EFFICIENT HEATING SOLUTIONS Part No. IRL 007 Rev....

USER, INSTALLATIONand

SERVICING INSTRUCTIONS

Vortex Outdoor Condensing Oil Boilers

For use with Kerosene only

Part No. IRL 007 Rev. 03 April 2010

Vortex External Modules

with outputs up to 240,000 Btu/h

This appliance is deemed a controlled service and specific regional statutoryrequirements may be applicable.

After installing the boiler leave these instructions with the User

IMPORTANT NOTICEThis appliance must be commissioned upon installation, the information recorded and returned to

Grant Engineering (Ireland) Ltd., using the form contained within the boiler passport provided.Failure to do so may invalidate the warranty.

EFFICIENT HEATING SOLUTIONS

GRANT

2 Grant Vortex External Module

Subject PageSection

1 Introduction .............................................. 3

2 User instructions ...................................... 4

3 Boiler technical information .................... 7

4 General boiler information ....................... 11

5 Condensate disposal ................................. 20

6 Boiler installation ..................................... 21

7 Commissioning and Boiler passport ........ 31

8 Information for the user ........................... 33

9 Boiler servicing ........................................ 34

10 Wiring diagram ........................................ 37

11 Fault finding ............................................. 38

12 Burner heads ............................................ 40

13 Burner spares ........................................... 41

14 Health and safety information .................. 43

15 EC declaration of conformity .................. 44

LIST OF CONTENTS

3Grant Vortex External Module

During the combustion process, hydrogen and oxygencombine to produce heat and water vapour. The watervapour produced is in the form of superheated steam inthe heat exchanger. This superheated steam containssensible heat (available heat) and latent heat (heatlocked up in the flue gas). A conventional boilercannot recover any of the latent heat and this energy islost to the atmosphere through the flue.

The Grant Vortex condensing boiler contains an extraheat exchanger which is designed to recover the latentheat normally lost by a conventional boiler. It does thisby cooling the flue gases to below 90° C, thusextracting more sensible heat and some of the latentheat. This is achieved by cooling the flue gases to theirdew point (approximately 55° C).

To ensure maximum efficiency, the boiler returntemperature should be 55° C or less, this will enablethe latent heat to be condensed out of the flue gases.The boiler will achieve nett thermal efficiencies of100%.

To achieve maximum performance from the GrantVortex boiler, it is recommended that the heatingsystem is designed so that a temperature differential of20° C between the flow and return is maintained. Theuse of modulating circulating pumps (now widelyavailable) and effective control systems should beconsidered.

The Grant Vortex boiler will however still operate atextremely high efficiencies even when it is not incondensing mode and therefore is suitable for fitting toan existing heating system without alteration to theradiator sizes. The boiler is capable of a maximumflow temperature of 75° C.

1 - INTRODUCTION

How a condensing boiler works1.1 Heating system design considerations1.2

To achieve the maximum efficiencies possible fromthe Grant Vortex boiler, the heating system should bedesigned 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 of60° C.

2 Design system controls with programmable roomthermostats or use weather compensating controlsto maintain return temperatures below 55° C.

The boiler should not be allowed to operate withreturn temperatures of less than 40° C when thesystem is up to operating temperature.

3 The use of a pipe stat is recommended to controlthe return temperature when using weathercompensating controls.


2 - USER INSTRUCTIONS

The boiler is fully automatic once switched on, providingcentral heating (and also heating your domestic hot waterif you have an hot water cylinder fitted).

An illuminated On/Off switch, see Fig. A, is fitted to theExternal modules, which lights when the boiler is switchedon, but does not necessarily indicate the burner is firing.

To access the External module controls, remove the frontpanel by turning the handle and withdrawing it forwardsat the bottom.

Controls for External modules - Fig. A

1 Ensure that - There is sufficient fuel, of the correcttype, in the supply tank and all fuel supply valves areopen. The water supply is on. The electricity supplyto the boiler is off. The Boiler On/Off switch is set tooff (the neon in the switch is not alight). The Testswitch is set to Off. The room thermostat (if fitted) isat the desired setting. The boiler thermostat is set tothe required setting.

2 Switch on the electricity supply to the boiler.

3 Set the Boiler On/Off switch to on. A neon in theswitch lights when it is in the on position.

The boiler will now light automatically.

About your boiler2.1

Boiler controls (see Fig. A)2.2

Lighting your boiler (see Fig. A)2.3

BOILER ON/OFF SWITCH

ISOLATES PUMP (IF WIRED

INTO BOILER CONTROL

PANEL) & BURNER ONLY.

THIS COVER IS TO BE

REMOVED BY QUALIFIED

PERSONNEL ONLY

DO NOT REMOVE COVER

WITHOUT ISOLATING

SWITCHED LIVE AND

FROST 'STAT

PERMANENT LIVE

TEST SWITCH

OVERIDES SYSTEM

CONTROLS TO

OPERATE BOILER

‘Lock-out’ reset buttonBoiler front

panel removed

Control Panel

DANGER THERE IS MORE THAN ONE LIVE SUPPLY TO

THIS CONTROL PANEL

BOILEROFF

OVERHEAT

RESET

TESTSWITCH

OFF

HEATING

THERMOSTAT

ON ON

REFER TO WIRING DIAGRAM IN MANUAL

Overheat thermostatreset button

(under screw cover)

Boilerthermostat

BoilerOn/Off switch

Testswitch


THIS CONTROL PANEL

BOILEROFF

OVERHEAT

RESET

TESTSWITCH

OFF

HEATING

THERMOSTAT

ON ON



For short periods - Set the boiler switch to OFF.To restart, set the switch to ON.

For long periods - Set the boiler switch to OFF. Ifrequired, the fuel supply valve may be closed and thewater and electricity supplies turned off at the mains.

Note: If the electricity, fuel and water supplies areturned off, the built-in frost thermostat will notoperate.

1 Check that the boiler switch is ON.

2 Check that any remote programmer (if fitted) isworking and is in an 'on' period.

3 Check that all thermostats are set to the desiredsetting and are calling for heat.

4 Check if the burner 'Lock-out' reset button (on theburner) is lit. If it is, press it to start the burner. Ifthe burner fails to light and goes to 'Lock-out'again, check that you have sufficient fuel in thestorage tank and that the fuel supply valve is open.Check that the fire valve in the oil supply line has nottripped.

5 Ensure that a fuse has not blown or that theelectricity 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 thesechecks then a fault exists. Switch off the electricitysupply to the boiler and contact your Service engineer.

Grant Vortex External modules operate on Class C2Kerosene only. You should always quote this type of fuelwhen ordering from your supplier.

Do not wait until the fuel runs out before you ordersome more. Sludge in the bottom of the tank may bedrawn into the fuel lines. If it is possible, switch off theboiler when the new supply is delivered and leave thefuel to settle for an hour before restarting the boiler.

1 Boiler thermostat - This control allows thetemperature of the water leaving the boiler to heatthe radiators and domestic hot water to be adjusted.

Note: If you have a cylinder thermostat on your hotwater cylinder, this will control the temperature ofyour domestic hot water. The boiler thermostatsetting must be equal to or above the cylinderthermostat setting to enable the cylinder thermostatto control the domestic hot water system.

2 Burner Lock-out reset button - If there is aburner malfunction, a built-in safety circuitswitches the burner off and the 'Lock-out' resetbutton (on the burner) will light. Usually suchmalfunctions are short lived and pressing the resetbutton will restore normal operation.

If the burner continually goes to 'Lock-out' a faultexists or the fuel supply is low. If you havesufficient fuel, you will need to call your Serviceengineer.

3 Safety thermostat - Your boiler is fitted with asafety overheat thermostat which will automaticallyswitch off the boiler in the case of a controlmalfunction causing overheating.

If your boiler goes off and you try to light it butnothing happens and the 'Lock-out' reset button onthe burner is not lit, the overheat thermostat hasprobably operated. The boiler will not light untilthe thermostat is reset. To reset, unscrew the smallplastic cap (see Fig. A), press the button thenreplace the cap.

If this condition continually repeats, contact yourService engineer.

4 Ventilation - Always ensure that the boiler hasadequate ventilation. Any ventilation openingsmust not be obstructed. Periodically check thatthey are clear.

Do not attempt to 'box in' the boiler or build acompartment around.

Do not place any combustible material around oron the boiler or flue pipe.

Do not place anything against the door of theExternal modules that might obstruct theventilation openings.

5 Flue terminal - The flue terminal must not beobstructed or damaged.

In severe conditions check that the terminal doesnot become blocked by snow.


Turning off your boiler (see Fig. A)2.4

Points to check if burner fails to light2.5

About your fuel2.6

General notes and care of your system2.7


6 Frost protection - Your Installer may have fitted afrost thermostat. If not, and you are likely to beaway for a short time, leave the boiler on with theboiler thermostat set at a low setting. For longerperiods the boiler and system should be drained.Contact your Service engineer for draining andfilling the system.

The control panel of the External modules includesa built-in frost thermostat factory set to 5°C.

Note: For Vortex External modules we recommendthat a combined antifreeze and corrosion inhibitorbe used in the primary water system.

7 Cleaning and servicing - Lightly wipe over thecase with a damp cloth and a little detergent. Donot use abrasive pads or cleaners.

You must have your boiler serviced at least once ayear to ensure safe and efficient operation. Contactyour Service engineer for further details.

Warning note - External equipment operated at230 volts should not be serviced or repairedunder adverse weather conditions.

8 Failure of electricity supply - If the electricitysupply fails, the boiler will not operate. It shouldrelight automatically when the supply is restored.

The boiler requires a 230/240 V ~ 50 Hz supply. Itmust 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 andshould have told you (or set it on the pressure gauge)the system pressure when cold (this is normallybetween 0.5 and 1.0 bar, which will increase slightlywhen hot). If the pressure (when cold) is below the setpressure mentioned above, you can re-pressurise thesystem. If the system requires frequent re-pressurising,ask your Installer or Service engineer to check theheating system for leaks and to check the expansionvessel air charge.

An automatic filling system should not be used on asealed central heating system.

The boiler or system will be fitted with an automaticair vent to remove air from the system. Any air trappedin the radiators should be removed by venting theradiators using the vent screw at the top of eachradiator. Only vent a radiator if the top is cool and thebottom is hot. Excessive venting will reduce thesystem pressure, so only vent when necessary andcheck the system pressure as mentioned above. Re-pressurise the system if necessary.

The boiler or system may be fitted with a safety valveto release excess pressure from the system. If water orsteam is emitted from the end of the safety valvedischarge pipe, switch off the boiler and contact yourInstaller or Service engineer.

The expansion vessel air charge must be checkedannually. Failure to maintain an adequate aircharge 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 andthe boiler is off. Do not overfill.

2 Ensure the flexible filling loop (see Fig. B) isconnected and that the shut off valve connecting itto the boiler is open and the double check valve atthe front is closed.A valve is open when the operating lever is in line withthe valve, and closed when it is at right angles to it.

3 Gradually open the double check valve on the frontof the filling loop until water is heard to flow.

4 Vent each radiator in turn, starting with the lowestone in the system, to remove air.

5 Continue to fill the system until the pressure gaugeindicates between 0.5 and 1.0 bar. Close the fillpoint valve.

6 Repeat steps 4 and 5 as required.

7 Close the valves either side of the filling loop anddisconnect the loop.


Electricity supply2.8

Sealed central heating system2.9

Sealed system filling loop arrangement - Fig. B


120/155

21

4.7

174

46

157,000

28 mm

28 mm

26.0 mbar

9.5 mbar

4.2 Amp

Boiler technical data3.1

3 - BOILER TECHNICAL INFORMATION

Model

Water content litre

gal

* Weight (dry) kg

Max. heat output kW

(kerosene) Btu/h

Flow connection

Return connection

Condensate connection

Waterside resistance

Flow/Return temp. diff. of 10°C

Flow/Return temp. diff. of 20°C

Maximum static head

Minimum circulating head

Boiler thermostat range

Limit (safety) stat shut off temp

Max. hearth temperature

Electricity supply

Motor power

Starting current

Running current

Oil connection

Max operating press - sealed sys

Max operating press - open sys

* Weight includes burner but excludes flue.

Vortex External Module

50/90

19

4.2

157

26

88,700

22 mm

22 mm

28.5 mbar

10.0 mbar

2.6 Amp

50/70

16.5

3.6

99

21

71,650

22 mm

22 mm

28.5 mbar

10.0 mbar

4.2 Amp

200/240

50

11

339

70

238,840

1¼" BSP

1¼" BSP

26.0 mbar

9.5 mbar

150 W max.

6.4 Amp

155/200

50

11

335

58

197,876

1¼" BSP

1¼" BSP

26.0 mbar

9.5 mbar

150 W max.

6.4 Amp

90/120

21

4.7

174

36

122,840

28 mm

28 mm

26.0 mbar

9.5 mbar

2.6 Amp

90 W max.

21.5 mm plastic overflow pipe

28 m

1m

65 to 75°C

111°C ± 3°C

Less than 50°C

230/240 V ~ 50 Hz Fused at 5 Amp

0.85 Amp

¼" BSP Male (on end of flexible fuel hose)

2.5 bar

2.5 bar



Note: Grant Vortex External modules are only for use with kerosene.

Grant Vortex External modules using Class C2 kerosene3.3

Sealed system data - none available for 155/200, 200/2403.2

Notes:1 The data given above is approximate only.2 The above settings may have to be adjusted on site for the correct operation of the burner.3 Gas Oil is not suitable for use with the Grant Vortex boiler range.4 The net flue gas temperatures given above are ± 10%.5 When commissioning the air damper must be adjusted to obtain the correct CO

2 level.

6 * Factory settings.7 The combustion door test point may be used for CO

2 and smoke readings only. Do not use this test point for temperature or efficiency readings.

8 When setting the 50/90 to 51,200 or 68,240 Btu/h output or the 120/155 to 123,000 Btu/h output the combustion head must be changed. Refer to Section7 Commissioning.When setting the 50/70 to 51,200 Btu/h output the burner air adjuster disc requires repositioning. Refer to Section 9.4 Cleaning the burner.

9 The installer must amend the boiler data label if the output is changed.

Flue gas analysisTo 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 isused please note the following:1. The test point is for CO

2 and smoke readings only.

2. The boiler efficiency and temperature must be taken from the flue test point on high level and vertical flue adaptors.3. Low level flues do not contain a test point. The temperature and efficiency readings must be taken from the flue terminal.

(kW)

15.0

18.3

21.0

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)

51,200

62,400

71,650

51,200

68,240

78,500

88,700

88,700

107,500

123,000

123,000

141,600

157,000

156,952

177,424

197,896

197,896

218,368

238,840

Nozzle

0.50/80°EH

0.55/80°EH

0.60/80°EH

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

Oilpress.(bar)

7.0

7.5

9.0

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

SmokeNo.

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

0 - 1

0 - 1

0 - 1

Fuel flowrate

(kg/h)

1.29

1.56

1.83

1.25

1.67

1.94

2.18

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 gastemp.(°C)

66

73

80

60 - 65

65 - 70

70 - 75

68

68

70

78

78

80

88

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

12.0

12.0

12.0

Burnerhead type

T1

T1

T1

T1

T1

T2

T2

T3

T3

T3

T3

T5

T5

GIB

GIB

GIB

GIB

GIB

GIB

Heat Output

50/70

Riello RDB2.2

50/90

Riello RDB1

90/120

Riello RDB2

120/155

Riello RDB2.2

155/200

Riello RDB3.2

200/240

Riello RDB3.2

Model andburner type

*

*

*

HARP/SEDBUKefficiency

(%)

93

94 - 95

97

92.62

94.1

93.6

*

Air discposition

B

C

C

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

*

*

Maximum 1.0 bar, Minimum 0.5 bar

2.5 bar

15 mm copper pipe

15 mm copper pipe

Model

Heating system pressure (cold)

Operating pressure of pressure relief valve

Expansion vessel size (approximately)

Max heating system volume (including boiler)

Cold water mains connection

Pressure relief valve discharge connection

Circulating pump head

50/70

10 litres

106 litres

6 m

50/90

12 litres

128 litres

6 m

90/120 and 120/155

16 litres

170 litres

7 m

Burnerhead setting

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

Fixed

0

0

0

0

0

4



Boiler dimensions3.4

Fig 1b - 50/90, 90/120 and120/155dimensions

Fig 1c - 155/200 and 200/240dimensions

Fig 1a - 50/70dimensions4 holes

50mm dia.in sidescovered withmovable plates

both

879

=244

=

637768

517

307

187

99112

Side flue exitif required

385

943

734

248

3 holes 50 mm dia.in base of boilerenclosure covered with movable plates

4 holes50mm dia.in sidescovered withmovable plates

both

1154

587945

233

68

50

10001154

816

418

179

1240

=382=



4 holes50mm dia.in sidescovered withmovable plates

both

1005

505800

269

908

=320=117132

50

756A

698

417

192



50/90 A = 81590/120, 120/155 A = 825


Grant Vortex External Modules have an insulatedweatherproof enclosure made of galvanised steel, andare designed for external installation, either against awall or free standing some distance away from theproperty, as required. For flue clearances see page 15.

The Vortex External modules are part of the Grant rangeof automatic pressure jet oil boilers have been designedfor use with a fully pumped central heating system withindirect domestic hot water cylinder. They are not suitablefor use with either a direct cylinder or a 'primatic' cylinderor gravity hot water..

The boilers are suitable for use on open vented orsealed central heating systems.

All models are supplied with the control panel andburner factory fitted.

The factory fitted low level discharge flue system canbe adjusted on site for either rear, left hand or righthand flue outlet position, as required.

An external Plume Diverter kit (Fig. 16) is also availablefrom your local stockist. Refer to Section 6.4 for furtherdetails.

All burners are pre-set for use with kerosene and aresupplied ready to connect to a single pipe fuel supplysystem with a loose flexible fuel line and 3/

8" to 1/

4" BSP

male adaptor supplied with the boiler.

If required, an additional flexible fuel line (600 mm) and3/

8" to 1/

4" BSP male adaptor are available to purchase

from your local stockist, for two-pipe oil supply systems.

The temperature of the water leaving the boiler to heatthe radiators and hot water cylinder is User adjustable.

The boiler is fitted with an overheat thermostat (whichallows it to be used on a sealed central heating system)which will automatically switch off the boiler if the heatexchanger exceeds a pre-set temperature of 111°C ± 3°C.

The control panel is fitted with an ON/OFF switch,boiler thermostat control knob and the manual resetbutton for the overheat thermostat

Boiler description4.1

Boiler components4.2

4 - GENERAL BOILER INFORMATION

Installation of a Grant Vortex boiler must be inaccordance with the following recommendations:-

a Local Building Regulations, and BuildingStandards issued by the Department of theEnvironment and any local Byelaws etc.

b Model and local Water Undertaking Byelaws.

c Applicable Control of Pollution Regulations.

d The following OFTEC requirements:-OFST 100 Polythene oil storage tanks for

distillate fuels.OFST 200 Fuel oil storage tanks and tank

bunds for use with distillate fuels,lubrication oils and waste oils.

Further information may be obtained from theOFTEC Technical Information Book 3(Installation requirements for oil fired boilersand oil storage tanks).

The installation should also be in accordance with thelatest edition of the following British Standard Codesof Practice:-

BS 715 Metal flue pipes, fittings, terminalsand accessories.

BS 799:5 Oil storage tanks.BS 1181 Clay flue linings and flue terminals.BS 4543:3 Factory made insulated chimneys for

oil fired appliances.BS 4876 Performance requirements for oil

burning appliances.BS 5410:1 Code of Practice for oil firing appliances.BS 5449 Forced circulation hot water systems.BS 7593 Code of Practice for treatment of

water in heating systems.BS 7671 Requirements for electrical

installations, IEE Wiring Regulations.

Failure to install and commission appliancescorrectly may invalidate the boiler warranty.

IMPORTANT

Before starting any work on the boiler, or fuel supplyplease read the health and safety information given inSection 14 on page 43.

Regulations to comply with4.3



4 A metal bowl type filter with a replaceablemicronic filter must be fitted in the fuel supply lineadjacent to the boiler. A shut-off valve should befitted before the filter, to allow the filter to beserviced.

5 A flexible fuel hose, adaptor and 1/4" BSP isolation

valve are supplied loose with the boiler for the finalconnection to the burner. If a two pipe system or'Tiger Loop' type de-aerator is used, an additionalflexible fuel hose (600 mm) and 3/

8" to 1/

4" BSP male

adaptor are available to purchase from your localstockist. If a 'Tiger Loop' is fitted it should not befitted indoors or within a boiler casing.

6 Metal braided flexible hoses should be replacedannually when the boiler is serviced. Long lifeflexible hoses should be inspected annually andreplaced at least every 60 months.

4.4.3 Single pipe system - (See Fig. 2)

1 Where the storage tank outlet is above the burnerthe single pipe system should be used. The heightof the tank above the burner limits the length ofpipe run from the tank to the burner.

2 As supplied the burner is suitable for a single pipesystem.

4.4.1 Fuel storage

The tank should be positioned in accordance with therecommendations given in BS 5410:1:1997, which givesdetails of filling, maintenance and protection from fire.

A steel tank may be used and must be constructed toBS 799:5:1987 and OFST 200.

A galvanised tank must not be used.

A plastic tank may be used and must comply withOFST 100.

Note: Plastic tanks should be adequately anduniformly supported on a smooth level surface, acrosstheir entire base area.

4.4.2 Fuel pipes

1 Fuel supply pipes should be of copper tubing withan external diameter of at least 10 mm.Galvanised pipe must not be used.All pipe connections should preferably use flaredfittings. Soldered connections must not be used onoil pipes.

2 Flexible hoses must not be used outside the boiler case.

3 A remote sensing fire valve (not a fusible head type)must be installed in the fuel supply line, with thesensing head located above the burner.Recommendations are given in BS 5410:1:1997.

Fuel supply4.4

Regional statutory requirements may deem this appliance to be a 'controlled service'.Where this is the case, it is a legal requirement that the appliance is installed and

commissioned either under the remit of building control or by a 'Competent person' suchas a suitably qualified Oftec registered technician.

Fig. 2 - Single pipe system

FilterFirevalve

Shut-offvalve

Shut-offvalve

A

Sludgevalve

Fillpipe

VentpipeLevel

gauge

Fuelstoragetank

Head A

(m)

Maximum pipe run (m)

0.5

1.0

1.5

2.0

10 mm OD pipe

10

20

40

60

12 mm 0D pipe

20

40

80

100

Firevalvesensor

Pump

1 m


4.4.5 Tiger Loop system - (See Figs. 4 and 5)

1 When the storage tank is below the burner, analternative to a two pipe system can be achievedusing the 'Tiger Loop' type oil deaerator. Thiseffectively removes the air from the oil supply on asingle pipe lift.

2 The de-aerator is connected close to the boiler as atwo pipe system (omitting the non-return valve) asshown in Fig. 4. Refer to the manufacturersinstructions supplied with the de-aerator.The de-aerator must be mounted vertically andexternally.

3 To be used with a de-aerator, the burner must befitted with an additional flexible fuel hose (a flexiblefuel hose (600 mm) and 3/

8" to 1/

4" BSP male adaptor

are available to purchase from your local stockist. SeeSection 4.4.6.

4.4.4 Two pipe system - (See Fig. 3)

1 When the storage tank outlet is below the burner,the two pipe system should be used. The pipe runsshould be as shown in Fig. 3. The return pipeshould be at the same level in the tank as thesupply pipe, both being 75 to 100 mm above thebase of the tank. The pipe ends should be asufficient distance apart so as to prevent anysediment disturbed by the return entering thesupply pipe.

2 Avoid the bottom of the tank being more than 3 mbelow the burner.

3 A non-return valve should be fitted in the supplypipe together with the filter and fire valve. A non-return valve should be fitted in the return pipe ifthe top of the tank is above the burner.

4 To be used with a two-pipe system, the burnermust be fitted with an additional flexible fuel hose(a flexible fuel hose (600 mm) and 3/

8" to 1/

4" BSP

male adaptor are available to purchase from yourlocal stockist.

5 The pump vacuum should not exceed 0.4 bar.Beyond this limit gas is released from the oil.

For guidance on installation of top outlet fuel tanks andsuction oil supply sizing, see OFTEC booklet T1/139.Available at www.oftec.org.uk


Fig. 3 - Two pipe system

Filter

Firevalve

Shut-offvalve

Shut-offvalve

Seesection 4.4.6

A

Return

Supply

Head A

(m)

Maximum pipe run (m)

0

0.5

1.0

1.5

2.0

3.0

3.5

10 mm OD pipe

35

30

25

20

15

8

6

12 mm OD pipe

100

100

100

90

70

30

20

Nonreturnvalve

Firevalvesensor

Sludgevalve

Fillpipe

VentpipeLevel

gauge

Fuelstoragetank

1 m



4.4.6 Two pipe oil supplies

Riello RDB burner - See Fig. 6

1 The fuel pump is supplied for use with a singlepipe fuel supply system. For use on a two pipesystem, it is necessary to fit the By-pass screw (seeFig. 6) into the tapping in the return port.

2 The By-pass screw is supplied in the boileraccessory pack.

3 Remove the plastic burner cover (two screws).

4 Remove and discard the blanking plug from thereturn connection of the pump and fit the By-passscrew using an hexagonal key.

5 Connect the return oil flexible fuel hose to the pump.

6 Connect the 3/8" to 1/

4" BSP adaptor to the flexible

fuel hose.

Fig. 4 - De-aeration device system

Fig. 5 - Tiger loop 'de-aeration' device

Fig. 6 - Riello RDB pump

1 Oil inlet connection2 Return connection3 By-pass screw4 Pressure gauge connection5 Pressure adjuster6 Vacuum gauge connection7 Solenoid8 Supply to nozzle

1 2

3

4

5

6

7

8

1/4" BSP femaleconnections

Tiger Loop

SUPPLYTO PUMP

RETURNFROM PUMP

SUPPLYFROM TANK

Fire valve

Tankmaster

Seesection 4.4.6

Sludgevalve

Fillpipe

Ventpipe

Fuelstoragetank

De-aeration devicee.g. Tiger Loop

See Fig. 5

Firevalvesensor

Supply

1 m

Return


1 A 230/240 V ~ 50 Hz mains supply is required.

The boiler must be earthed.

2 The supply must be fused at 5 Amp and there mustonly be one common isolator for the boiler andcontrol system, providing complete electricalisolation.

3 A fused double pole switch or a fused three pinplug and shuttered outlet socket should be used forthe connection.

4 The power supply cable should be at least 0.75 mm²PVC as specified in BS 6500, Table 16.

5 All the wiring and supplementary earth bondingexternal to the boiler must be in accordance withthe current I.E.E. Wiring Regulations.

6 Any room thermostat or frost thermostat used mustbe suitable for use on mains voltage.

7 The boiler requires a permanent mains supply, donot interrupt it with any external time control.

8 In the event of an electrical fault after installationof the boiler, the following electrical system checksmust be carried out:- Short circuit, Polarity, Earthcontinuity and Resistance to earth.

1 External Modules are supplied with a factory fittedfrost protection thermostat, located inside theboiler control panel. This is pre-wired to the boilerelectrical system and factory set to 5°C.

2 For total system protection against freezing,particularly during extended periods withoutelectrical power, Grant recommend the use of acombined heating system antifreeze and corrosioninhibitor, used in accordance with themanufacturer's instructions.


1 The External Module must stand on a solid, levelsurface capable of supporting the weight of the boilerwhen full of water, e.g. a prepared concrete standing,paving slabs bedded down on sand/cement, or similar.

2 The Module can be installed either against the buildingor 'free standing' some distance away from the building.

3 The Module must be positioned such that therequired clearances from the low level flue outlet,as shown in Fig. 7, are achieved.

4 Adequate clearance must be left around the Modulefor servicing. In particular, a minimum clearance of600 mm above the Module for removal of the toppanel and 600 mm at the opposite end to the flue outletfor access to the burner.

Sufficient clearance is required at the rear of theboiler to allow the rear panel to be removed foraccess to the condensate trap.

5 The flue terminal must be a minimum distance of1.8 m from an oil storage tank.

The flue terminal should be positioned so as toavoid products of combustion accumulating instagnant pockets around the building or enteringinto buildings.

Electricity supply4.5

Frost protection4.6

Boiler location4.7



Fig. 7 - Clearances for flue terminals

Distances measured to rim of terminal.

Clearances recommended by Grant Engineering(IRL) Limited in accordance with BuildingStandards and Building Regulations.

Notes:1 An opening means an openableelement, such as an openablewindow, or a permanent openingsuch as a permanently open air vent.

2 Notwithstanding the dimensionsgiven, a terminal should be at least300 mm from combustible material,e.g. a window frame.

3 A way of providing protection ofcombustible material would be to fita heat shield at least 750 mm wide.

A Below gutters, eaves or balconies (with protection)

B Horizontally from a door, window or air vent

C Above ground, flat roof or balcony level

D Below gutters, eaves or balconies (without protection)

E From an external corner

F From a terminal facing the terminal

G From a surface facing the terminal

H Vertically from a terminal on the same wall

I Horizontally from a terminal on the same wall

J Directly below an opening, air brick, window, etc.

K From a vertical drain pipe or soil pipe

L From an internal corner

*600

600

300

*600

300

1200

600

1500

**750

600

300

300

Terminal position Min. distance

The terminal should be positioned so as to avoid products of combustion accumulating in stagnant pocketsaround the building or entering into buildings. Care should also be taken that the plume from the condensedflue gases does not cause a nuisance.

Notes: * 75 mm with protection.

** Only applies if one or both terminals are balanced flues.


See Figs. 8, 9, 10 and 11


Water connections4.8

Fig. 8 - 50/90 connections

Fig. 9 - 50/70, 90/120, 120/155 connections

The flow and return pipework can exit the boilerenclosure either through the openings provided in bothsides (under the movable cover plates) and through thewall when installed against the building, or down andthrough the openings provided in the base of theenclosure for 'free standing' installations.

Ensure the flow pipe is vented as its the highest pointof the boiler.

To avoid the danger of dirt and foreign matter enteringthe boiler the complete heating system should bethoroughly flushed out - before the boiler is connectedand then again after the system has been heated and isstill hot. This is especially important where the boileris used on an old system.

For optimum performance after installation, this boiler and itsassociated central heating system must be flushed in accordancewith the guidelines given in BS 7593:1992 'Treatment of waterin domestic hot water central heating systems'.

This must involve the use of a proprietary cleaner, suchas BetzDearborn's Sentinel X300 or X400, or FernoxRestorer. Full instructions are supplied with theproducts, but for immediate information, pleasecontact BetzDearborn on 0151 4209563 or Fernox on0179 9550811.

For Long term protection against corrosion and scale,after flushing, it is recommended that an inhibitor such asBetzdearborn's Sentinel X100 or Fernox MB-1 is dosedin accordance with the guidelines given in BS 7593:1992.

Failure to implement the guidelines will invalidate thewarranty.

Heating flow

Thermostat phials

Heating return

Heating return

Heating flow

Thermostat phials

Compression straight

Compression elbow

Compression straight

Female socket

in fittings kit

in fittings kit

in fittings kit

fitted

22 mm pipe

22 mm pipe

28 mm pipe

1¼" BSP

Compression

Compression

Compression

Female socket

fitted

fitted

fitted

fitted

Size

Fitting

Fitting

Supplied

Supplied

Flow connection

Return connection

50/70

50/90

90/120, 120/155

155/200, 200/240

22 mm pipe

22 mm pipe

28 mm pipe

1¼" BSP

Size

Boiler model

50/70

50/90

90/120, 120/155

155/200, 200/240

Boiler model

Fig. 10 - 155/200, 200/240 connections

Heating return

Thermostat phialsHeating flow



See Fig. 12

Grant sealed system kits, incorporating circulatingpumps are available. See Section 6.5 and 6.6.

1 The boiler is only suitable for use with a sealed systemcomplying with the requirements of BS 5449.The maximum temperature of the central heatingwater is 75°C.

2 The system must be provided with the followingitems:-a Diaphragm expansion vessel complying with

BS 4814.b Pressure gauge.c Safety valve.d Approved method for filling the system.Refer to BS 7074:1 for further guidance.

Fig. 11 - All models rear view (panel removed)

3 The expansion vessel can be fitted in either thereturn or flow pipework in any of therecommended positions as shown in Fig. 12. Toreduce the operating temperature of the expansionvessel diaphragm, position it below the pipe towhich it is connected. The expansion vessel may bepositioned away from the system, providing theconnecting pipe is not less than 13 mm diameter.

4 The pressure gauge should have an operating rangeof 0 to 4 bar.

5 The safety valve, set to operate at 2.5 bar, shouldbe fitted in the flow pipework near to the boiler.The pipework between the safety valve and boilermust be unrestricted, i.e. no valves. The safetyvalve should be connected to a discharge pipewhich will allow the discharge to be seen, butcannot cause injury to persons or property.

Fig. 12 Sealed system

Condensate trap

Condensate outlet to drain

Sealing cap must be fitted

Flexible hose from outlet ofcondensing heat exchanger

Sealed system kit4.9



6 Provision should be made to replace water lostfrom the system. This can be done manually (whereallowed by the local water undertaking) using anapproved filling loop arrangement incorporating adouble check valve assembly.

7 An automatic air vent should be fitted to thehighest point of the system as the air vent fitted tothe boiler is for venting the boiler only.

8 The system design pressure (cold) should be between0.5 and 1.0 bar. This pressure is equivalent to themaximum static head in bar + 0.3 (1 bar = 10.2 metresof water).

9 All fittings used in the system must be able towithstand pressures up to 3 bar.

10 Radiator valves must comply with the requirementsof BS 2767(10):1972.

11 One or more drain taps (to BS 2879) must be usedto allow the system to be completely drained.

12 For proprietary expansion vessel/valve/gaugepacks, refer to the manufacturers instructions forthe correct location on the heating system.

13. An automatic filling valve should not be fitted.

Also refer to Sections 6.5 and 6.6.

1 A 15 mm discharge pipe must be connected to thesafety valve outlet connection. The pipework betweenthe safety valve and the boiler must be unrestricted,i.e. no valves. The discharge pipe should terminate sothat it cannot cause injury to persons or property.

2 A 15 mm double check valve ballofix type valve isprovided on the flexible filling loop hose forconnection of the cold mains supply to the heatingsystem. The cold mains supply should terminateinside the boiler casing.

3 A drain cock is fitted at the bottom on the front ofthe boiler to allow the heating system to be drained

4 The expansion vessel is connected via a flexiblehose to allow it to be moved to gain access to thebaffle cleaning cover. When replacing the vessel,care should be taken to ensure that the flexibleconnecting hose is not twisted.

On underfloor systems it is essential that the returntemperature must be maintained above 40° C toprevent internal corrosion of the boiler water jacket.

General - Grant boilers are compatible with bothcopper and plastic pipe. Where plastic pipe is used itmust be of the oxygen barrier type and be of thecorrect class (to BS 7291:Part 1:1990) for theapplication concerned.

IMPORTANT: The first metre of pipeworkconnected to both the heating flow and returnconnections of the boiler must be made in copper onall types of system - sealed or open-vented.

Sealed systems - If plastic pipe is to be used, theinstaller must check with the plastic pipe manufacturerthat the pipe to be used is suitable for the temperatureand pressures concerned. Pipe must be Class S to BS7291: Part 1:1990.

Underfloor systems - Plastic pipe may be used onUnderfloor systems where the plastic pipe is fittedafter the thermostatic mixing valve. Copper tube mustbe used for at least the first metre of flow and returnprimary pipework between the boiler and theunderfloor mixing/blending valves.

Pipework materials4.12

Underfloor heating systems4.11

Water connections - Sealed system kit4.10


5 - CONDENSATE DISPOSAL

General requirements5.1

Connections5.2

Pipework5.3

When in condensing mode the Grant Vortex boilersproduce condensate from the water vapour in the fluegases. This condensate is slightly acidic with a phvalue of around 3 (similar to vinegar). Provision mustbe made for the safe and effective disposal of thiscondensate.

Condensate can be disposed of using one of thefollowing methods of connection:

Internal connection (preferred option)

• into an internal domestic waste system (fromkitchen 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 foulwater)

• purpose made soakaway

All condensate disposal pipes MUST be fitted with atrap - whether they are connected internally orexternally to a domestic waste system/soil stack or runexternally to a gully, hopper or soakaway.

Connections into a rainwater hopper, external drain orgulley should be terminated inside the hopper/drain/gulley below the grid level but above the water level.

Condensate disposal pipes should not be connecteddirectly into rainwater downpipes or to waste/soilsystems connected to septic tanks.

Condensate should not be discharged into 'grey water'systems that re-use water used in the home (notincluding water from toilets).

It should be noted that connection of a condensate pipeto the drain may be subject to local Building Controlrequirements.

Condensate disposal pipework must be plastic (plasticwaste or overflow pipe is suitable).

IMPORTANT: Copper or steel pipe is NOT suitableand MUST NOT be used for condensate disposal.

Condensate disposal pipes should have a minimum'nominal' diameter of 22 mm (¾") - e.g. use 21.5 mmOD polypropylene overflow pipe.

Condensate disposal pipes must be fitted with a fall(away from the boiler) of at least 2.5° (~45 mm fallper metre run).

Note: Where it is not possible for the pipe to falltowards the point of discharge - either internally into awaste system or externally to a gulley (e.g. for boilersinstalled in a basement), it will be necessary to use acondensate pump.

Condensate disposal pipes should be kept as short aspossible and the number of bends kept to a minimum.

Pipes should be adequately fixed to prevent sagging,i.e. at no more than 0.5 metre intervals.

External pipework

Ideally, external pipework, or pipework in unheatedareas, should be avoided. If unavoidable, externalpipework should be kept as short as possible (less than3 metres) and 32 mm waste pipe used to minimise therisk of ice blocking the pipe in freezing conditions.

The number of bends, fittings and joints on externalpipes should be kept to a minimum to reduce the riskof trapping condensate.

Note: For boiler installed in an unheated area such asan outhouse or garage, all condensate pipework shouldbe considered as an ‘external’.

To keep external pipework to a minimum, locate thesoakaway as close as possible to the boiler but ensureit is at least 1 metre from building foundations andaway from other services, e.g. gas, electricity, etc.

The condensate pipe may be run above or belowground level and can enter either the top or side of thesoakaway tube. Refer to Fig.13.

Ensure that the drainage holes in the soakaway tubeface away from the building.

Backfill both the soakaway tube, and the hole aroundit, with 10 mm limestone chippings.

Condensate soakaway5.4


Fig. 14 - Condensate trap


Fig. 13 - Purpose made condensate soakaway

Ground level

32 mm waste pipe external to the building

2.5 fallO

25 mm

300 mm

400 mmmin.

Two rows of 3 x 12 mmholes at 25 mm centresand 50 mm from the bottomof the tube. Holes facingaway from the property.

Cement seal

100 mmplastictube

Sealedend

Backfill with 10 mmlimestone chippings

Only use a soakaway where the soil is porous anddrains easily. Do not use in clay soils or where thesoil is poorly drained.

WARNING: Any damage due to condensate backingup into the boiler due to a high water table, in the caseof a soakaway, or flooded drains when the condensatedisposal is via a gulley or soil stack, is not covered bythe Grant product warranty.

Grant Vortex External Modules are supplied with a factory-fitted condensate trap to provide the required 75 mm waterseal in the condensate discharge pipe from the boiler.

This trap incorporates a float (which will create a sealwhen the trap is empty) and an overflow warningoutlet (fitted with a plastic sealing cap), See Fig. 14.

Condensate trap5.5

The trap is factory-fitted inside the boiler casing,mounted in the rear of the boiler (opposite end to theburner) on the inside of the right hand side panel - inan accessible position to allow for routinemaintenance. See Fig. 11.

A flexible hose connects the outlet of the condensingheat exchanger to the trap inlet. Ensure the straightconnector on the hose is fully pushed onto the 'top hat'inlet connector of the trap.

With the trap fitted inside the boiler casing, the sealingcap MUST be fitted.

If connecting the condensate discharge (either internallyor externally) into a waste system or soil stack - thesealing cap MUST be fitted in the trap outlet.

Condensate trap

Condensateoutlet to drain

Overflow warningoutlet(with cap)

Condensate drain pipefrom boiler



The condensate trap outlet is at an angle of 48° belowthe horizontal. This is to automatically give a 3° fall onany 'horizontal' runs of condensate disposal pipe. Referto Fig.13.

The outlet of the trap will accept 21.5 mm to 23 mmOD Polypropylene overflow pipe for the condensatedischarge pipe.

Possible routes for disposal pipework

The casing of the Vortex External Module has several50 mm diameter openings in both the sides and base ofthe casing. These are designed to allow pipework topass through the casing, as required, to suit theinstallation. These openings can be used to allow thecondensate disposal pipe to exit the casing in one ofthe following ways:

Side outlet – The lower opening on either side of theboiler casing can allow the condensate disposal pipe tobe installed as follows:

• Connection to an internal stack – passing backthrough the wall of the house

• Connection to an external soil stack adjacent to theboiler

• Discharge into an adjacent (external) drain orgulley

• Discharge into a soakaway – with pipe either aboveor below ground level

Bottom outlet – There are three openings in the baseof the boiler casing that can allow the condensatedisposal pipe to be installed as follows:

• Discharge into a drain or gulley beneath the boiler(e.g. drain built in to the concrete base for theboiler)

• Discharge into a soakaway – with pipe belowground level

The trap MUST be checked at regular intervals (e.g.on every annual service) and cleaned as necessary toensure that it is clear and able to operate.

Note: The bottom bowl is sealed to the trap body andcannot be removed.

To inspect and clean the trap:

1 Disconnect flexible condensate hose from inletconnector.

2 Unscrew the outlet connection nut.

3 Remove the outlet connector and nut from trap.

4 Remove trap from bracket.

5 Remove float from trap – clean if necessary.

6 Inspect inside of trap and clean as necessary.

7 Re-assemble trap, re-fit to boiler and re-connectflexible hose. Ensure that hose is fully pushed ontothe trap inlet connector.

IMPORTANT: Failure to regularly check and cleanthe condensate trap may result in damage to the boilerand will not be covered by the Product Warranty.

Condensate disposal pipework5.6 Inspection and cleaning of trap5.7


1 Carefully remove the packaging from the boilerand lift it off the pallet.

2 The flue terminal guard is supplied loose inside theboiler.

3 Remove the case top panel (four screws).

4 The flue may exit the casing from the left, right or rearof the casing. The casing has two removable blankingpanels and a flue exit panel. Fit the panel with the flueexit hole and seal in the required position.

5 Slacken the wing nuts holding the flue elbow androtate the elbow to the required direction for theflue to exit the casing.

6 Push the end of the flue terminal section with thered seal through the seal in the casing. The terminalhas been factory lubricated. Take care not todislodge or damage the red seals.

7 Carefully insert the terminal into the flue elbow untilthe bend of the terminal contacts the outer casing,then, pull the terminal forward approximately 25 mmand rotate the bend so that the outlet is horizontal.

Rear Exit - The flue must discharge away from thebuilding.Side Exit - The flue should discharge towards therear of the casing to prevent flue gases re-enteringthe boiler casing through the air inlet vents on thecasing front door.The flue terminal must be fitted horizontally toprevent dripping from the end of the terminal.

6 - BOILER INSTALLATION

Unpack the boiler6.1

Fig. 15

8 Tighten the wing nuts holding the flue elbow and fit thestainless steel flue guard using the two screws provided.

9 The top panel of the casing has been designed so thatit may be fitted to create a slight slope away from theside positioned against the wall. To tilt the top panel,loosen the four top panel casing screws, one at eachcorner and push down on the side furthest from thewall. Tighten the screws. See Fig. 15.

1 If the boiler is to be fitted against the wall, prepare thewall to accept the heating system pipework. To markthe wall for drilling, refer to Fig. 1 for the positions ofthe pipework openings in the enclosure sides.

Note: Pipework should be insulated where itpasses through the wall into the boiler enclosure.

If the boiler is to be installed 'free standing' (i.e.away from a wall) and the pipework rununderground, slide away the covers to open the twopipe openings in the base of the boiler enclosure.Using a sharp knife, cut through the polystyrene inthe base, around the edge of the holes, to allow theflow and return pipes to enter the enclosure.

2 The electrical supply to the boiler should be routedthrough the wall in a suitable conduit, such that itenters the boiler enclosure via one of the unusedpipework openings. The cable can be routed to thefront of the boiler, for connection to the boilercontrol panel, either over the top or beneath theboiler heat exchanger. Heat resistant PVC cable, ofat least 1.0 mm² cross section should be usedwithin the boiler enclosure.

Preparations for installation6.2



If the Grant sealed system kit is fitted, refer to Section6.6 for details on filling and venting the sealed heatingsystem.

See Figs. 16 and 17

Where it is not possible to terminate the factory suppliedlow level flue, there are two alternative options;

Plume diverter kit - This single wall stainless steel flueaccessory is designed to divert the flue gases up andterminate at a higher level than the factory suppliedterminal. When fitting the plume diverter kit, follow theinstructions supplied with the kit. See Fig. 16.

Horizontal system - This option uses a straight boilerconnector, elbows and extensions as shown in Fig. 17.

A complete list of flue components are given on page 25.

All flue components are stainless steel and fully insulatedwith 'O' ring seals and locking bands.

1 The flue must terminate in a down draught free area,i.e. at least 600 mm above the point of exit through theroof or preferably above the ridge level.

2 The condensate may be allowed to run back intothe boiler. A condensate drain at the base of theflue system is not required.

3 The flue terminal must be at least 600 mm fromany opening into the building, and 600 mm aboveany vertical structure or wall less than a horizontaldistance of 750 mm from the terminal.

It is important to ensure that the flue system is sealedand that condensate cannot escape. Up to 1.5 l/h ofcondensate can be produced in a conventional fluesystem.

Flue systems6.4

3 The oil supply line should be installed up to theposition of the boiler. Refer to Section 4.4.2 fordetails. The final connection into the boiler enclosurecan be made with 10 mm soft copper, routed along thebase of the enclosure (either between the enclosureand wall or in front of the enclosure) to enter throughone of the holes located in the bottom edge side panel,at the front (burner) end.

Refer to Section 4.8 and 4.19 and Figs. 8, 9, 10 or 11.for the size, type and position of the connections.

The Flow and Return pipework can be routed to eitherside of the boiler as required.

For condensate disposal pipework refer to Section 5.

1 To gain access to the water connections, removethe two screws securing the bottom of the backpanel and remove it by withdrawing it forwards atthe bottom. Remove the top casing panel.

2 To gain access to the burner, remove the frontpanel by turning the handle and withdrawing itforwards at the bottom..

3 If required, fit the Grant sealed system kit, seeSection 6.5.

4 Carefully manoeuvre the boiler in position to lineup with pipework through the wall. Complete thewater connections.

Note: Check that the baffles are in position andthat the cleaning cover is correctly fitted and agood seal made.

5 If the boiler is installed against a wall, fit the wallflashing strip. Position the strip with the bottomedge of the wider flange 20 mm above theenclosure top panel, with the narrow flange (withthe three fixing holes) flat against the wall. Thestrip should overhang the top panel by an equalamount at each end.

Mark the position of the three fixing holes onto thewall, drill and plug the wall and secure the stripwith suitable screws (not supplied).

6 Fill and vent the water system and check for leaks,rectifying where necessary.

Make the water connections6.3



Fig. 16 - Plume diverter kit (Outdoor boiler)

Self tappingscrew 3mm(x2)

Locking band(x2)

Telescopiclocking band(x1)

Locking band(x2)

Adjustablewall bracket(x2)

Terminalelbow (x1)

Telescopicflue pipe1000mm long(x2)

Starter elbow(x1)

Plume diverter kit components

GP

DA

90 =

1240 -

2080

GP

DA

200 =

1290 -

2140


Fig. 17 - Horizontal external flue

Garden wall

Outdoormodule

Garden wall

Extensions

45° elbows

Straightterminals

Straightstarter

Maximum horizontallength 3 metres


The following flue components are available from your local stockist

50/70 and 50/90 models

Item

External starter elbow

External starter - straight

150 mm extension

250 mm extension

450 mm extension

950 mm extension

195-270 mm adjustable extension

45° elbow

High level terminal

Vertical terminal

Wall bracket - standard

Wall bracket - extended

Straight terminal - Horizontal flue

Part No.

GKM90

GKM90C

GX150/90

GX250/90

GX450/90

GX950/90

GXA250/90

GE45/90

GTH90

GTV90

GWB90

GEB90

GTL90

90/120, 120/155, 155/200 and 200/240 models

Item

External starter elbow

External starter - straight

150 mm extension

250 mm extension

450 mm extension

950 mm extension

195-270 mm adjustable extension

45° elbow

High level terminal

Vertical terminal

Wall bracket - standard

Wall bracket - extended

Straight terminal - Horizontal flue

Part No.

GKM200

GKM200C

GX150/200

GX250/200

GX450/200

GX950/200

GXA250/200

GE45/200

GTH200

GTV200

GWB200

GEB200

GTL200


Fig. 19 - 50/70 rear view (showing pump assembly)


See Figs. 18 and 19

1 The kit includes the following items:

Pressure relief valve and automatic air ventManifold pipe10 litre expansion vessel with flexible hose andsealing washerExpansion vessel mounting bracketFilling loop kitPressure gauge (mounted on compression tee)6 m head circulating pump with 22 mm gate typevalves15 mm copper pressure relief valve discharge pipe(in two pieces with push-fit connector)Pump support bracket (with fixing screws)

2 Unscrew and remove the two nuts and washersfrom the two cleaning door studs. Remove cleaningdoor from boiler.

3 Remove the ½" BSP black iron plug from the frontof the boiler waterway, using a 3/

8" drive socket

wrench.

4 Fit the ½" BSP straight connector end of theflexible expansion vessel hose into the tapping onthe front of the waterway using a suitable threadsealant.

5 Fit the ¾" BSP connection on the flexibleexpansion vessel hose to the vessel using the blackrubber sealing washer supplied and tighten theunion nut.

6 Replace the cleaning door on the two door studs.Fit the expansion vessel mounting bracket onto thestuds. Replace the nuts and washers and re-tightento secure door and bracket.

Sealed system kit - 50/706.5a

7 Fit the pressure relief valve and automatic air ventonto the manifold pipe. Then fit the manifold pipeend into the 22mm compression connector on theboiler flow pipe. Refer to Fig. 18.

Fig. 18 - 50/70 top view (showing automatic airvent, pressure relief valve and manifold)

Pressure relief valve

Manifoldpipe

Automaticair vent

Pressure reliefvalve discharge pipe

Tectiteconnector

8 Fit both 22 mm pump valves to the circulatingpump using the sealing washers provided.

9 Fit the pump support bracket, with the screwsprovided, using the two holes in the left hand sidepanel flange (viewed from rear of boiler as shownin Fig. 19).

Pump supportbracket

Screws

Pump andvalve assy.


10 Fit the pump/pump valve assembly to the end ofthe pressure relief valve/auto air vent manifoldpipe. Ensure that the pump shaft is horizontal andthe pump motor is facing towards the right side ofthe boiler (viewed from the rear as shown in Fig.19). The flow arrow on the body of the pump mustface in the required direction of flow – away fromthe boiler flow connection – downwards in thiscase.

11 Ensure that the pump/valve assembly is supportedby the bracket. The upper part of the lower valveshould rest on the support bracket, with the body ofthe valve passing through the cut-out. Connect theflow pipework to the lower pump valve.

12 Assemble the two sections of the pressure reliefvalve discharge pipe using the 15 mm straightpush-fit connector provided. Adjust the pressurerelief valve so that the outlet points to the rear leftcorner of the boiler (viewed from the rear of theboiler).

13 Fit the pressure relief valve discharge pipe to thepressure relief valve outlet using the nut and oliveprovided. Route the pipe down the left hand rearside of the boiler and locate the lower end throughthe slot in the bottom flange of the left hand sidepanel.

14 The circulating pump may be wired into the boilercontrol panel if required. Refer to Section 10.

15 The pressure gauge and filling loop should beinstalled in a convenient position inside thebuilding.


Sealed system kit - 50/906.5b

See Fig. 20

1 The kit includes the following items:

Pressure relief valve and automatic air ventManifold pipe12 litre expansion vessel with flexible hose andsealing washerFilling loop kitPressure gauge (mounted on compression Tee)6 m head circulating pump with 22 mm gate type valves15 mm copper pressure relief valve discharge pipe

2 Remove the ½” BSP black iron plug from the front ofthe boiler waterway, using a 3/

8" drive socket wrench.

3 Fit the ½” BSP straight end of the flexibleexpansion vessel hose to the tapping on the front ofthe waterway using a suitable thread sealant.

4 Position the 12 litre expansion vessel on the frontof the boiler combustion door locating the bracketinto the slot of the combustion door.

5 Fit the ¾” BSP connection of the flexibleexpansion vessel hose to the vessel using the blackrubber washer supplied and tighten the nut.

6 Fit the 22 mm compression elbow onto the boilerflow connection.

7 Fit the pressure relief valve and automatic air ventonto the manifold pipe. Then fit the manifold pipeend into the 22mm compression connector on theboiler flow pipe.

8 Fit both 22 mm pump valves to the circulatingpump using the sealing washers supplied.

9 Fit the pump assembly to the automatic air vent/pressure relief valve assembly ensuring that thepump shaft is horizontal and the pump motor isfacing towards the front of the boiler. The flowarrow on the body of the pump must face in thedirection of flow away from the boiler connection.

10 Fit the pressure relief valve discharge pipe to thepressure relief valve using the nut and olivesupplied. Route the discharge pipe through the slotin the base of the right hand side panel. Push thepanel insulation back to expose the slot.


12 The pressure gauge and filling loop should beinstalled in a convenient postion inside thebuilding.



5 Fit the vessel support bracket to the bottom two studsof the combustion door and refit the nuts and washers.Tighten to ensure an adequate seal is made.

6 Position the 16 litre expansion vessel onto thesupport bracket in front of the boiler combustiondoor locating the top of the vessel behind thecontrol panel first.

7 Screw in the locking screw on the base of thebracket to secure the vessel in place.

8 Fit the ¾” BSP connection of the flexibleexpansion vessel hose to the vessel using the blackrubber washer supplied and tighten the nut.

Sealed system kit - 90/120 and 120/1556.5c

Fig. 20 - Sealed system pump assembly

Automatic air vent

Flow connectionon top of boiler

Compression elbow

Front of boiler

9 Fit the 28 mm compression elbow onto the boilerflow connection.

10 Fit the pressure relief valve and automatic air ventonto the manifold pipe. Then fit the manifold pipeend into the 28mm compression connector on theboiler flow pipe.

11 Fit both 28 mm pump valves to the circulatingpump using the sealing washers supplied.

12 Fit the pump assembly to the automatic air vent/pressure relief valve assembly ensuring that thepump shaft is horizontal and the pump motor isfacing towards the front of the boiler. The flowarrow on the body of the pump must face in thedirection of flow away from the boiler connection.

13 Fit the pressure relief valve discharge pipe to thepressure relief valve using the nut and olivesupplied. Route the discharge pipe through the slotin the base of the right hand side panel. Push thepanel insulation back to expose the slot.


The expansion vessel fitted is supplied with a chargepressure of 1.0 bar (equivalent to a max. static head of10.2 metres). The charge pressure must not be lessthan the actual static head at the point of connection.Do not pressurise the vessel above 1.5 bar.

The air pressure in the vessel must be checked annually.

The central heating system volume, using the expansionvessel as supplied, must not exceed the recommendedvolumes. If the system volume is greater, an extraexpansion vessel (complying with BS 4841) must befitted as close as possible to the central heating returnconnection on the boiler. The charge pressure of the extravessel must be the same as the vessel fitted in the boiler.Refer to BS 7074:1 for further guidance.

The air charge pressure may be checked using a tyrepressure gauge on the expansion vessel Schraedervalve. The vessel may be re-pressurised using asuitable pump. When checking the air pressure thewater in the heating system must be cold and thesystem pressure reduced to zero.

See Fig. 20

1. The kit includes the following items:

Pressure relief valve and automatic air ventassemblyManifold pipe16 litre expansion vessel with flexible hose andsealing washerFilling loop kitPressure gauge(mounted on compression Tee)7 m head circulating pump with 28 mm gate type valves15 mm copper pressure relief valve discharge pipe

2 Remove the ½” BSP black iron plug from the front ofthe boiler waterway, using a 3/

8" drive socket wrench.

3 Fit the ½” BSP straight end of the flexibleexpansion vessel hose to the tapping on the front ofthe waterway using a suitable thread sealant.

4 Remove the nuts and washers from the boilercombustion door.

Sealed system expansion vessel pressure6.6



See wiring diagrams in Section 10

Note: A test switch is fitted to the control panel toallow the boiler to be test-fired. When On, theswitch by-passes the external control system.

1 Undo the three screws and remove the lefthandcover from the control panel to gain access to theboiler terminal block.

2 Pass the mains power supply cable through thecable grommet in the control panel, through thecable clamp and connect to the terminal block asfollows:-

Live (brown) to terminal 2 - marked permanentliveNeutral (blue) to terminal 3 - marked mainsneutralEarth (green/yellow) to terminal 4 - markedmains earth

3 If the circulating pump is to be fitted within theboiler enclosure, the pump live must be connectedto terminal 7 of the boiler terminal block.

Pass the pump power supply cable through thecable grommet in the control panel, through thecable clamp and connect to the terminal block asfollows:-

Earth (green/yellow) to terminal 10 - marked ENeutral (blue) to terminal 9 - marked NLive (brown) to terminal 7

Connecting the pump in this way allows it to beisolated using the isolating switch fitted in the boilercontrol panel, for servicing or maintenance work.

4 Ensure that the cable clamp is tightened and that allcables are secure.

5 Replace the cover on the control panel, with theyellow warning label facing outwards and secure withthe three screws.

Do not switch on the electrical power to theExternal Module at this stage.

See Fig. 6

If a two pipe system is to be used refer to Section 4.4.6.

1 Remove the oil inlet plug from the fuel pump andconnect the elbow of the flexible fuel hose suppliedwith the boiler.

2 Connect the flexible fuel hose to the rigid supplyusing the adaptor supplied. The supply enters theenclosure through one of the holes in the bottom ofthe side panels.

1 Automatic air vent(s) are fitted to the top of theboiler. Check that the small cap on the top of eachair vent is screwed on fully, then unscrew it onecomplete turn - the cap remains in this positionfrom now on.

2 If the flexible filling loop is used to fill the system, ensureit is connected and that the valve connecting it to thesystem is open and the valve at the front is closed.A valve is open when the operating lever is in line withthe valve, and closed when it is at right angles to it.

3 Ensure that the mains cold water supply valve is open(operating lever in line with the valve), then turn on themains cold water supply and gradually open the frontvalve on the filling loop until water is heard to flow.

4 Vent each radiator in turn, starting with the lowestone in the system, to remove air.

5 It is important that the pump is properly vented toavoid it running dry and damaging its bearings. Togain access to the pump for venting it is necessaryto remove the top panel, or rear panel (50/70 modelonly).Remove the cap, then unscrew and remove the plugfrom the centre of the pump. Using a suitablescrewdriver rotate the exposed spindle about oneturn. Replace the plug and cap.

6 Check the operation of the safety valve by turningthe head anticlockwise until it clicks. The click isthe safety valve head lifting off its seat allowingwater to escape from the system.Check that this is actually happening.

7 Continue to fill the system until the pressure gaugeindicates between 0.5 and 1.0 bar. Close the fill pointvalve and check the system for water soundness,rectifying where necessary. Water may be releasedfrom the system by manually operating the safetyvalve until the system design pressure is obtained.

Connect the power supply6.7 Connect the fuel supply6.8

Fill the sealed system6.9



Burner components6.10

Fig. 21 - RDB burner components

1 Pump2 Control box3 Reset button with lock-out lamp4 Flange with gasket (do not remove from boiler)

7

8

1

23

5

4

6

5 Air damper adjustment screw6 Air supply tube connection (balanced flue)7 Pump pressure adjustment screw8 Pressure gauge connection

Note:Remove the factory fitted air inlet spigot adaptor (item 6, above) from the air intake onthe top right hand side of the burner and fit the grey plastic air inlet grille in its place.

See Note below

8 The system design pressure (cold) should bebetween 0.5 bar and 1.0 bar. The pressure isequivalent to the maximum static head in bar + 0.3(1 bar = 10.2 metres of water), where the statichead is the vertical height from the centre of theexpansion vessel to the highest point of the system.

9 Close the valves either side of the filling loop anddisconnect the loop.


7 - COMMISSIONING and BOILER PASSPORT

Refer to Fig. 22 for boiler controls

Note: Check that the baffles are in position andthat the cleaning cover is correctly fitted and agood seal made.

IMPORTANT:Check that the turbulators are in position and thatthe ends are vertical (see Fig. 28).

Note: If the 50/90 model is down-rated to 68,240 or51.200 Btu/h, or the 120/155 to 123,000 Btu/h theburner head must be changed. See Section 3.3 andSections 9.2 and 9.4.

The Riello RDB 2.2 burner fitted to 50/70 boilerincorporates a secondary air adjustment shutter locatedwithin the air inlet housing. If the burner is to bedown-rated to the minimum output of 51,200 Btu/h, itis essential that this internal shutter be correctlyadjusted. To do this proceed as follows:

1. Switch off the boiler and isolate from the electricalsupply.

2. Remove the burner from the boiler.

3. Undo the two screws and remove the air inlet coverfrom the side of the burner.

Fig. 22

4. The secondary air shutter disc is factory set in position‘C’ – i.e. with the cut-out marked C located againstthe die-cast boss on the fan housing. See Fig 23.

5. Remove the screw from the centre of the air shutterdisc, and re-position the disc such that the cut-out‘B’ (see Section 3.3) is located against the castboss on the fan housing. Replace the screw in thecentre of the air shutter disc and tighten.

6. Re-fit the air inlet cover to the side of the burner.

7. Change nozzle - Refer to Section 3.3 for correctnozzle for new output setting.

8. Re-fit the burner to the boiler.

Fig. 23 - 50/70 burner air adjuster disc (shownset to position 'C')

D

E

F

G

H

LM I

Boiler Passport - The Installer is responsible for completing the boiler passport supplied with this boiler andreturning the paperwork to Grant Engineering (IRL) Ltd.. This appliance must be correctly commissioned inaccordance with the appliance instructions and the details returned to Grant Engineering (IRL) Ltd. using the

address shown on the back of this manual.

BOILER ON/OFF SWITCH

ISOLATES PUMP (IF WIRED

INTO BOILER CONTROL

PANEL) & BURNER ONLY.

THIS COVER IS TO BE

REMOVED BY QUALIFIED

PERSONNEL ONLY

DO NOT REMOVE COVER

WITHOUT ISOLATING

SWITCHED LIVE AND

FROST 'STAT

PERMANENT LIVE

TEST SWITCH

OVERIDES SYSTEM

CONTROLS TO

OPERATE BOILER

‘Lock-out’ reset buttonBoiler front

panel removed

Control Panel


THIS CONTROL PANEL

BOILEROFF

OVERHEAT

RESET

TESTSWITCH

OFF

HEATING

THERMOSTAT

ON ON


Overheat thermostatreset button

(under screw cover)

Boilerthermostat

BoilerOn/Off switch

Testswitch


THIS CONTROL PANEL

BOILEROFF

OVERHEAT

RESET

TESTSWITCH

OFF

HEATING

THERMOSTAT

ON ON



7 - COMMISSIONING

It is important that the following commissioningprocedure is carried out to ensure safe and efficientoperation of the boiler.

1 Check that the water system has been vented (andpressurised if sealed system) and there are no leaks.

Ensure the flow pipe has been vented.

2 Check that all fuel line valves are open.

3 Remove the plastic burner cover (two screws) if itwas not previously removed.

4 Connect a combined vent manifold and pressuregauge to the pressure gauge connection port on the oilpump. See Fig. 21. Open the vent screw on your ventmanifold to vent the supply while the pump is running.

5 Check that all system controls are calling for heat andturn the boiler thermostat to maximum. Switch on theelectricity supply.

Note: The boiler will start as soon as the electricitysupply to it is switched on.

6 The burner fan should start and the burner shouldlight within about 12 seconds. If the burner doesnot light and the 'Lock-out' reset button lights, waitfor about 45 seconds then press the reset button torestart the ignition process. This procedure mayhave to be repeated several times during firstlighting.

7 With the burner alight, check the fuel pressure.Refer to the Technical Information, Section 3.3.Adjust the pressure if necessary - see Fig. 21.

8 Operate the boiler until it reaches normal operatingtemperature. Check oil supply/return pipe for leaks,rectifying where necessary.

9 Check the operation of the boiler thermostat.Ensure that by turning it anticlockwise it switchesthe burner off.

10 With the burner alight, re-check the fuel pressureand re-adjust if necessary. Turn the boiler off,remove the pressure gauge and replace the plug inthe pump.

11 Having ensured that there are no oil leaks, replace theburner cover.

12 Relight the boiler and allow it to run for 20minutes.

Insert combustion probe into the end of the flueterminal to measure the CO

2 level.

Do not use the boiler test point.

13 Check the smoke number, if satisfactory check theCO

2. Set the CO

2 to the value given in Section 3.3

for the boiler concerned.

Use the hexagonal key supplied to adjust theburner air damper (see Fig. 21) as required.Turning the screw anti-clockwise closes thedamper and increases CO

2 level, turning the screw

clockwise opens the damper and reduces CO2 level.

Re-check the smoke number if the damper has beenmoved. Under no circumstances must the smokenumber be above 1.

Note: It is important that the air damper iscorrectly set.

Note: To obtain the correct CO2 level, the final

flue gas reading must be taken with all casingpanels fitted.

14 Check the flue gas temperature.

15 When the boiler has been adjusted and is runningsatisfactorily, balance the central heating system byadjusting the radiator lock shield valves. Start withthe radiator nearest the boiler and adjust the valvesto achieve the required temperature drop acrosseach radiator. If thermostatic radiator valves havebeen installed, check the system by-pass.

16 Switch off the boiler.

17 With the system hot, check again for leaks,rectifying where necessary. Drain the system whileit is hot to complete the flushing process. Refill andvent (and pressurise if a sealed system) the system.

18 A suitable central heating system inhibitor must beadded to protect the system against the effect ofcorrosion.

19 Replace the top, front and rear panels.

Note: After commissioning the boiler complete theboiler passport that comes supplied with the boiler andreturn the commissioning details to Grant Engineering(IRL) Ltd..

If the boiler is to be left in service with the User, setthe controls and room thermostat (if fitted) to theUser's requirements.

If the boiler is not to be handed over immediately,close the boiler fuel supply valve and switch off theelectricity supply.If there is any possibility of the boiler being left duringfrost conditions, then the boiler and system should bedrained.


7 - COMMISSIONING

IMPORTANT NOTE:

A combustion test point is provided on the front cleaningdoor.

This test point is not suitable for measuring the final CO2

level, smoke number, boiler efficiency or conventionalflue draught.

At this test point on the cleaning cover the flue gastemperature reading will be higher than that measured inthe flue thus resulting in an inaccurate efficiency reading.To obtain an accurate flue gas CO

2 level, smoke number,

temperature and efficiency, the reading can only bemeasured at the low level flue terminal or the test pointon the conventional flue starter elbow where fitted withall the casing panels fitted.

8 - INFORMATION FOR THE USER

The User must be advised (and demonstrated ifnecessary) of the following important points:-

1 How to light and turn off the boiler and how tooperate the system controls.

2 The precautions necessary to prevent damage tothe central heating system and to the building, inthe event of the boiler not being in operationduring frost conditions.

3 The importance of servicing the boiler to ensuresafe and efficient operation. This should normallyonly be required once a year.

4 The type of fuel used.

5 That any servicing or replacement of parts mustonly be carried out by a suitably qualified engineer.

6 Ensure that the boiler controls and room thermostat(if fitted) are set to the User's requirements.

7 If the boiler is used on a sealed heating system, tellthe user the system pressure and show them theposition of the safety valve discharge pipe.

8 Show the User how to reset the overheat thermostatand how to restart the boiler if it goes to 'Lock-out'.

Leave this Instruction manual with the User.

To ensure your continued Boiler Warranty, the annualservice must be carried out by an OFTEC RegisteredTechnician or an otherwise competent person.

Use of non-competent persons may invalidate thiswarranty. A list of OFTEC Registered Technicians isavailable at www.oftec.org or alternatively telephoneOFTEC on 0845 658 5080 (UK) or 01 864 5771 (ROI).


9 - BOILER SERVICING

To ensure efficient operation of the boiler it isrecommended that it is checked and serviced as necessaryat regular intervals. The frequency of servicing willdepend upon the particular installation conditions andusage, but in general once per year should be adequate.

Servicing and replacement of parts must only becarried out by a suitably qualified engineer.

Important: Details of every service should be enteredin the boiler passport. This information may berequired to validate the Grant extended warranty.

IMPORTANTBefore starting any work on the boiler, or fuel supplyplease read the health and safety information given inSection 14 on page 43.

Note: A test switch is fitted to the control panel toallow the boiler to be test-fired. When On, theswitch by-passes the external control system.

1 Check the flue terminal and ensure it is not blockedor damaged.

2 Run the boiler and check the operation of its controls.

3 Ensure that all water/fuel system connections andfittings are sound. Remake any joints and check thetightness of any fittings that may be leaking.

If the boiler is used on a sealed central heatingsystem, check the system pressure, check theoperation of the pressure relief valve and check theexpansion vessel air charge. See Section 6.6.

Refill, vent and re-pressurise the system asnecessary. See Section 6.9.

4 Check that the louvres in the front panel are clear.

5 Remove any sludge/water from the fuel tank byopening the sludge valve at the lower end of the tank.

6 With the fuel supply valve closed, clean/replace thefilter element and clean the filter bowl.

7 Flexible fuel supply hoses should be inspectedannually when the boiler is serviced and braidedhoses replaced every year. If in doubt replace thehoses.

Warning: Before servicing, set the boiler On/Offswitch to Off, isolate the electricity supply and closethe fuel supply valve. Allow the boiler to cool.The data label on the inside of the case side panel willindicate the nozzle fitted.

1 Remove the front panel by turning the handle andwithdrawing it forwards at the bottom.

2 Remove the four screws securing the top panel andcarefully lift it off, taking care not to damage theinsulation.

Note: The top panel has been designed to providea slight fall away from the side positioned against awall, the side of the top panel with the fixingscrews closer to the bottom edge is the highest sideand goes against the wall.

3 Remove the burner fixing nut (top of mountingflange) and withdraw the burner.If required, disconnect the flexible oil hose(s), usea suitable container to prevent any oil spillage.

Note: If two flexible hoses are connected to theburner, identify (mark if necessary) which is theinlet and return if they are to be disconnected.

1 Remove the nuts and washers securing the frontcleaning door and withdraw the door. Take care - itis heavy.

2 Remove the baffles as shown in Fig. 24, 25, 26 or27.

3 Remove all deposits from the baffle plates and allthe boiler internal surfaces using a stiff brush andscraper if necessary.

4 Check the condition of the flue, clean as necessary.

5 Check the condition of the front cleaning door seal,replace if necessary.

6 Replace the baffles, ensuring they are correctlyfitted. See Fig. 24, 25, 26 or 27.

Note: 50/70 - Ensure that the front handle on thetop baffle (No. 4) is correctly located over the frontsection of baffle No. 3.

7 Pull out the spiral turbulators from the heat exchangertubes. See Fig. 28.Clean the turbulators using a stiff brush

Test the heat exchanger condensate drain bypouring water into one of the lower tubes andobserve whether the water dicharges from the22mm condensate outlet. Replace the turbulators.

IMPORTANT: When replacing the turbulatorsensure that the flat end sections are all positionedvertically.

Important notes prior to servicing9.1

Dismantling prior to servicing9.2

Cleaning the boiler9.3



Fig. 25 - 50/90 baffles

Fig. 26 - 90/120 and 120/155 baffles

1

2

3

4

Fig. 24 - 50/70 baffles

8 Replace the front cleaning door, ensuring the sealis in good condition and secure it in position withthe nuts and washers previously removed. Tightento form a seal.

9 Remove the condensate trap and check that it is notblocked and is operating correctly, i.e. the float isfree to move. Clean the trap and float as required.Refer to Section 5.7.

10 Check that the boiler condensate outlet isunobstructed. Clean if necessary.

Fig. 27 - 155/200, 200/240 baffles

Top baffle Bottom baffle

Fig. 28 - Removal/replacement of spiralturbulators (50/90 shown)

Turbulators

Position in vertical plane

IMPORTANT:The ends of theturbulators mustbe vertical



Fig. 29

4 ± 0.3 mm

3 to 3.5 mm

Clamp screw

Cleaning the burner9.4

50/70, 70/90, 90/120 and 120/155 - See Section 13

1 Combustion head - Loosen the two screwssecuring the combustion head and withdraw thehead. Clean and refit the combustion head.

2 Inspect the ignition electrodes - Remove thecombustion head.

Loosen the electrode clamp screw and withdraw theelectrode assembly. Wipe clean and check for anycracks in the ceramic insulation. Replace if necessary.

Check the electrode settings

Electrode tips approximately 4 mm apart and 3 to3.5 mm in front of the nozzle, see Fig 29.

3 Nozzle - The nozzle should be replaced on anannual service - Check that the nozzle size and typeare correct, refer to table in Section 3.3 and boilerdata label.

With the combustion head removed, loosen theelectrode assembly clamp screw and slide theelectrodes away from the nozzle.

Do NOT attempt to clean the nozzle.

Remove the nozzle using a good fitting spanner(16 mm). The use of an ill-fitting spanner willdamage the nozzle and could lead to an incorrectflame pattern. Always check the electrodesettings after replacing the nozzle, see Fig. 29.

155/200 or 200/240 models - See Section 13.2 and Fig. 30

1 Combustion head - Loosen the two screwssecuring the combustion head (NOT the screws inthe slotted ring, Fig. 32) and withdraw the head.Clean and refit the combustion head.

2 Inspect the ignition electrodes - Remove thecombustion head.Loosen the electrode clamp screw, disconnect theleads and withdraw the electrode assembly. Wipeclean and check for any cracks in the ceramicinsulation. Replace if necessary.

3 Check the electrode and diffuser settings - Fig. 31

To adjust the diffuser disc: Loosen the diffuser clampscrew and slide the disc along the nozzle holder toachieve the gap 'A' in Fig. 31, tighten the screw.

To adjust the electrodes: Loosen the electrodeclamp screw and move the electrode unit to achievethe gap 'B' in Fig. 31, tighten the screw.

Fig. 30

Combustionhead

Combustion headfixing screw

Electrode clampscrew

Electrodeleads

Nozzleholder

Diffuser clampscrew

Burnerflange

Fig. 31

A

BElectrode clamp screw

5.75 0-0.2

3+0.50

Diffuser clamp screw

4.0 +0.5

7.5 +0.7- 0.5

_B

ADiffuser disc

4 The combustion head position is adjustable on the155/200 and 200/240 burners. Check that it is fullyclosed (position 0), or the 4th line if the 200/240has been set to maximum output (70 kW).

To adjust the head setting, refer to Fig. 32 andproceed as follows: Loosen the two screws in theslotted ring - NOT the two fixing screws, and turnthe blast tube until '0' lines up with the edge of theslotted ring. Tighten the two screws.



Vortex External Module wiring diagram

Colour code: br - Brown, r - Red, bl - Blue, y - Yellow, g/y - Green/Yellow

1

2

3

4

5

6

7

8

9

10

11

12

13

L

L

N

E

L

N

E

L

N

E

Earth toswitch cover

Control boxchassis earth

Control boxchassis earth

Testswitch

Limitthermostat

C 2

Boilerthermostat

C 1

Frostthermostat

1

2

Mains On/Offswitch

5B 2A

4B 1A

Switched Live

Permanent Live

Mains Neutral

Mains Earth

To CH valve if required

Pump Live

Pump Neutral

Pump Earth

Burner Live

Burner Neutral

Burner Earth

g/y

y

g/y

g/y g/y

g/y

g/y

g/y

g/y

br

br

blbl

rr

r y

bl

y

y

r

bl

r

r

r

Fig. 32

0

Screw

Slotted ring

Screw Combustionhead

Combustionhead fixingscrew

All models

1 Photocell - The photocell is a push-fit in the burnerbody. Carefully pull out the photocell to clean.

2 Burner fan - With the air intake grille or spigotremoved, remove the screws securing the fanhousing cover (R/H side of burner) and remove thecover. Inspect the fan and housing and clean asnecessary. Replace the cover.

3 Pump filter - With the burner cover removed,remove the four screws securing the pump endcover. Remove the filter and wash in kerosene.Check for the presence of sludge or water. Replacethe filter and end cover, ensure the 'O' ring is inposition.

Re-assemble in reverse order.

To ensure safe and efficient operation of the boilerit is important that re-commissioning is carried out,especially combustion checks (CO

2 level, flue gas

temperature and smoke number) after the boilerhas been serviced.

Refer to the Commissioning instructions starting onpage 31.

10 - WIRING DIAGRAM


11 - FAULT FINDING

Burner fault finding11.1M

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tow

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12

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11 - FAULT FINDING

Boiler fault finding11.2

Warning: Always isolate the electricity supply to the boiler before working on the boiler.

Ensure that an adequate supply of fuel is available and that the fuel supply valveis open.Check the condition of the fuel filter, clean if necessary.Ensure fuel supply is reaching burner and vent pump.

Ensure electricity supply to the boiler is switched on and that all controls are callingfor heat.Ensure that the overheat thermostat has not tripped, reset if necessary.Check that a mains supply is present at the burner terminal block. If not, check theboiler and overheat thermostat.

Press the reset button on the burner control box if it is lit.Refer to burner fault finding flow diagram.

If the flame is unstable, check the combustion settings.Refer to burner fault finding flow diagram.

Insufficient air supply - check the air damper setting and the condition of the fan.Check the nozzle size and type.Fuel pressure may be too high - check and adjust.

Insufficient air supply - check the air damper setting and the condition of the fan.Check the nozzle size and type.

Insufficient air supply - check the air damper setting and the condition of the fan.Check the nozzle size and type.Fuel pressure may be too low - check and adjust.Insufficient draught - clean boiler heat exchanger and check condition of flue.

Undersize nozzle and/or low fuel pressure.Check condition of boiler heat exchanger and clean if necessary.Check the boiler thermostat.Check the combustion settings.Check the condition of the fuel filter.

Faulty boiler thermostat.

Check all fuel line connections, remake as necessary.

Check boiler cleaning cover and seal are correctly fitted.Check burner is correctly fitted onto flange.Check flue is correctly sealed into flue outlet of boiler.Check the condensate pipe and trap are operating correctly.

Faults Remedies

Boiler will not start

1 No fuel supply.

2 No electricity supply.

3 Burner not starting - fuel andelectricity supplies present.

4 Burner lights but goes to 'lock-out'.

Boiler works but:-

5 Visible smoke from flue or highsmoke number.

6 Burner pulsates.

7 Flame slow to stabilise during start up.

8 Water temperature low.

9 Boiler operating on overheatthermostat.

10 Oil odours.

11 Combustion fumes smell.


12 - BURNER HEADS

Vortex External Module - Burner Heads

20 dia.

15 x 4.5dia.

5 x R5

T2 - 50/90

20dia.

15 x 5.5dia.

5 x R5

T3 - 90/120, 120/155

23dia.

15 x 5.5dia.

5 x R5

T5 - 120/155

18dia.

15 x 4dia.

5 x R3

T1 - 50/70, 50/90

GIB - 155/200, 200/240


1 Not applicable ........................................... -2 Flange ....................................................... 30057863 Combustion head T1 - 50/70, 50/90 .......... 30025073 Combustion head T2 - 70/90 ..................... 30024233 Combustion head T3 - 90/120, 120/155 .... 30024473 Combustion head T5 - 120/155 ................. 30025334 Electrode assembly .................................... 30075135 Electrode bracket ...................................... 30065526 Nozzle holder ............................................ 30086427 Collar ........................................................ 30086438 High voltage lead ...................................... 30087949 Air damper assembly ................................. 300864710 Fan - 50/70 ................................................ 300570810 Fan - 90/120 .............................................. 300864510 Fan - 50/90, 120/155 ................................. 300578811 Photocell ................................................... 300864612 Capacitor 4.5 µF ....................................... 300283713 Seal kit ...................................................... 3008878

Key No. Description Part No. Key No. Description Part No.

14 Needle valve ............................................. 300758215 Regulator .................................................. 300865116 Pump seal .................................................. 300043917 Pump ........................................................ 300865418 'O' ring ...................................................... 300716219 Filter - 'O' ring ........................................... 300865320 Connector ................................................. 300360221 Flexible pipe ............................................. 300767222 Tube .......................................................... 300864423 Pressure gauge connector .......................... 300887624 Drive coupling .......................................... 300044325 Solenoid .................................................... 300864826 Motor ........................................................ 300283627 Cover ........................................................ 300864928 Control box assembly ................................ 300865229 Solenoid lead ............................................ 300885130 Cover ........................................................ 300887931 Air intake cover ......................................... 3008649

13 - BURNER SPARE PARTS

Riello RDB1, 2, 2.2 burner - exploded view13.1


Riello RDB3.2 burner - exploded view13.2

1 Flange ............................................. 30086372 Combustion head GIB ..................... 30025723 Diffuser disc assembly .................... 30201804 Nozzle holder .................................. 30025705 High voltage lead ............................ 30087946 Collar .............................................. 30089577 Seal kit ............................................ 30089638 Air damper assembly ....................... 30088399 Insulation ........................................ 300895810 Fan .................................................. 300579911 Photocell ......................................... 300864612 Cover .............................................. 300896213 Electrode ......................................... 302012114 Capacitor 5 µF ................................ 300896015 Connector ....................................... 3003602

Key No. Description Part No. Key No. Description Part No.

16 Flexible pipe ................................... 300572017 Motor .............................................. 300896418 Pressure gauge connector ................ 300887619 Tube ................................................ 300896120 Drive coupling ................................ 300044321 Solenoid .......................................... 300864822 Solenoid lead .................................. 300885123 Pump .............................................. 300865424 Pump seal ........................................ 300043925 Filter - 'O' ring ................................. 300865326 Regulator ........................................ 300865127 Needle valve ................................... 300758228 Control box assembly ...................... 300865229 Cover .............................................. 3008649

13 - BURNER SPARE PARTS


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 toprovide information on substances hazardous to health (COSHH Regulations 1988).Adhesives, sealants and paints used in the manufacture of the product are cured and present no known hazards whenused in the manner for which they are intended.The following other materials are present in the product:

Insulation materials

Material Types: Ceramic fibre board, mineral wool.

Description: Rigid board, slabs, sleeves, gaskets, ropes.

Known Hazards: May cause temporary irritation or rash to skin. High dust levels may irritate eyes and upperrespiratory system.

Precautions: Avoid unnecessary or rough handling, or harsh abrasion of boards. Normal handling and use ofmaterial should not produce high dust levels.Avoid inhalation, and contact with skin and eyes.After handling always follow normal good hygiene practices.

Protection: Use disposable gloves, face mask and eye protection.

First Aid: Eyes - If irritation occurs, wash eyes with copious amounts of water. If symptoms persist, seekimmediate medical advice.Skin - If irritation occurs, wash under running water before washing with soap and water.Inhalation - Remove to fresh air, drink water to clear throat and blow nose to remove dust/fibres.Ingestion - Drink plenty of water.

Sealants

Material Types: Silicone elastomer.

Description: Sealant and adhesive.

Known Hazards: Irritation to eyes.

Precautions: Avoid inhalation of vapour, contact with eyes and prolonged or repeated contact with skin.After handling always follow normal good hygiene practices.

Protection: Use eye protection. Rubber or plastic gloves should be worn where repeated contact occurs and aface mask worn when working in confined spaces.

First Aid: Eyes - Flush eyes with water for 15 minutes. Seek immediate medical attention.Skin - Wipe off and wash with soap and water.Inhalation - Remove to fresh air.

Kerosene and Gas oil fuels (Mineral oils)

Known Hazards: The effect of mineral oils on the skin vary according to the duration of exposure and the type of oil.The lighter fractions remove the protective grease naturally present on the skin, leaving it dry, liableto crack and more prone to damage by cuts, abrasions and irritant chemicals.Skin rashes (Oil acne) most often on arms, but also on any part of the body in contact with oil oroily clothing.Contact with fuel oils can cause dermatitus.

Precautions: Avoid as far as possible any skin contact with mineral oil or with clothing contaminated withmineral oil.The use of a lanolin-based barrier cream is recommended, in conjunction with regular washing withsoap and rinsing with water to ensure all oil is removed from the skin.Take care to prevent clothing, especially underwear, from becoming contaminated with oil.Do not put oily rags or tools in pockets, especially trouser pockets.Have first-aid treatment at once for an injury, however slight.Do not inhale any vapours from mineral oils.

D247

GRANT ENGINEERING (IRELAND) LTD.,CRINKLE, BIRR, CO. OFFALY.

Telephone: (057) 9120089 / 9120352

This manual is accurate at the date of printing but will be superseded and should bedisregarded if specifications and/or appearances are changed in the interests of continuedproduct improvement.

All goods sold are subject to our official Conditions of Sale, a copy of which may beobtained on application.

© Grant Engineering (Ireland) Limited 2010. No part of this manual may be reproducedby any means without prior written consent.

TERMS OF GUARANTEE

1. The Company shall mean Grant Engineering (Ireland) Limited.

2. The Boiler is guaranteed for a period of 12 months from the date of installation, providing that any workundertaken is authorised by the company and carried out by an approved service agent.

3. The shell (heat exchanger) of oil boilers supplied by Grant Engineering (Ireland) Limited are guaranteed for aperiod of 5 years from the date of installation. All other boiler components, excluding consumables (such asnozzles and filters), for 1 year from the date of installation.

4. This guarantee does not cover breakdowns caused by incorrect installation, neglect, misuse, accident orfailure to operate this boiler in accordance with the manufacturers instructions.

5. This guarantee is not transferable unless sanctioned by the Company.

6. The Company will endeavour to provide prompt service in the unlikely event of a problem occurring, butcannot be held responsible for any consequence of delay however caused.

7. This guarantee does not cover labour, handling or shipping.

8. This guarantee applies to boilers installed on the island of Ireland both North and South. Provision forwarranty cover elsewhere is subject to agreement with Grant Engineering (Ireland) Limited.

EFFICIENT HEATING SOLUTIONS

15 - EC DECLARATION OF CONFORMITY

We declare that the Grant Vortex range of Oil Boilers equipped with Riello RDB burners approved toEN 267: 1991 satisfy the requirements of the following European Directives:-

1. 89/336/EEC - Electromagnetic Compatibility DirectiveReferred to the generic standards EN 55014: 1993, EN 50082: 1: 1992

2. 73/23/EEC - Electrical Equipment Safety Regulations DirectiveReferred to the generic standard NO: 3260: The Electrical Equipment (Safety) Regulations: 1994

3. 92/42/EEC - Hot Water Boiler Efficiency DirectiveReferred to the generic standard The Boiler (Efficiency) (Amendment) Regulations 1994(SI 1994/3083)

EFFICIENT HEATING SOLUTIONS Part No. IRL 007 Rev....

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