air damper assembly Insulation Fan Photocell Cover Electrode Capacitor 5 µF Connector Flexible hose Motor Pressure gauge connector Tube Drive coupling...

[Page 52] Grant Vortex Pro

52 Cleaning door nut and washer set Double pole switch Baffle set (complete) - 15/21 Baffle set (complete) - 15/26 Baffle set (complete) - 26/36 and 36/46 Baffle set (complete) - 46/58 Baffle set (complete) - 58/70 Turbulator baffle - single (a...

[Page 53] Grant Vortex Pro

53 14 Health and Safety Information Under the Consumer Protection Act 1987 and Section 6 of the Health & Safety at Work Act 1974, we are required to provide information on substances hazardous to health (COSHH Regulations 1988). Adhesives, ...

[Page 54] Grant Vortex Pro

54 15 EC Declaration of Conformity EC Declaration of Conformity We declare that the Grant VORTEX range of Oil Boilers equipped with Riello RDB burners approved to EN 267: 1999 satisfy the requirements of the following European Directives:- 1. 89...

[Page 55] Grant Vortex Pro

55 16 Warranty Warranty 16.1 The Vortex Oil Boiler Warranty Dear Customer You are now the proud owner of a Grant Vortex Pro condensing boiler from Grant Engineering (UK) Ltd. that has been designed to give years of reliable, trouble free operatio...

[Page 56] Grant Vortex Pro

56 Warranty 7. The Company will endeavour to provide promt service in the unlikely event of a problem occurring, but cannot be held responsible for any consequences of delay however caused. 8. This guarantee applies to Grant boilers installed...

[Page 57] Grant Vortex Pro

57 Notes 17 Notes ...

[Page 58] Grant Vortex Pro

7 User Instructions 89/336/EEC 73/23/EEC 92/42/EEC ...

[Page 59] Grant Vortex Pro

6 User Instructions 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. Frost Protection Your Installer may have fitted a frost the...

[Page 60] Grant Vortex Pro

5 User Instructions 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 burn...

[Page 61] Grant Vortex Pro

4 User Instructions Introduction This User Guide is intended to assist the User in the operation of the Grant VORTEX Pro boilers. The engineers manual for the installation and maintenance of this boiler is attached to the reverse of these instru...

[Page 62] Grant Vortex Pro

3 Contents Contents Introduction About your Boiler Boiler Controls Lighting your Boiler If your Boiler Fails to Light Turning off your Boiler General Notes and Care of your system Boiler Thermostat Burner Lock-out Indicator and Reset Button Overhea...

[Page 63] Grant Vortex Pro

2 Service Log 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. All goods sold are subject to our of�...

[Page 64] Grant Vortex Pro

Part No. Doc 37 Rev.19 May 2012 D317 Grant Vortex Pro Kitchen/Utility, System and Boiler House Floor Standing Condensing Oil Boiler Range User Instructions ...