Grant CondensingIndoor Wall Hung Oil Boiler Range

Installation & Servicing Instructions

Part No. DOC 84. Rev 00. May 2009

Commissioning Report

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For use with Kerosene only.

After installing the boiler leave theseinstructions with the User.

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

Date:

Commissioning engineer: Tel. No:

Boiler model/output: kW

Fuel type: Kerosene

Nozzle size: Pump pressure:

Air setting: Flue gas % CO2:

Net flue gas temp: Smoke No:

GRANT ENGINEERING (IRELAND) LIMITEDCrinkle, Birr, Co. Offaly, IrelandTel: (057) 91 20089 Fax: (057) 91 21060 Email: info@grantengineering.ie www.grantengineering.ie

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/orappearances are changed in the interests of continued product improvement.All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.© Grant Engineering (Ireland) Limited 2008. No part of this manual may be reproduced by any means without prior writtenconsent.

Contents

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1 Introduction 41.1 How a condensing boiler works 4

1.2 Boiler Description 4

1.3 Boiler Components 5

2 Technical Data 62.1 Boiler technical data –

Condensing wall-hung boilers 6

2.2 Condensing boilers using Class C2 kerosene 7

2.3 Flue gas analysis 7

2.4 Boiler panel assembly 8

3 Oil Storage & Supply System 93.1 Fuel supply 9

3.2 Burner oil connection 11

4 Boiler Installation Information 134.1 Introduction 13

4.2 Boiler location 13

4.3 Preparation for installation 13

4.4 Dismantling the boiler 13

4.5 Installing the boiler 15

4.6 Regulations compliance 16

4.7 Completion 17

4.8 Before you commission 17

4.9 Heating system design considerations 17

4.10 Underfloor heating systems 17

4.11 Pipework materials 17

4.12 Underfloor pipework 17

5 Pipe Connections 185.1 Water connections 18

6 Condensate Disposal 196.1 General requirements 19

6.2 Connections 19

6.3 Pipework 19

6.4 External pipework 19

6.5 Condensate soakaway 19

6.6 Condensate trap 20

6.7 Condensate disposal pipework 20

6.8 Inspection and cleaning of trap 20

7 Electrical 217.1 Connecting the power supply 21

7.2 Frost protection 21

7.3 Control system wiring diagrams 22

7.4 Boiler control panel wiring diagrams 23

8 Flue System & Air Supply 248.1 Air supply 24

8.2 Conventional flue systems 25

8.3 Connecting a conventional flue 27

8.4 Balanced flue systems 27

8.5 Prepare the wall 31

8.6 High level and vertical balanced flue 31

9 Commissioning 329.1 Before switching on 32

9.2 Switching on 32

9.3 Running the boiler 33

9.4 Balancing the system 33

9.5 Completion 33

10 Boiler Servicing 3410.1 Checking before servicing 34

10.2 Dismantling prior to servicing 34

10.3 Cleaning the boiler 34

10.4 Cleaning the burner 35

11 Fault Finding 3611.1 Burner fault finding 36

11.2 Boiler fault finding 39

12 Spare Parts 40

13 Health & Safety Information 4213.1 Insulation materials 42

13.2 Kerosene and gas oil fuels (mineral oils) 42

14 EC Declaration of Conformity 43

1 Introduction

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This manual is intended to guideengineers in the installation andmaintenance of Grant CONDENSINGWall Hung boilers. A User Guide forthe operation of this boiler isattached to the reverse of this manual.

The following special text formats areused in this manual for the purposeslisted below:

Warning of possible human injury asa consequence of not following theinstructions in the warning.

To ensure maximum efficiency, the boilerreturn temperature should be 55°C orless, this will enable the latent heat to becondensed out of the flue gases.

The boiler will achieve net thermalefficiencies of 100%.

To achieve maximum performance fromthe Grant CONDENSING Wall Hungboiler, it is recommended that theheating system is designed so that atemperature differential of 20°C betweenthe flow and return is maintained. Theuse of modulating circulating pumps(now widely available) and effectivecontrol systems should be considered.

The Grant Condensing boiler willhowever still operate at extremely highefficiencies even when it is not incondensing mode and therefore issuitable for fitting to an existing heatingsystem without alteration to the radiatorsizes. The boiler is capable of amaximum flow temperature of 75°C.

1.2 Boiler DescriptionThe Grant CONDENSING Wall Hungrange of automatic pressure jet oilboilers have been designed for use witha fully pumped central heating systemwith indirect domestic hot watercylinder. They are not suitable for usewith either a direct cylinder or a'primatic' cylinder or gravity hot water.

The boilers are suitable for use onsealed central heating systems.

All models are supplied with the controlpanel and burner factory fitted.

The boilers can be connected to either aconventional flue system or a balancedflue system, as required.

For Conventional Flue ApplicationsWhere a chimney is to be lined -Grant recommends the use of the Grant‘Orange’ flue system,specifically designed for the Condensingrange of condensing boilers. Refer toSection 9.2 for further details.

Caution concerning likely damage toequipment or tools as aconsequence of not following theinstructions in the caution.

The flue system materials andconstruction MUST be suitable foruse with oil-fired condensing boilers.Failure to fit a suitable conventionalflue may invalidate the warranty onthe boiler.

For Balanced Flue ApplicationsThe following flue kits are available fromyour local stockist.

Refer to Section 9.4 for further details.

Yellow SystemStandard low level concentric balancedflue - components available:

• Low level concentric balanced flue short - standard

• Extensions 225mm, 450mmand 675mm

• 90° extension elbow

• 45° extension elbow

• 45° elbow

Green SystemStandard external high level/vertical fluestarter kit (room sealed) - componentsavailable:

• External high level/vertical flue starterkit short

• (room sealed)

• Extensions 150mm, 250mm,450mm, 950mm

• and adjustable 195 to 270mm

• 45° elbow

• High level terminal

• Vertical terminal

Note text. Used for emphasis orinformation not directly concernedwith the surrounding text but ofimportance to the reader.

1.1 How a CondensingBoiler WorksDuring the combustion process,hydrogen and oxygen combine toproduce heat and water vapour. Thewater vapour produced is in the form ofsuperheated steam in the heatexchanger. This superheated steamcontains sensible heat (available heat)and latent heat (heat locked up in theflue gas). A conventional boiler cannotrecover any of the latent heat and thisenergy is lost to the atmospherethrough the flue.

The Grant CONDENSING Wall Hungcondensing boiler contains an extraheat exchanger which is designed torecover the latent heat normally lost bya conventional boiler. It does this bycooling the flue gases to below 90°C,thus extracting more sensible heat andsome of the latent heat. This is achievedby cooling the flue gases to their dewpoint (approximately 55°C).

! WARNING

! CAUTION

! NOTE

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White SystemHigh level concentric balanced flue kit -components available:

• Extensions 225mm, 450mm, 950mm

• and adjustable 275 to 450mm

• 45° elbow

• Vertical concentric balanced flue kit

• Extensions 225mm, 450mm, 950mm

• and adjustable 275 to 450mm

• 45° elbow

1.3 Boiler ComponentsAll burners are pre-set for use withkerosene and are supplied ready toconnect to a two pipe fuel supplysystem with two flexible fuel lines and3/8" to 1/4" BSP male adaptor suppliedwith the boiler.

The temperature of the water leavingthe boiler to heat the radiators and hotwater cylinder is User adjustable.

The boiler is fitted with an overheatthermostat (which allows it to be usedon a sealed central heating system)which will automatically switch off theboiler if the heat exchanger exceeds apre-set temperature of 111°C ± 3°C.

The control panel is fitted with anON/OFF switch, boiler thermostatcontrol knob and the manual resetbutton for the overheat thermostat.

To access the controls, open the lowerfront panel by pulling it down as shownin Figure 1-1.

The controls are shown in Figure 1-2.

Figure 1-1: Boiler lower front panel in down position

Figure 1-2: Boiler controls

2 Technical Data

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2.1 Boiler Technical Data – Condensing Wall-hung Boilers

Kitchen/Utility

Model 40/55 55/70

Water content Litres 11 11

Gal 2.4 2.4

Weight - complete boiler (dry) kg 85.7 92.2

lbs 189 203

Weight - boiler shell only (dry)* kg 56.0 56.0

lbs 123 123

Max heat input (kerosene) kW 17.0 21.0

Btu/h 58,000 71,650

Flow connection 22mm - connector (supplied fitted)

Return connection 22mm - connector (supplied fitted)

Min. flow rate ΔT=10°C l/h 1420 1740

Min. flow rate ΔT=20°C l/h 710 870

Condense connection Accepts 21.5mm Ø polypropylene overflow pipe

Flue diameter (conventional flue) mm 100mm

Waterside resistance ΔT=10°C mbar 28.5

Waterside resistance ΔT=20°C mbar 10

Maximum static head m 28

Minimum circulating head m 1

Boiler thermostat range °C 65 to 75

Limit (safety) stat cut-off temperature °C 111 ± 3

Max casing temperature °C less than 50

Electricity supply 230V ~ 50Hz Fused at 5 Amp

Motor power Watts 75

Starting current Amps 2.25

Running current Amps 0.85

Oil connections 1/4" Male BSP

Conventional flue draughtN/m² Min - 8.7 Max - 37

in.wg Min - 0.035 Max - 0.15

Max operating pressure - open system bar 2.5

* Weight of shell - without baffles & clean-out door 45.7kg

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2.2 Condensing Boilers using Class C2 Kerosene

Heat Heat Oil Burner Fuel FlueInput output SEDBUK Nozzle pressure Smoke head flow gas CO2

rate tempModel kW Btu/h kW Btu/h efficiency bar No. type kg/h °C %

13.0 44,350 12.7 43,300 94.9 0.35 80ºEH 7 0 No.1 Fixed 1.09 60 - 65 11 - 12

40/55 14.5 49,470 *14.0 47,770 94.9 0.40 80ºEH 10 0 No.1 Fixed 1.21 65 - 69 11 - 12

17.0 58,000 16.5 56,300 94.9 0.50 80ºEH 7 0 No.1 Fixed 1.43 65 - 69 11 - 12

17.0 58,000 16.5 56,300 93.8 0.50 80ºEH 7 0 No.1 Fixed 1.43 65 - 69 11 - 12

55/70 19.3 65,850 *18.7 63,800 93.8 0.50 80ºEH 10 0 No.1 Fixed 1.61 70 - 75 11 - 12

21.0 71,650 20.3 69,270 93.8 0.60 80ºEH 8 0 No.1 Fixed 1.82 75 - 79 11 - 12

Notes:1. Data given is approximate only.2. The above settings may have to be adjusted on site for correct operation of burner. 3. Gas oil is not suitable for use with the Grant CONDENSING Wall Hung boiler range.4. The net flue gas temperatures given above are ± 10%.5. When commissioning the air damper must be adjusted to obtain correct CO2 level.6. * Factory settings: 40/55 → 14kW 55/70 → 18.7kW7. Combustion door test point may be used for CO2 and smoke readings only. Do not use this test point for temperature or efficiency readings.8. The installer must amend the boiler data label if the output is changed.

2.3 Flue Gas AnalysisTo allow the boiler to be commissionedand serviced, the boiler is supplied witha combustion test point on the frontcleaning door. When this test point isused please note the following:

• The test point is for CO2 and smokereadings only.

• The boiler efficiency and temperaturemust be taken from the flue testpoint on high level, vertical andconventional flue adaptors.

Concentric low level flues do not containa test point. The temperature andefficiency readings must be taken fromthe flue terminal.

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Figure 2-1: Grant CONDENSING Wall Hung boiler panel assembly

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ReturnCold mains

PRVCondensate

Electricity

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FlowReturnCold mainsElectricity

Top

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325

240

100

100

72

220

842

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2.3 Boiler Panel Assembly

All dimensions in the diagram above are in millimetres.

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3.1 Fuel SupplyFuel StorageThe tank should be positioned inaccordance with the recommendationsgiven in BS 5410:1:1997, which givesdetails of filling, maintenance andprotection from fire.

A steel tank may be used and must beconstructed to BS 799:5:1987 andOFS T200.

A galvanized tank must NOT be used.

A plastic tank may be used and mustcomply with OFS T100.

Plastic tanks should be adequatelyand uniformly supported on asmooth level surface, across theirentire load bearing base area, that is,the area in contact with the ground.

Fuel PipesFuel supply pipes should be of coppertubing with an external diameter of atleast 10mm.

Galvanised pipe must not be used.

All pipe connections should preferablyuse flared fittings. Soldered connectionsmust not be used on oil pipes.

Flexible pipes must NOT be usedoutside the boiler case.

A remote sensing fire valve must beinstalled in the fuel supply line (outside)where it enters the building, with thesensing head located above the burner.

Recommendations are given inBS 5410:1:1997.

A metal bowl type filter with areplaceable micronic filter must be fittedin the fuel supply line adjacent to theboiler. A shut-off valve should be fittedbefore the filter, to allow the filter to beserviced.

Two flexible fuel lines, adaptors and 1/4"BSP isolation valves are supplied loosewith the boiler for the final connection tothe burner, with a two pipe system or'Tiger Loop' type de-aerator.

Metal braided flexible pipes should bereplaced annually when the boiler isserviced. Long life flexible pipes shouldbe inspected annually and replaced atleast every 60 months.

! CAUTION

! CAUTION

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Two Pipe System - (See Figure 3-1)With the storage tank outlet below theburner, a two pipe system should beused. The pipe runs should be as shownin Figure 3-1. The return pipe should be atthe same level in the tank as the supplypipe, both being 75 to 100mm above thebase of the tank. The pipe ends shouldbe a sufficient distance apart so as toprevent any sediment disturbed by thereturn entering the supply pipe.

Avoid the bottom of the tank beingmore than 3m below the burner.

A non-return valve should be fitted inthe supply pipe together with the filterand fire valve. A non-return valve shouldbe fitted in the return pipe if the top ofthe tank is above the burner.

The pump vacuum should not exceed0.4 bar.

Beyond this limit gas is released fromthe oil.

For guidance on installation of topoutlet fuel tanks and suction oil supplysizing, see OFTEC Technical InformationBook 3. Available from OFTEC.

Filter

Fire valve

Fire valve

Shut-off valve

Shut-off valve

Supply

Supply

Return

Return

A

Fire valve sensor

Fire valve sensor

Level Gauge

Non return valve

Shut-off valve

See section 4.4

Vent pipe

Vent pipe

Fill pipe

Fill pipe

Fuel storage tank

Sludgevalve

Sludgevalve

H Pipe Length (m)

(m) ø 6mm ø 8mm ø 10mm

0.5 19 60 100

1 21 66 100

1.5 23 72 100

2 25 79 100

2.5 27 85 100

3 29 91 100

3.5 31 98 100

Figure 3-1: Two pipe system

Tiger Loop System -(See Figures 3-2 and 3-3)When the storage tank outlet is belowthe burner, an alternative to a two pipesystem can be achieved using a'Tiger Loop' type oil de-aerator.This effectively removes the air fromthe oil supply on a single pipe lift.

The de-aerator is connected close to theboiler as a two pipe system (omitting thenon-return valve) as shown in Figure 3-2.Refer to the manufacturers instructionssupplied with the de-aerator.

The de-aerator must be mountedvertically, Figure 3-2.

To prevent any possibility of fuelfumes entering the building, thede-aerator must be fitted outside inaccordance with BS 5410:1:1997.

! WARNING

Tankmaster

Fuelstoragetank

De-aeration device e.gTiger Loop see Figure 3-3

See section 4.4

Figure 3-2: De-aeration device system

Figure 3-3: Tiger loop de-aeration device

To burnerFrom burner

From tank

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3.2 Burner Oil ConnectionThe burner fuel pump is supplied for usewith a two-pipe fuel supply system. Foruse on a single pipe system, it isnecessary to fit the ‘horseshoe’ washerinto the tapping in the pump - refer toFigure 3-5.

Figure 3-4: Burner components

Figure 3-5: Fitting/location of ‘horseshoe’ washer

Burner head (blast tube)

Combustion air inlet

Combustionair adjuster

Lockout reset button

Motor

Control box

Oil pump

Ignition sparkgenerator

Photocell

Fan housing

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Main Burner ComponentsRemove the control panel (secured bytwo screws) to gain access to theburner. It may be necessary to removethe burner from the boiler to accessconnections in the fuel pump.

To do this, unscrew the single nut atthe top of the burner (using a 13mmspanner) and rotate the burnerclockwise and withdraw the burner fromthe boiler, as shown in Figure 3-6.

Burner ConnectionThe procedure is as follows:

1. Remove and discard the blankingplugs from the suction (inlet) andreturn connections of the pump.Refer to figure 3-7.

2. Connect the suction and return oilflexible fuel lines to the pump.

3. Connect the 3/8" to 1/4" BSPadaptor to the flexible fuel line usingthe adaptor supplied. The supplyenters through one of the holes inthe casing.

Item Description

01 Inlet (suction) port

02 Return port

03 Bleed and pressure gauge port

04 Vacuum gauge port

05 Pressure adjustment

06 Nozzle outlet

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Figure 3-6: Burner removal

Figure 3-7: Danfoss BFP11 R3 oil pump

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Burner fixing nut

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4 Boiler Installation Information4.1 IntroductionThe boiler is supplied already fullyassembled in a carton which is carefullypacked with packing materials. As theboiler is wall mounted all of the contentof the boiler casing must be removedwith the packaging before installationcan begin, to give access to the rearfixing panel. The installation proceduretherefore begins with unpacking anddismantling of the packed boiler.

4.2 Boiler LocationThe boiler should be fixed to a wall thatis firm, flat and vertical. It does notrequire any special base provisions asthe temperature of the boiler casing isless than 50°C.

Sufficient clearance must be allowed atthe front of and below the boiler toremove the burner and baffles forservicing.

4.3 Preparation for InstallationThe following procedure must beperformed before you can begindismantling the boiler for installation:

1. With the boiler on the pallet, openthe carton and remove all packingmaterials and the carton from theboiler.

2. Lift open lower front panel, slidepanel to left or right and detach fromthe boiler.

4.4 Dismantling the BoilerDismantle the boiler as follows, keepingall components, screws and washers forre-assembly:

1. Slacken off hose clip on burner airinlet and remove snorkel tube fromboiler.

3. Remove upper front panel. Pullbottom edge of panel sharplyupwards to disengage retainingclips and lift off from boiler.

4. Remove internal packaging fromwithin boiler casing.

5. Remove filling loop and flexible oilhose packs from within boiler.

2. Unscrew earth wire from undersideof top casing panel.

3. Slacken screws at rear of top casingpanel and remove screws securingtop panel to side panels. Pull panelforwards to remove from boiler.

4. Disconnect burner plug.

5. Unscrew inlet connection tocondensate trap and remove trapfrom boiler.

6. Remove thermostat phials from theirpocket (in right side of heatexchanger – below returnconnection).

7. Slacken control panel retainingscrews and remove control panelfrom boiler.

Figure 4-1: Boiler front panel open

Figure 4-2: Dismantling the boiler

Figure 4-3: Removing thermostat phials

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11. Remove screws securing right handside panel to bottom panel. Removeright hand side panel from boiler bylifting upwards to disengage tabs.

12. Repeat procedure to remove lefthand side panel from boiler.

13. Slacken screws at rear of bottomcasing panel and remove bottompanel from boiler.

20. Undo retaining screw and removetransit bracket from top of boilershell.

21. Push boiler shell upwards todisengage it from mounting bracketon back panel of boiler.

22. Lift boiler shell away from backpanel and stand it upright on thefour feet.

23. Unscrew and remove the two transitscrews & nuts securing mountingbracket and back panel to pallet.

15. Unscrew compression connectionon boiler shell and remove flow pipefrom boiler.

16. Unscrew top right compressionconnection and remove return pipefrom boiler.

17. Using a 13mm socket, slackenburner retaining nut (on top ofburner). Rotate burner clockwise(towards rear of boiler), pull burnerto the right until burner head is clearof mounting flange and removeburner from boiler.

Figure 4-5: Removing burner

18. Using 13mm spanner, unscrew thetwo clean-out door retaining nutsand remove door from front of boilershell.

Figure 4-6: Removing clean-out door

19. Remove baffles from boiler shell.

Figure 4-7: Removing baffles fromboiler shell

Figure 4-4: Removing flow & return pipe

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Figure 4-8: Installing the back panel

Figure 4-9: Fixing the back panel

7. Locate the mounting bracket on tothe back panel, aligning the fourholes in the bracket with those inthe back panel. Ensure that themounting ‘hooks’ are pointingupwards and secure using thefixings supplied.

8. Lift the boiler shell and hang it on themounting bracket – ensuring that themounting plates on either side of theshell are fully located in the verticalslot of both mounting hooks.

9. Re-fit the return pipe to top righthand connection on boiler shell.Pass return pipe from systemthrough hole in back panel (either attop or bottom of panel, as required)and connect to boiler return pipe.

10. Re-fit flow pipe to compressionconnection on boiler shell. Pass flowpipe from system through hole inback panel (either at top or bottomof panel, as required) and connect toboiler flow pipe.

Figure 4-10: Re-fitting flow & return pipe

Figure 4-11: Re-fitting baffles intoboiler shell

4.5 Installing the BoilerYou are now ready to install the boiler.The procedure is as follows:

1. If a back outlet flue system is to beused, remove the large circular flueknockout from back panel. If the rearoutlet PRV discharge is to be used,remove the knockout from the backpanel (as shown in the figure below.

If side outlet flue is to be used (toeither left or right) then mark positionas it may be necessary to cut flue holeBEFORE installing boiler on to wall.

6. Remove the back panel from thewall. Drill the holes for the mountingbracket fixings and fit the wall plugsprovided. Drill all other necessaryholes. If required, core drill the wallfor a back outlet flue and drill a holefor the PRV discharge pipe.Re-mount the back panel on thetwo keyholes slots.

! NOTE

It is recommended that the systemflow and return pipes are connected tothe boiler at this point in theinstallation.

11. Re-fit burner. First remove burnersecuring nut, locate burner headinto hole in burner flange/boiler shelland locate mounting screw throughhole on top of burner. Re-fit nut andtighten to secure burner in place.Connect flexible oil lines from oilsupply pipework to burner. It isrecommended that the copper oillines are installed at this stage whilethe side panels are not in place.

12. Re-fit baffles into boiler shell –ensuring they are in the correctorder (check marking on each baffle)as shown below

! NOTE

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2. Locate and hold the back panel in therequired position on the wall. Check itis level using a spirit level on the topflange. Mark position of the holes forthe two keyhole slots. Remove theback panel from the wall.

3. Drill and fit wall fixing plugs in the twoholes. Fit suitable screws and mountthe back panel on the wall using thetwo keyhole slots. Check again thatthe back panel is level beforeproceeding.

4. Mark the position of the fourmounting bracket fixings on to thewall from the back panel. Also markthe positions of the flow and returnpipes, the electrical power supply,and the condensate discharge pipe.

5. If using a back outlet flue and/orrear PRV outlet is to be used, alsomark these holes on to the wall.

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13. Locate clean-out door onto the twostuds, re-fit nuts and tighten tosecure door in place.

14. If side outlet flue system is to beused, remove flue ‘knockout’ fromeither the left or right side casingpanel, as required.

15. Re-fit left hand casing panel locatingtabs on rear edge of panel into slotsin back panel. Firmly push sidepanel downwards to fully engagetabs.

16. Repeat process to re-fit right handcasing panel.

17. Re-fit bottom casing panel andsecure in place with screws (withwashers).

18. If top outlet flue system is to beused, remove the flue ‘knockout’ inboth the top casing panel and thetop flange of the back panel. Fit theboiler connector (supplied in the fluekit) to the top of the boiler shell,ensuring it is firmly connected andmaking a seal on the neoprenegasket. Refer to flue installationinstructions for further details.

19. Re-fit top casing panel and securein place with screws (with washers).Ensure that the ends of the frontflange fit into the slots in the topfront of side panels.

20. Re-fit control panel – locating fixingscrews into slots in front flange ofbottom panel. Tighten screws tosecure.

21. Re-locate thermostat bulbs inpocket at rear right hand side ofboiler shell.

22. Re-connect burner plug.

24. Re-fit snorkel tube to air inletconnection on burner. Tighten hoseclip to secure.

4.6 Regulations ComplianceInstallation of a Grant CONDENSINGWall Hung boiler must be in accordancewith the following recommendations:-

• The Department of the Environmentand any local Byelaws which youmust check with the local authorityfor the area.

• Model and local Water UndertakingByelaws.

• Applicable Control of PollutionRegulations.

• The following OFTEC requirements:

- OFS T100 Polythene oil storagetanks for distillate fuels.

- OFS T200 Fuel oil storage tanksand tank bunds for use withdistillate fuels, lubrication oils andwaste oils.

Further information may be obtainedfrom the OFTEC Technical InformationBook 3 (Installation requirements for oilfired boilers and oil storage tanks).

The installation should also be inaccordance with the latest edition of thefollowing British Standard Codes ofPractice:

• BS 715 Metal flue pipes, fittings,terminals and accessories.

• BS 799:5 Oil storage tanks.

• BS 1181 Clay flue linings and flueterminals.

• BS 4543:3 Factory made insulatedchimneys for oil fired appliances.

• BS 4876 Performance requirementsfor oil burning appliances.

• BS 5410:1 Code of Practice for oilfiring appliances.

• BS 5449 Forced circulation hotwater systems.

• BS 7593 Code of Practice fortreatment of water in heatingsystems.

• BS 7671 Requirements for electricalinstallations, IEE Wiring Regulations.

25. If balanced flue system is fitted,connect other end of snorkel tube toair inlet spigot of flue system.

26. If a conventional flue system isused, locate other end of snorkel intop of boiler, ensuring that inlet totube is not restricted.

27. Fit flue system to boiler – refer toflue system installation instructions.

28. Re-fit upper front casing panel –hook top edge over front edge oftop panel, locate pins into springretaining clip on each side panel andpush firmly home to secure.

29. Re-fit lower front panel – with thepanel at 45° to vertical, locate thetabs into the horizontal slots in frontof bottom panel. Slide to either leftor right and lift into closed positionagainst magnetic catches.

Figure 4-12: Re-fitting condensate trap

Figure 4-13: Re-fitting snorkel tube

23. Re-fit condensate trap. Connectcondensate discharge pipe to outletof trap.

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4.11 Pipework MaterialsGrant boilers are compatible with bothcopper and plastic pipe. Where plasticpipe is used it must be of the oxygenbarrier type and be of the correct class(to BS 7291:Part 1:1990) for theapplication concerned.

For Long term protection againstcorrosion and scale, after flushing, it isrecommended that an inhibitor such asBetzdearborn's Sentinel X100 or FernoxMB-1 is dosed in accordance with theguidelines given in BS 7593:1992.

Failure to implement these guidelineswill invalidate the warranty.

4.9 Heating System DesignConsiderationsTo achieve the maximum efficiencypossible from the Grant CONDENSINGWall Hung boiler, the heating systemshould be designed to the followingparameters:

Radiators:-• Flow temperature 70°C

• Return temperature 50°C

• Differential 20°C

Underfloor:-• Flow temperature 50°C

• Return temperature 40°C

• Differential 10°C

Size radiators with a mean watertemperature of 60°C.

Design system controls withprogrammable room thermostats or useweather compensating controls tomaintain return temperatures below55°C.

The boiler should not be allowed tooperate with return temperatures ofless than 40°C when the system is upto operating temperature.

The use of a pipe stat is recommendedto control the return temperature whenusing weather compensating controls.

4.10 Underfloor Heating SystemsIn underfloor systems it is essential thatthe return temperature must bemaintained above 40°C to preventinternal corrosion of the boiler waterjacket.

Failure to install and commissionappliances correctly may invalidatethe boiler warranty.

Before starting any work on theboiler, or fuel supply please read thehealth and safety information given inSection 14.

4.7 CompletionPlease ensure that the OFTEC CD/10installation completion report (providedwith the boiler) is completed in full.

Leave the top copy with the User.

Retain the carbon copy.

Ensure that the User Information pack(supplied with the boiler) is handed overto the Householder.

4.8 Before you CommissionTo avoid the danger of dirt and foreignmatter entering the boiler the completeheating system should be thoroughlyflushed out - before the boiler isconnected and then again after thesystem has been heated and is still hot.This is especially important where theboiler is used on an old system.

For optimum performance afterinstallation, this boiler and its associatedcentral heating system must be flushedin accordance with the guidelines givenin BS 7593:1992 'Treatment of water indomestic hot water central heatingsystems'.

This must involve the use of aproprietary cleaner, such asBetzDearborn's Sentinel X300 or X400,or Fernox Restorer. Full instructions aresupplied with the products, but for moredetails of BetzDearborn’s products, viewthe website www.sentinel-solutions.netand for more details of Fernox productsview the website www.fernox.com.

The system should incorporate alow-pressure switch to shut offpower to the boiler if the systempressure drops below 0.2 bar.A suitable low pressure switch kit isavailable to purchase from GrantEngineering (IRELAND) Limited, PartNo. MPCBS 62.

4.12 Underfloor PipeworkPlastic pipe may be used on Underfloorsystems where the plastic pipe is fittedafter the thermostatic mixing valve.Copper tube must be used for at leastthe first metre of flow and return primarypipework between the boiler and theunderfloor mixing/blending valves.

! NOTE

The first metre of pipeworkconnected to both the heating flowand return connections of the boilermust be made in copper.

! NOTE! WARNING

! WARNING

5 Pipe Connections

18

Pip

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ons

5.1 Water ConnectionsFlow and Return Connections -All modelsOn all models a 22mm compressionconnection is provided for both theheating flow and return connections.

Holes are provided in the top andbottom casing panels to route thepipework as required.

All pipes to be fitted into thecompression connectors providedshould be cut using a pipe slicer orpipe cutter - to leave the pipe endswith a slight radius and free from anyburrs or sharp edges. Pipes to beused with these fittings should not becut square using a hacksaw.

A drain cock is fitted at the bottom onthe front of the boiler to allow theheating system to be drained.

Figure 5-1: Non-system boiler flow andreturn connections

Figure 5-3: Grant Condensing Wall Hung boiler withfront casing removed

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6 Condensate Disposal6.1 General RequirementsWhen in condensing mode the GrantCONDENSING Wall Hung boilersproduce condensate from the watervapour in the flue gases. Thiscondensate is slightly acidic with a phvalue of around 3 (similar to vinegar).Provision must be made for the safe andeffective disposal of this condensate.

Condensate can be disposed of usingone of the following methods ofconnection:

Internal Connection (preferred option):• Into an internal domestic waste

system (from kitchen sink, washingmachine, 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 partof a combined system where sewercaries both rainwater and foul water)

• Purpose made soakaway

All condensate disposal pipes mustbe fitted with a trap - whether they areconnected internally or externally to adomestic waste system/soil stack or runexternally to a gully, hopper or soakaway.

6.2 ConnectionsConnections into a rainwater hopper,external drain or gulley should beterminated inside the hopper/drain/gulley below the grid level butabove the water level.

Condensate disposal pipes should notbe connected directly into rainwaterdownpipes or to waste/soil systemsconnected to septic tanks.

Condensate should not be dischargedinto ’grey water’ systems that re-usewater used in the home (not includingwater from toilets).

It should be noted that connection of acondensate pipe to the drain may besubject to local Building Controlrequirements.

6.3 PipeworkCondensate disposal pipework must beplastic (plastic waste or overflow pipe issuitable).

Condensate disposal pipes shouldhave a minimum ‘nominal’ diameter of22mm (3/4”) - e.g. use 21.5mm ODpolypropylene overflow pipe.

Condensate disposal pipes must befitted with a fall (away from the boiler) ofat least 2.5° (~45mm fall per metre run).

Copper or steel pipe is NOT suitableand MUST NOT be used.

For boiler installed in an unheatedarea such as an outhouse or garage,all condensate pipework should beconsidered as an ‘external’.

6.5. Condensate SoakawayTo keep external pipework to aminimum, locate the soakaway as closeas possible to the boiler but ensure it isat least 1 metre from buildingfoundations and away from otherservices, e.g. gas, electricity, or water.

The condensate pipe may be run aboveor below ground level and can entereither the top or side of the soakawaytube. Refer to Figure 6-1.

Ensure that the drainage holes in thesoakaway tube face away from thebuilding.

Backfill the soakaway tube and the holearound it with 10mm limestonechippings.

Only use a soakaway where the soil isporous and drains easily. Do not use inclay soils or where the soil is poorlydrained.

Any damage due to condensatebacking up into the boiler due to ahigh water table, in the case of asoakaway, or flooded drains whenthe condensate disposal is via agulley or soil stack, is not covered bythe Grant product warranty.

Where it is not possible for the pipeto fall towards the point of discharge- either internally into a waste systemor externally to a gulley (e.g. forboilers installed in a basement), it willbe necessary to use a condensatepump.

Condensate disposal pipes should bekept as short as possible and thenumber of bends kept to a minimum.

Pipes should be adequately fixed toprevent sagging, i.e. at no more than0.5 metre intervals.

6.4 External PipeworkIdeally, external pipework, or pipeworkin unheated areas, should be avoided. Ifunavoidable, external pipework shouldbe kept as short as possible (less than 3metres) and 32mm waste pipe used tominimise the risk of ice blocking thepipe in freezing conditions.

The number of bends, fittings and jointson external pipes should be kept to aminimum to reduce the risk of trappingcondensate.

! NOTE

! NOTE

! NOTE

! CAUTION

Figure 6-1: Purpose made condensate soakaway

32mm waste pipeexternal to the building

Two rows of 3 x 12mmholes at 25mm centres and50mm from the bottom ofthe tube. Holes facing awayfrom the property.

Backfill with10mm limestonechippings

Sealedend

100mmplastic tube

Cement seal

Ground level2.5° fall

25mm

300mm

400mm

min.

20

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6.7. Condensate DisposalPipeworkThe boiler is supplied with a flexibleplastic condense disposal pipe, factory-fitted to the outlet of the trap.

This flexible discharge pipe must berouted through the boiler to exit via oneof the pre-cut ‘knock-outs’ in thebottom flange of the boiler back panel -at the right rear of the bottom casing.

Push out the ‘knock-out’ from the holetaking care not to distort the back panelflange.

The outlet end of this flexible pipe willaccept 21.5mm OD to 23mm ODPolypropylene overflow pipe forconnection of the condensate dischargepipe below the boiler.

When connecting plastic dischargepipe, ensure that the pipe is fullypushed into the outlet end connectoron the flexible pipe to prevent thepossibility of leakage.

6.6. Condensate Trap Grant Condensing Wall-hung boilers aresupplied with a factory-fittedcondensate trap to provide the required75mm water seal in the condensatedischarge pipe from the boiler.

This trap incorporates a float (which willcreate a seal when the trap is empty) andan overflow warning outlet (fitted with aplastic sealing cap), See Figure 6-3.

The trap is factory-fitted inside the boilercasing – mounted on the outlet of thecondensing heat exchanger - in anaccessible position to allow for routinemaintenance.

A ‘push-fit’ elbow connects the outlet ofthe condensing heat exchanger to thetrap inlet. Ensure the elbow is fullypushed onto the ‘top hat’ inletconnector of the trap.

With the trap fitted inside the boilercasing, the sealing cap must be fitted.

Figure 6-3: Condensate trap

The bottom bowl is sealed to the trapbody and cannot be removed.

To inspect and clean the trap

1. Disconnect and remove snorkeltube to gain access to trap.

2. Leave inlet connector fitted toconnecting elbow.

3. Unscrew the inlet connection nut.

4. Separate trap from the ‘top hat’ inletconnector and nut.

5. Unscrew outlet connection nut,disconnect disposal pipe from trap.

6. Remove trap from boiler.

7. Remove float from trap – clean ifnecessary.

8. Inspect inside of trap and clean asnecessary.

9. Re-assemble trap, re-fit to boilerand re-connect inlet connection.Ensure that elbow is fully pushedonto the ‘top hat’ inlet connectorand disposal pipe is correctlyconnected to trap outlet.

6.8 Inspection and Cleaningof TrapThe trap must be checked at regularintervals (e.g. on every annual service)and cleaned as necessary to ensurethat it is clear and able to operate.

Figure 6-2: Condensate traplocation in-situ

! NOTE

Failure to regularly check and cleanthe condensate trap may result indamage to the boiler and will not becovered by the Product Warranty.

! NOTE

! CAUTION

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7 Electrical

The Condensing boiler containselectrical switching equipment andmust be earthed.

The supply must be fused at 5 Amp andthere must only be one common isolatorfor the boiler and control system,providing complete electrical isolation.

A fused double pole switch or a fusedthree pin plug and shuttered outletsocket must be used for theconnection.

The power supply cable should be atleast 0.75mm2 PVC as specified inBS 6500, Table 16.

All the wiring and supplementary earthbonding external to the boiler must be inaccordance with the current I.E.E.Wiring Regulations.

Any room thermostat or frost thermostatused with the Condensing boiler mustbe suitable for use on mains voltage.

In the event of an electrical fault afterinstallation of the boiler, the followingelectrical system checks must becarried out:

• Short circuit

• Polarity

• Earth continuity

• Resistance to earth

The Condensing boiler requires a230/240 V ~ 50 Hz supply. It must beprotected by a 5 Amp fuse.

Figure 7-6 is the wiring diagrams for theCONDENSING Wall Hung boiler.

7.1 Connecting the PowerSupplyIt is recommended that the boiler shouldbe connected to a switched mainspower supply from a programmer orcontrol system. A three core cable isrequired to connect the boiler terminalblock to the live supply. Refer to Figures7-1 to 7-4 for typical control systemwiring diagrams.

7.2 Frost ProtectionFor additional protection of either theentire heating system, or the boiler andlocalised pipework, it is recommendedthat a frost thermostat be installed.

Refer to Section 7.3 for connectiondetails.

To protect the heating system, the frostthermostat should be sited within thehouse in such a place that it can detectany rise and fall in the ambient airtemperature, i.e. in a room with aradiator.

Where the frost thermostat is installedoutside the house (to protect a boilerinstalled in an external boiler room orgarage) or in an attic, it is recommendedthat it be used in conjunction with apipe thermostat to avoid unnecessaryand wasteful overheating of theproperty. The pipe thermostat should belocated on the boiler return pipe, andset to operate at 25°C. Refer to Section7.3 for connection details.

! WARNING

When wiring in the supply cable tothe boiler, allow sufficient cablelength so that the control panel canbe hooked to the top panel of thecase during the service operation.

The procedure is:

1. Remove the lower and upper frontpanels, if they have not already beenremoved.

2. Remove the top of the control panelor the wiring cover (on Kitchenmodels)and open the cable clamp.

3. Route the supply cable through thehole in the rear panel (using thegrommet supplied) up to the controlpanel, pass it through the cableclamp and connect to the boilerterminal block as follows:

• Brown to live (terminal 1)

• Blue to mains neutral (terminal 2)

• Green/Yellow to mains earth(terminal 3)

• Tighten cable clamp

• Refit panels

! NOTE

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7.3 Control System Wiring Diagrams

Figure 7-2: Models with 2 X 2-port control system

FrostThermostat

PipeThermostat

(if fitted)

Room Stat

Gre

y

Whi

te

Gre

en/Y

ello

w

Blu

e

Ora

nge

CylinderStat

Mid PositionZone Valve

wiring centre

Supply toburner

Boiler Terminal Block

Pump

240 V50 Hz

L

1 3 4 N L

N E

L N E L E N

1

1 2

2 1

1

C 23

3 4 5 6 7 8 9 10

2 3 4 5 6

L

7

L

E

N

L

ENL

FrostThermostat

PipeThermostat

(if fitted)

Grey

Blue Blue

Room Stat

Bro

wn

Bro

wn

Gre

en/Y

ello

w

Green/Yellow

Gre

y

Orange

Zone Valve Zone Valve

Motor MotorDHWHTG

Orange

CylinderStat

wiring centre

Supply toburner

Boiler Terminal Block

Pump

240 V50 Hz

L

1 3 4 N L

N E

L N E L LE N

1 2 3 4 75 6

1 2

2 1 1 C3

3 4 5 6 7 8 9 10

LENL

ENL

Figure 7-1: Models with 3-port valve control system

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7.4 Boiler Control Panel Wiring Diagrams

BoilerOn/Off

c/w neon

ControlledThermostat

LimitThermostat

Lock outNeon Red

Mains Supply: Use 2pole isolator withpower “ON” indicator

4 core whiteinsulation

4 core whiteinsulation

Brown

Black

Brown Brown

Blue

Blue

Blue

Green/Yellow

BlueB

rown

Green/Yellow

Green/Yellow

Fit covers asabove on plugand socket

Gre

en/

Yello

wBlu

eR

ed

Red

2 4 5 6 7

BlkBlG/Y

Br

BlkBl

G/Y

Br

BrBlBlk G/Y

Figure 7-6: Wiring Diagram – Indoor models

31

1 C C 2

1A

4B 5B

2A

N L2 E N L1L2

L1N

L2L1

N

EL

L

N

E

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8 Flue System and Air Supply8.1 Air SupplyA sufficient permanent air supply to theboiler should be provided for thefollowing reasons:

• For proper combustion of fuel andeffective discharge of combustionproducts to the open air.

• For the ventilation of any confinedspace in which the boiler is installedto prevent overheating of the boiler any equipment in and near theboiler.

It should be both the designer’s andinstaller’s concern that the air requiredfor these functions be introduced so asto cause as little discomfort as possibleto the building occupants and thus tooffer them the least temptation toobstruct the ventilators.

Further details may be obtained fromBS 5410:1:1997.

For a boiler fitted in a compartment,which is ventilated as shown, noadditional allowance is necessary.

Open flue - Extract fans, where needed,should be in accordance withSection 4.4 in BS 5410 Part 1 1997.

All ventilation areas given are fordomestic applications. For all othercases refer to BS 5410 Part 2 1978.

Figure 8-1: Air supply for room sealed balanced flue boilers

Figure 8-2: Air supply for conventional flue boilers

Condensing Wall-hung boilers - Ventilation areas

Output 40/55 kW 55/70 kW

Area cm2 in2 cm2 in2

Vent A 83 13 116 18

Vent B 165 26 231 36

Vent C 83 13 116 18

Vent D 165 26 231 36

Vent E 248 38 347 54

Room sealed balanced flue noventilation required to room

Conventional open flue Conventional open fluecompartment ventilation from room

Conventional open fluecompartment ventilation from outside

Room sealed balanced fluecompartment ventilation from outside

Room sealed balanced fluecompartment ventilation from room

B

B

A

C C D

E

C

D

A

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Under no circumstances can GrantCondensing boilers be installed withexisting flue systems. Only fluesystems and components suitable forwet flues should be used.

Failure to install the correct type offlue system will invalidate thewarranty.

Grant condensing boilers have highoperating efficiencies and low flue gastemperatures. Care must be taken toensure the flue system is suitable for thevery low flue gas temperatures andcondensate in the flue gases.

Suitable conventional flue systems areavailable from Grant Ireland.

The flue must terminate in a downdraught free area, i.e. at least 600mmabove the point of exit through the roofor preferably above the ridge level.

The condensate may be allowed to runback into the boiler. A condensate drainat the base of the flue system is notrequired.

The high level flue terminal must be atleast 600mm from any opening into thebuilding, and 600mm above any verticalstructure or wall less than a horizontaldistance of 750mm from the terminal.

If an existing chimney is to be used, it must be lined with a smooth borestainless steel liner suitable for use withoil fired condensing boilers. The top andbottom of the annular space must besealed.

Grant recommends the use of the Grant'Orange' flue system, specificallydesigned for the Condensing range ofcondensing boilers.

The internal flue liner diameter for allmodels is 100mm (4 in).

8.2 Conventional Flue Systems The maximum vertical height (from thetop of the boiler to the terminal) for the'Orange' system is 19 metres.

If a rigid flue is used externally,it must be of the twin-wall typeincorporating seals at all joints,constructed with a stainless steel innerskin and be suitably insulated andweatherproofed. The internal fluediameter for a rigid flue for all modelsis 100mm (4 inches).

As no flue adaptor is supplied withthe boiler, in order to correctlyconnect the hybrid system, it will benecessary to purchase the Grant CFadaptor kit (Ref. CFA15/70).

If required, it is possible to use the whitepainted single-wall straight flueextensions, adjustable extensions andelbows from the Grant 'Orange' systemfor the internal section of the fluesystem. These components can befitted between the boiler connector andflue adaptor. The flue adaptor, to whichthe external twin-wall 'Green' fluecomponents are connected, cantherefore be situated just before the fluesystem passes through the wall.

Grant 'Orange' system single-wallflue components must not be usedexternally.

The maximum vertical height (from thetop of the boiler to the terminal) for thesystem is 8 metres.

Grant ‘Green’ twin-wall flue isrecommended for externally run fluesto reduce the possibility of thecondensate freezing in the flue.

No part of any flue system should bemade of an asbestos material;aluminium must not be used in any partof the flue. Only stainless steel fluecomponents should be used.

If the draught conditions aresatisfactory, the flue should terminatewith a standard cowl.

Refer to the locally applicable BuildingRegulations, BS 5410:1 and OFTECInstallation Requirements (OFTECBooks 2 and 3) for further guidance onconventional flue systems.

It is important to ensure that the fluesystem is sealed and that condensatecannot escape. Up to 1.5 l/h ofcondensate can be produced in aconventional flue system.

Use only flue systems suitable for oilfired condensing boilers.

Do not use fire cement. The use of hightemperature silicone sealants isrecommended.

! NOTE

! NOTE

! NOTE

! CAUTION

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Flue Lining KitsGrant EZ-Fit Flexi Pack conventionalflue system (Orange System)A range of Flexi pack conventional fluelining kits are available from GrantIreland. The packs have beenspecifically produced for GrantCondensing oil fired condensing boilers.

The pack includes a terminal/topplate/flexi flue adaptor, stainless steelsmooth bore flexible flue liner, a rigid toflexi adaptor and a boiler flue connector.

ExtensionsA range of white powder coated singlewall extensions are available to connectthe boiler to the flexible liner.

The nominal diameter of the extensionsis 100mm.

Extensions are supplied with lockingbands.

Flue extensions cannot be cut.

Also available are:

• An adjustable extension

• 45° elbow

The rigid flue between the boiler andflexible flue liner should incorporate anadjustable section to allow inspectionand cleaning of the flue system.

C

Figure 8-4: Grant Orange flue system ina typical brick chimney

Figure 8-3: Orange system extensions

! NOTE

Vertical terminal kit

45° elbow kit

Extension kits

Extension kits

Locking band

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8.3 Connecting a Conventional Flue1. Unscrew and remove top casing

panel.

2. Push out the pre-cut blanking panel.

If the Grant ‘Orange’ flue system isbeing used, follow the instructionssupplied with the flue kit.

If the Grant ‘Green’ system (100mmrigid twin wall flue) is to be fitted to theboiler then the Grant CF adaptor kit(Ref. CFA15/70) must be used – refer toSection 1.2.

To fit the adaptor kit, proceed asfollows:

1. Fully screw the length of threadedstudding (provided in the kit) into thenut located in the centre of theboiler flue outlet.

2. Fit the boiler connector (from the CFadaptor kit) over the threadedstudding.

3. Position flange on to the neoprenegasket around the boiler flue outlet,ensuring that small spigot on thebase of the connector is located inthe hole in the centre of theneoprene gasket and that end ofstudding passes through the hole inthe of the spacer bracket.

4. Fit the washer and wing nutprovided onto end of threadedstudding and secure the connectorin position by tightening down onwing nut – as shown in Figure 9-6.

5. Re-fit the top casing panel to theboiler – fitting it over the boilerconnector.

6. Fit the flue adaptor (from the adaptorkit) into the boiler connector.

Figure 8-6: Boiler flue connector

8.4 Balanced Flue SystemsApart from a conventional flue, severalbalanced flue options are available foruse with the Grant Condensing WallHung boilers. All are suitable for usewith Class C2 kerosene.

Lubricate the seal on the adaptorusing the lubricant provided beforeattempting to fit the flue adaptor.

7. Fit the first section of flue into theflue adaptor and secure using theclamp band provided.

8. Assemble the remainder of the fluesystem as required, lubricating theseal on each component beforefitting.

! NOTE

! NOTENone of the flue sections in thefollowing system can be cut.

Low Level Horizontal Balanced Flue(Yellow system)Available in either Short (for singlethickness brick walls) and Standard kits.

Extensions are available which extendthe flue by 225mm, 450mm or 675mm.

90° and 45° elbows are also available.

The maximum flue length - from thecentre of the boiler flue outlet to theouter face of the wall - is 4 metres (withor without elbows included). No morethan 2 x 45° or 1 x 90° elbow should befitted per system.

The low level balanced flue (Yellowsystem) is supplied with a stainless steelguard. This must be fitted in allcircumstances to prevent objects fromentering the flue outlet.

The guard must be fitted centrally overthe flue terminal and securely fixed tothe wall.

Figure 8-7: Low level balanced flue

Test pointscrew

Threadedstudding

Wing nut

Washer

Neoprenegasket

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High Level Horizontal Balanced Flue(White system)The High Level (horizontal) balanced flue(white system) allows the flue to risevertically within the building beforeexiting through the wall horizontally.

The maximum flue length - from the topof the boiler flue outlet to the outer faceof the wall - is 10 metres for allCondensing boilers.

The following items are additionallyavailable:

• Extensions to extend the flue by225mm, 450mm or 950mm.

• An adjustable extension of 275 to450mm.

• A 45° elbow - No more than6 x 45° elbows should be fittedper system. Each elbow reduces theoverall maximum length of thesystem by 1 metre.

Vertical Balanced Flue(White system)Allows the flue to rise vertically from theboiler to exit through the roof.

The maximum flue length - from the topof the boiler flue outlet to the terminal -is 12 metres for all Condensing boilers.

The following items are additionallyavailable:

• Extensions to extend the flue by225mm, 450mm or 950mm.

• An adjustable extension of 275 to450mm.

• A 45° elbow - No more than6 x 45° elbows should be fittedper system. Each elbow reduces theoverall maximum length of thesystem by 1 metre.

Figure 8-9: High level balanced flue

Figure 8-8: White system extensions

White System Components

Item – for models up to 26 kW output Part No.High level flue kit – 1.2 metre HL K01 50/90Vertical flue kit – 3 metre VT K05 50/90225mm extension EXT K31 225/90450mm extension EXT K09 450/90950mm extension EXT K11 950/90275-450mm adjustable extension EXT K13 ADJ/9045°elbow ELB K21 45/90Pitched roof flashing – aluminium (for VT K05 50/90) VT MF 90Pitched roof flashing – lead (for VT K05 50/90) VT K25 P90Flat roof flashing – aluminium (for VT K05 50/90) VT K27 F90Wall bracket BRK 29 90

950mmextension

450mmextension

225mmextension

275 to450mmadjustableextension

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Green System Components

Item – for models up to 26 kW output Part No.

Starter kit – standard GK90Starter kit – short GK90S150mm extension GX150/90250mm extension GX250/90450mm extension GX450/90950mm extension GX950/90195-270mm adjustable extension GXA250/9045º elbow GE45/90High level terminal GTH90Vertical terminal GTV90Wall bracket – standard GWB90Wall bracket – extended GEB90

External Balanced Flue(Green system)Where it is not practical to use a lowlevel (Yellow system) or internal highlevel/vertical (White system) balancedflue, the boiler can be fitted with anexternal vertical/high level flue (Greensystem).

See Figure 9-11.

The Starter kit fits to the boiler in thesame way as a low level balanced flue(Yellow system) and the external Teeallows the connection of a twin wallinsulated flue pipe and a combustion airinlet - providing a room sealed fluesystem.

The external system can terminate ateither high level or vertically (above rooflevel) as required.

See Figure 9-11.

The minimum dimensions for locatingthe terminal from building features(windows, doors, etc.) are shown inFigure 9-12.

The terminal must be positioned so asto avoid products of combustionaccumulating in stagnant pocketsaround the buildings or entering intobuildings. Care should be taken that theplume from condensed flue gases doesnot cause a nuisance.

The following external flue (Greensystem) components are available fromGrant Ireland:

Figure 8-11: External balanced flue(Green system)

Vertical terminal kit

45° elbow kit

High level terminal kit

Extended wall bracket

Extension kits

Starter kit

Wall bracketLocking band

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Figure 8-12: Clearances for Balanced flue terminals

Terminal position Min. distance (mm)

A Below a gutter or sanitary pipework 600*

B Horizontal from an opening, air brick or window 600

C Above ground or balcony level 300

D Below eaves or balcony 600*

E From an internal or external corner 300

F From a terminal facing the terminal 1200

G From a surface facing the terminal 600

H Vertical from terminals on the same wall 1500

I Horizontal from terminals on the same wall 750**

J Below an opening, air brick, window, etc. 600

K From vertical sanitary pipework 300

L Vertical flue from wall 750

M From an oil storage tank 1800

Notes:* 75mm with protection.** Only applies if one or both terminals are balanced flues.

D

DL

C

C

B

B

B

D

F

E

K

A

E

C

G

M

J

J

H

I

1. An opening means an openableelement, such as an openablewindow, or a permanent openingsuch as a permanently open airvent.

2. Notwithstanding the dimensionsgiven, a terminal should be atleast 300mm from combustiblematerial, e.g. a window frame.

3. A way of providing protection ofcombustible material would be tofit a heat shield at least 750mmwide.

! NOTE

Distances measured to rim of terminal.

Clearances recommended by GrantEngineering (Ireland) Limited inaccordance with British Standards andBuilding Regulations.

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! NOTE

! NOTEDimension B given in Figure 9-14includes an extra 10mm over the sizeof the terminal to provide clearancefor fitting.

Fitting instructions for the high levelbalanced flue and vertical balancedflue are supplied with the flue kits.

Adjustable ExtensionsThe adjustable extensions aretelescopic. The wall terminal section isadjustable and is suitable for a wallthickness of 215mm to 450mm.

Simply adjust to the required lengthusing a twisting motion. The outer pipesmust overlap by a minimum of 25mm.

8.6 High Level and VerticalBalanced FlueIf the boiler is to be used with the highlevel balanced flue (White system) makethe hole in the wall as shown inFigure 9-14.

Figure 8-14: Flue hole dimensions and position for high level system

Low level balanced flue - Yellow systemExternal flue starter kit - Green system

High level balanced flue - White system

Rear flue Side flue

Figure 8-13: Flue hole dimensions and position for low level systems

Dimension (mm)

A dia B C D

127 112 H + 765* 220*H is the height from the floor to underside ofboiler casing

Dimension (mm)

A dia B C min D min D max E

175 112 H + 1207* H + 1707* H + 2107* 220*H is the height from the floor to underside of boiler casing

Dimension B given in Figure 9-13includes an extra 10mm over the sizeof the terminal to provide clearancefor fitting.

8.5 Prepare the WallIf the boiler is to be used with a low levelbalanced flue (Yellow system) make thehole in the wall for the flue as shown inFigure 9-13.

A

A

C

C

D

Rear flue Side flue

B

H

H

A

A

B

CD

C

D

H

E

H

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9 CommissioningIt is important that the followingcommissioning procedure is carried outto ensure safe and efficient operation ofthe boiler.

To access the controls, open the lowerfront panel by pulling it down as shownin Figure 10-1.

The controls are shown in Figure10-2.

9.1 Before Switching On1. Check that the turbulators are in

position and that the ends arevertical.

2. Check that the baffles are in positionand that the cleaning cover iscorrectly fitted and a good sealmade. See Section 4.5.

3. Check that the water system hasbeen vented and there are no leaks.

Figure 9-1: Boiler lower front panel in down position

Figure 9-2: Boiler controls

! NOTE

4. Ensure the automatic air vent on thecondensing heat exchanger is open.

5. Check that all fuel line valves areopen.

6. Connect a combined vent manifoldand pressure gauge to the pressuregauge connection port on the oilpump. See Fig. 3-4. Open the ventscrew on the vent manifold to ventthe supply while the pump isrunning.

7. Set the boiler On/Off switch to Off.Check that all system controls arecalling for heat and turn the boilerthermostat to maximum.

9.2 Switching on1. Switch on the electricity supply.

2. Set the boiler On/Off switch to On.The burner fan should start and theburner should light within about 12seconds. If the burner does not lightand the 'Lock-out' reset buttonlights, wait for about 1 minute, thenpress the reset button to restart theignition process. This proceduremay have to be repeated severaltimes during first lighting.

3. With the burner alight, check thefuel pressure.

4. Refer to the Technical Information,Section 2.3.

5. Adjust the pressure if necessary -see Fig. 3-4. (Note that the 'MainsOn' neon lights lit when the boiler isswitched on does not necessarilyindicate the burner is firing. It merelyindicates that the power isconnected).

It is important that the oil pressure iscorrectly set.

6. Operate the boiler until it reachesnormal operating temperature.Check oil supply/return pipe forleaks, rectifying where necessary.

7. Check the operation of the boilerthermostat. Ensure that by turning itanticlockwise it switches the burneroff.

8. With the burner alight, re-check thefuel pressure and re-adjust ifnecessary. Turn the boiler off,remove the pressure gauge andreplace the plug in the pump.

9. Ensure that there are no oil leaks andthe flexible air tube is connected tothe burner (balanced flue models).

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9.3 Running the Boiler1. Re-light the boiler and allow it to run

for at least 20 minutes.

2. Check the smoke number, ifsatisfactory check the CO2. Set theCO2 to the value given in Section 2.3for the boiler concerned.

3. Turn the air control knob on theburner to adjust the burner airdamper (see Figure 10-3) asrequired. Turning the knobanti-clockwise closes the damperand increases CO2 level. Turning theknob clockwise opens the damperand reduces CO2 level.

4. Re-check the smoke number if thedamper has been moved. Under nocircumstances must the smokenumber be above 1.

Figure 9-3: Thermostat phial position

! NOTEIt is important that the air damper iscorrectly set.

5. Check the flue gas temperature.

Check that both the boiler overheatand boiler control thermostat bulbsare correctly located in theirrespective pockets. For location ofthermostat pockets, refer toFigure 10-3.

6. Also check the condition of boththermostat capillaries, i.e. that theyare not damaged, broken or kinked,and that they are not trapped orcrushed between any internal boilercomponents.

! NOTE

! NOTE

After commissioning the boilercomplete the Commissioning Reportin the front of this manual and theOFTEC CD/11 commissioning report.Leave the top copy with the User andretain the carbon copy.

9.4 Balancing the System1. When the boiler has been adjusted

and is running satisfactorily, balancethe central heating system byadjusting the radiator lock shieldvalves. Start with the radiatornearest the boiler and adjust thevalves to achieve the requiredtemperature drop across eachradiator. If thermostatic radiatorvalves have been installed, checkthe system by-pass.

2. Switch off the boiler.

9.5 Completion1. With the system hot, check again

for leaks, rectifying where necessary.Drain the system while it is hot tocomplete the flushing process. Refilland vent the system.

2. A suitable central heating systeminhibitor must be added to protectthe system against the effects ofcorrosion.

If the boiler is to be left in service withthe User, set the controls, remoteprogrammer and room thermostat tothe User's requirements.

If the boiler is not to be handed overimmediately, close the boiler fuel supplyvalve and switch off the electricitysupply.

If there is any possibility of the boilerbeing left during frost conditions,then the boiler and system should bedrained.

To allow the boiler to be commissionedand serviced correctly a combustiontest point is provided on the frontcleaning door.

The CO2 and smoke test may all becarried out using this test point.

The test point is not suitable formeasuring boiler efficiency orconventional flue draught.

When using the test point on thecleaning cover note that the flue gastemperature reading will be higher thanthat measured in the flue thus resultingin an inaccurate efficiency reading. Toobtain an accurate flue gas temperatureand efficiency, the reading can bemeasured only outside through the lowlevel flue terminal. For high level andvertical balanced flues the reading maybe taken from the flue test pointprovided . Refer to Section 2.3.

For Conventional flue draughtmeasurement and efficiency a test pointis provided in the conventional flueadaptor.

! CAUTION

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10 Boiler ServicingTo ensure efficient operation of theboiler it is recommended that it ischecked and serviced as necessary atregular intervals. The frequency ofservicing will depend upon the particularinstallation conditions and usage, but ingeneral once per year should beadequate.

Servicing and replacement of partsmust only be carried out by a suitablyqualified engineer.

6. Remove any sludge/water from thefuel tank by opening the sludgevalve at the lower end of the tank.

7. With the fuel supply valve closed,clean/replace the filter element andclean the filter bowl.

8. Braided flexible fuel supply hoses assupplied with the boiler should bereplaced annually when the boiler isserviced. If long-life hoses havebeen installed, these should beinspected annually. If in doubtreplace the hoses. In any event,these hoses must be replaced everyfive years.

10.3 Cleaning the Boiler

The procedure for cleaning the boiler isas follows:

1. Remove the nuts and washerssecuring the front cleaning door andwithdraw the door. Take care – it isheavy.

2. Remove the baffles as shown inFigure 11-1.

3. Remove all deposits from the baffleplates and all the boiler internalsurfaces using a stiff brush andscraper if necessary.

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

5. Check the condition of the frontcleaning door seal and replace ifnecessary.

6. Replace the baffles, ensuring theyare correctly fitted.

7. Pull out the spiral turbulators fromthe heat exchanger tubes.

8. Clean the turbulators using a stiffbrush.

9. Test the heat exchanger condensatedrain by pouring water into one ofthe lower tubes and observewhether the water discharges fromthe 22mm condensate outlet.Replace the turbulators, ensuringthe ends are vertical.

Figure 10-1: Removing the baffles

! WARNING

! NOTE

! CAUTIONDetails of every service should beentered in the Service Log, in theBoiler Handbook.

This information may be required tovalidate the Grant extended warranty.

Before starting any work on theboiler, or fuel supply please read thehealth and safety information given inSection 13.

10.1 Checking Before Servicing

The following sequential checks shouldbe made before any servicing:

1. Check the flue terminal and ensure itis not blocked or damaged.

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

3. Ensure that all water/fuel systemconnections and fittings are sound.Remake any joints and check thetightness of any fittings that may beleaking.

4. Refill, vent and re-pressurisethe system as necessary.

5. Check that any ventilation openingsare adequate and are clear.

Before servicing, set the boilerOn/Off switch to Off, isolate theelectricity supply and close the fuelsupply valve.

Allow the boiler to cool.

The data label on the front of the boilerwill indicate the fuel used and the nozzlefitted.

10.2 Dismantling Prior to Servicing

The procedure for dismantling the boileris as follows:

1. Remove the front panels.

2. Disconnect the flexible air tube fromthe burner.

3. Remove the burner fixing nut (top ofmounting flange) and rotate theburner clockwise and withdraw theburner. The burner has a lug to fitover a bracket on the front of thecombustion chamber to hold it whileservicing takes place.

With two flexible hoses connected tothe burner, identify (mark ifnecessary) which is the inlet andreturn if they are to be disconnected.

! WARNING

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10. Replace the front cleaning door,ensuring the seal is in goodcondition and secure it in positionwith the nuts and washerspreviously removed. Tighten to forma seal.

11. Remove the condensate trap andcheck that it is not blocked and isoperating correctly, i.e. the float is freeto move. Clean the trap and float asrequired. Refer to Section 6.8.

12. Check that the boiler condensateoutlet is unobstructed. Clean ifnecessary.

! NOTEThe condensate trap and condensateoutlet must be checked on everyservice and cleaned as necessary.

10.4 Cleaning the Burner

The procedure is:

1. Combustion head - Loosen the twoscrews securing the combustionhead and withdraw the head.

2. Clean the combustion head.

3. Inspect the ignition electrodes -Loosen the electrode clamp screwand withdraw the electrodeassembly. Wipe clean and check forany cracks in the ceramic insulation.Replace if necessary.

4. Nozzle - The nozzle should bereplaced on an annual service -Check that the nozzle size and typeare correct, refer to table in Section3.3 and boiler data label.

5. Do not attempt to clean the nozzle.

6. Remove the nozzle using a goodfitting spanner (16mm).

Figure 10-2: Electrodes showing setting

4mm 3mm

! CAUTIONThe use of an ill-fitting spanner willdamage the nozzle and could lead toan incorrect flame pattern.

7. Always check the electrode settingsafter replacing the nozzle, see Figure11-2.

8. Re-connect the HT leads to theelectrodes and refit the combustionhead.

All modelsPhotocell - The photocell is a push-fit inthe burner body. Carefully pull out thephotocell to clean.

Burner fan – Remove the air intake fromthe burner. Check, inspect and cleanthe fan as required. Replace the cover.

Pump filter - Remove the four screwssecuring the pump end cover. Removethe filter and wash in kerosene. Replacethe filter and end cover, ensure the 'O'ring is in position.

Re-assemble in reverse order.

To ensure safe and efficient operationof the boiler it is important that re-commissioning is carried out,especially combustion checks (CO2

level, flue gas temperature andsmoke number) after the boiler hasbeen serviced.

Refer to the Commissioninginstructions in Section 10.

! WARNING

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11 Fault Finding11.1 Burner Fault Finding Chart1. Burner fails to start – no flame – no lock out

Symptoms Possible Causes Actions

Motor fails to run No electrical supply to boiler Check On/Off switch is On - mains neon is lit

Lock-out light not lit Fuse has blown Check or replace fuse

If fuse has blown - check reason for failure

Boiler thermostat not calling Adjust boiler thermostat to call for heat

Heating controls are not calling Adjust programmer & room thermostat to call

Overheat thermostat has operated Check and reset overheat thermostat if required

If operated - check reason for operation

No power to burner Check for 230V at control box mains terminals

Control box faulty Replace faulty control box

2. Burner fails to start – no flame – goes to lock out

Symptoms Possible Causes Actions

Motor fails to run No power to burner motor Check for 230V at motor plug terminals

Burner lock-out Burner motor capacitor faulty Check and replace if necessary

Burner motor faulty Replace burner motor

Burner motor stalled

Seized oil pump Check and replace faulty oil pump

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3. Burner starts – no flame – goes to lock out

Symptoms Possible Causes Actions

Motor runs Flame instability

Burner pre-purges Carbon/soot on blast tube Clean blast tube

Burner does not fire No oil pressure Check pump drive coupling - replace if failed

Burner lock-out Low oil pressure Check oil pump pressure is correct

Excessive combustion air Adjust air damper setting

Excessive flue draught - CF only Rectify condition (draught stabiliser required?)

False light Check photocell is not sensing ambient light

No ignition spark Check HT lead connections are sound

Check ignition electrode gap is correct

Check for 230V at ignition transformer

Check transformer - replace if faulty

No oil at nozzle Check for sufficient fuel in tank

Check fire valve has not tripped

Check all oil supply valves are open

Check oil line & pump is not airlocked

Check operation of solenoid valve

Check pump drive coupling - replace if failed

Check fuel pump - replace if seized

Restriction in oil supply Check filters, valves and oil lines and rectify

Fuel contamination (water in tank) Check tank, filters, oil line for water

4. Burner fires – goes to lock out

Symptoms Possible Causes Actions

Motor runs Flame instability

Burner pre-purges Carbon/soot on blast tube Clean blast tube

Burner fires Fuel contamination (water in tank) Check tank, filters, oil line for water

Burner lock-out Low oil pressure Check oil pump pressure - reset if necessary

Excessive combustion air Adjust air damper setting

Excessive flue draught - CF only Rectify condition

Photocell not sensing light Check photocell is clean and unobstructed

Photocell failed Replace faulty photocell

Defective nozzle Replace nozzle

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5. Delayed ignition – burner starts violently

Symptoms Possible Causes Actions

Burner pulsates on start-up Excessive combustion air Re-commission burner - adjust air setting

Low oil pressure Check and re-commission burner

Partially blocked nozzle Replace nozzle

Fuel contamination (water in tank) Check tank, filters, oil line for water

Fan slipping on shaft Check and re-tighten

Pump coupling loose or worn Check and replace

Burner starts violently Delayed ignition Check electrode settings

Check electrodes for damage

Check HT lead connections are sound

Check HT leads for damage or arcing

6. Burner cycles on and off

Symptoms Possible Causes Actions

Burner firing Restriction in oil supply Check filters, valves and oil lines and rectify

Burner stops firing Fuel contamination (water in tank) Check tank, filters, oil line for water

Pre-purge starts Partially blocked nozzle Replace nozzle

Burner fires Vitiated combustion air - BF only Disconnect snorkel tube and check operation

Burner stops firing Check flue terminal for obstructions and rectify

Check flue system for leaks and rectify

Boiler thermostat hunting Replace faulty thermostat

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11.2 Boiler Fault FindingAlways isolate the electricity supply to the boiler before working on the boiler.

Fault

Boiler will not start: Remedies

1 No fuel supply. Ensure that an adequate supply of fuel is available and that the fuel supply valve is open.Check the condition of the fuel filter, clean if necessary. Ensure fuel supply is reaching burner and vent pump.

2 No electricity supply. Ensure electricity supply to the boiler is switched on and that all controls are calling for 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 the boiler and overheat thermostat.

3 Burner not starting - fuel and Press the reset button on the burner if lit on the control box.electricity supplies present. Refer to burner fault finding flow diagram.

4 Burner lights but goes to ‘lock-out’. If the flame is unstable, check the combustion settings. Refer to burner fault finding flow diagram.

Boiler works but:

5 Visible smoke from flue or high Insufficient air supply – check the air damper setting and the condition of the fan.smoke number. Check room ventilation is adequate. See Section 9.1.

Check the nozzle size and type. Fuel pressure may be too high – check and adjust.

6 Burner pulsates. Insufficient air supply – check the air damper setting and the condition of the fan.Check room ventilation is adequate, See Section 9.1.Check the nozzle size and type.

7 Flame slow to stabilise Insufficient air supply – check the air damper setting and the condition of the fan.during start up. Check room ventilation is adequate, See Section 9.1.

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.

8 Water temperature low. 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.

9 Boiler operating on overheat Faulty boiler thermostat. No circulation, check circulating pump. Check for air lock.thermostat.

10 Fumes and puffing during starting Check the condition of the chimney, ensure it is not blocked and is high enough to produce(conventional flue). the required draught. Check that there is an adequate air supply near the burner and that a

kitchen fan is not drawing products out of the burner.

11 Oil odours. Check all fuel line connections, remake as necessary.

12 Combustion fumes smell. 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.

40

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This section gives an exploded view ofthe Ecoflam MAX1 burner in the GrantCONDENSING Wall Hung boiler, and aparts list associated with it.

12 Spare Parts

23 22

35

2628

25

02

08

01

05

06

03

04 1009

11

1416

12 13

33

34

15

18 30

29 20

36

19

3134

17

Figure 12-1: Burner components diagram

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Key No. Description Ecoflam Part No. Grant Part No.

01 Oil Pump Danfoss BFP11 R3 P121/3 EBS01

02 Coil Danfoss V510/2 EBS02

03 Oil valve Danfoss V412/1 EBS03

04 Coupling AEG MP504 EBS04

05 Nipple TN 6X 700 BFRO1103/001 EBS05

06 Hoses NW 6X 700 S931/055 EBS06

09 Motor 75W AEG M181/12 EBS09

10 Capacitor 3µF x 75W AEG C107/9 EBS10

11 Ignition transformer Danfoss CM T130 EBS11

12 Control box base Landis A402 EBS12

13 Control box Landis LOA24 A117/1 EBS13

14 Photoresistor Landis A208/3 EBS14

15 Wiring terminal box E228 EBS15

16 Protection box BFC02046/056 EBS16

17 Fan 120 x 34 W123/2 EBS17

18 Fan scoop BFC02049/001 EBS18

19 O-ring BFG01043 EBS19

20 Cover air inlet - Wall-hung 40/55 BAA10019 EBS20

21 Cables BFE01401/3 EBS21

22 Electrodes BFE01109 EBS22

23 Burner head BFB01326/007 EBS23

25 Nozzle holder support BFC10031/001 EBS25

26 Nozzle holder BFC11017 EBS26

28 Rod BFA06429/001 EBS28

29 Flange BFF01022/001 EBS29

30 Gasket BFG02016 EBS30

31 Anti-jamming filter D.E.M S132/3 EBS31

33 Oil pipe BFT05258 EBS33

34 Pipe gasket BFG01042 EBS34

35 Nozzle - Wall-hung 12.7kW 0.35 80ºEH - M1BS27/75

Nozzle - Wall-hung 14.0kW 0.40 80ºEH - M1BS27/50

Nozzle - Wall-hung 16.5 & 18.7kW 0.50 80ºEH - M1BS27/46

Nozzle - Wall-hung 20.3kW 0.60 80ºEH - M1BS27/31

36 Ring BFC03039/4 EBS36

42

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Under the Consumer Protection Act1987 and Section 6 of the Health &Safety at Work Act 2005, we arerequired to provide information onsubstances hazardous to health(COSHH Regulations 1988).

Adhesives, sealants and paints used inthe manufacture of the product arecured and present no known hazardswhen used in the manner for which theyare intended.

The following other materials arepresent in the product:

13.1 Insulation MaterialsMaterial Types: Ceramic fibre board,mineral wool.

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

Known Hazards: May cause temporaryirritation or rash to skin. High dust levelsmay irritate eyes and upper respiratorysystem.

Precautions: Avoid unnecessary orrough handling, or harsh abrasion ofboards. Normal handling and use ofmaterial should not produce high dustlevels.

Avoid inhalation, and contact with skinand eyes.

After handling always follow normalgood hygiene practices.

Protection: Use disposable gloves, facemask and eye protection.

First Aid: Eyes - If irritation occurs,wash eyes with copious amounts ofwater. If symptoms persist, seek

immediate medical advice.

Skin - If irritation occurs, wash underrunning water before washing with soapand water.

Inhalation - Remove to fresh air, drinkwater to clear throat and blow nose toremove dust/fibres.

Ingestion - Drink plenty of water.

Material Types: Silicone elastomer.

Description: Sealant and adhesive.

Known Hazards: Irritation to eyes.

Precautions: Avoid inhalation of vapour,contact with eyes and prolonged orrepeated contact with skin.

After handling always follow normalgood hygiene practices.

Protection: Use eye protection. Rubberor plastic gloves should be worn whererepeated contact occurs and a facemask worn when working in confinedspaces.

First Aid: Eyes - Flush eyes with waterfor 15 minutes. Seek immediate medicalattention.

Skin - Wipe off and wash with soap andwater.

Inhalation - Remove to fresh air.

13.3 Kerosene and Gas OilFuels (mineral oils)Known Hazards: The effect of mineraloils on the skin vary according to theduration of exposure and the type of oil.

The lighter fractions remove theprotective grease naturally present onthe skin, leaving it dry, liable

to crack and more prone to damage bycuts, abrasions and irritant chemicals.

Skin rashes (Oil acne) most often onarms, but also on any part of the bodyin contact with oil or oily clothing.

Contact with fuel oils can causedermatitis.

Precautions: Avoid as far as possibleany skin contact with mineral oil or withclothing contaminated with mineral oil.

The use of a lanolin-based barrier creamis recommended, in conjunction withregular washing with

soap and rinsing with water to ensure alloil is removed from the skin.

Take care to prevent clothing, especiallyunderwear, from becomingcontaminated with oil.

Do not put oily rags or tools in pockets,especially trouser pockets.

Have first-aid treatment at once for aninjury, however slight.

Do not inhale any vapours from mineraloils.

13 Health and Safety Information

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We declare that the Grant Condensingrange of Oil Boilers equipped withEcoflam MAX1 burners approved toEN 267: 1999 satisfy the requirementsof the following European Directives:-

1. 89/336/EEC - ElectromagneticCompatibility Directive

Referred to the generic standardsEN 55014: 1993, EN 50082: 1: 1992

2. 73/23/EEC - Electrical EquipmentSafety Regulations Directive

Referred to the generic standardNO: 3260: The Electrical Equipment(Safety) Regulations: 1994

3. 92/42/EEC - Hot Water BoilerEfficiency Directive

Referred to the generic standardThe Boiler (Efficiency) (Amendment)Regulations 1994 (SI 1994/3083).

In non-EU CountriesIn non-EU countries, dispose ofelectrical and electronic equipment andall surplus packaging in accordancewith national and regional regulations.

Complies with EC Low voltageElectromagnetic compatibility and Boiler efficiency Directives.

89/336/EEC73/23/EEC92/42/EEC

In EU CountriesThe following information is provided toenable regulatory compliance with theEuropean Union (EU) directivesidentified and any amendments made tothese directives when using electrical orelectronic equipment in EU countries.

Disposal of Electrical andElectronic EquipmentEuropean Union (EU) Directive2002/96/EC Waste Electrical andElectronic Equipment (WEEE)

Do not dispose of electrical or electronicequipment in landfill sites. In the EU, it isthe individual recipient’s responsibility toensure that discarded electrical orelectronic materials are collected andrecycled according to the requirementsof EU environmental law.

Disposal of Surplus PackagingEuropean Parliament and CouncilDirective 94/62/EC Packaging andPackaging Waste

Do not dispose of surplus packaging inlandfill sites. In the EU, it is the individualrecipient’s responsibility to ensure thatpackaging materials are collected andrecycled according to the requirementsof EU environmental law.

14 EC Declaration of Conformity

User Instructio

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6

User Instructio

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Overheat ThermostatYour boiler is fitted with a safetyoverheat thermostat which willautomatically switch off the boiler in thecase of a control malfunction causingoverheating. If your boiler goes off andyou try to light it but nothing happens,and the 'Lock-out' neon on the controlpanel is not lit, the overheat thermostathas probably operated. The boiler willnot light until the thermostat is reset. Toreset, unscrew the small plastic capmarked reset (see Figure 1), press thebutton then replace the cap.

If this condition continually repeats,contact your Service engineer.

Remote Programmer Refer to the instructions supplied withyour particular system programmer.

VentilationAlways ensure that the boiler hasadequate ventilation. Any ventilationopenings provided by the Installer mustnot be obstructed.

Periodically check that they are clear.

Do not attempt to 'box in' the boiler orbuild a compartment around it beforeconsulting your Installer.

Do not place any combustible materialaround or on the boiler or flue pipe

Flue TerminalThe flue terminal, which may be on theoutside wall must not be obstructed ordamaged.

In severe conditions check that theterminal does not become blocked bysnow.

Frost ProtectionYour Installer may have fitted a frostthermostat. If not, and you are likely tobe away for a short time, leave theboiler on with the boiler thermostat setat a low setting. For longer periods theboiler and system should be drained.

Contact your Service engineer fordraining and filling the system.

Cleaning and ServicingLightly wipe over the case with a dampcloth and a little detergent. Do not useabrasive pads or cleaners.

You must have your boiler serviced atleast once a year to ensure safe andefficient operation. Contact your Serviceengineer for further details.

Failure of Electricity SupplyIf the electricity supply fails, the boilerwill not operate. It should relightautomatically when the supply isrestored.

If a remote programmer is connected, itmay retain the time settings for sometime and may not have to be reset to thecorrect time of day when the supply isrestored. Refer to the instructionssupplied with your programmer forfurther details. It is recommended thatyou check the time settings after apower failure has occurred.

Electricity SupplyThe boiler requires a 230/240 V ~ 50 Hzsupply. It must be protected by a5 Amp fuse.

The electricity connections to theboiler must be earthed.

!WARNING

User Instructio

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If your Boiler Fails to LightMake the following checks:

1.Check that the boiler On/Off switchis ON.

2.Check that the programmer isworking and is in an 'on' period.

3.Check that all thermostats are set tothe desired setting and are callingfor heat.

4.Check if the burner 'Lock-out'indicator neon on the control panelis lit. If it is, remove the upper frontcasing panel and locate the lockoutreset button on the burner behindthe control panel. See Figure 3.

5.Press the Reset button on theburner. If the burner fails to light andgoes to 'Lock-out' again, check thatyou have sufficient fuel in thestorage tank and that the fuelsupply valve is open.

6.Check that the fire valve in the oilsupply line has not tripped.

7.Ensure that a fuse has not blown orthat the electricity supply has notfailed.

8.Check to see if the overheatthermostat has operated (see thesection Overheat thermostat).

If the burner still fails to light aftercarrying out these checks then a faultexists. Switch off the electricity supplyto the boiler and contact your Serviceengineer.

Turning off your BoilerFor short periods:Set the On/Offswitch to OFF.

To restart, simply set the switch to ON.

For long periods:Set the On/Off switchto OFF and switch off the electricitysupply to the boiler. If required, the fuelsupply valve may be closed and thewater and electricity supplies turned offat the mains.

To restart, refer to the full lightinginstructions given in the Section Lightingyour boiler

About your FuelGrant Condensing Wall Hung boilersoperate only on Class C2 Kerosene toBS 2869:1998.

You should always quote this type offuel when ordering from your supplier.

Do not wait until the fuel runs out beforeyou order some more. Sludge in thebottom of the tank may be drawn intothe fuel lines. If it is possible, switch offthe boiler when the new supply isdelivered and leave the fuel to settle foran hour before restarting the boiler.

General Notes and Care ofyour SystemBoiler ThermostatThis control allows adjustment of thetemperature of the water leaving theboiler to heat the radiators anddomestic hot water.

Figure 3:Burner fuel pump

If you have a cylinder thermostat onyour hot water cylinder, this will controlthe temperature of your domestic hotwater. The boiler thermostat settingmust be equal to or above the cylinderthermostat setting to enable thecylinder thermostat to control thedomestic hot water system.

Burner Lock-out Indicator andReset ButtonIf there is a burner malfunction, a built-insafety circuit switches the burner off andthe 'Lock-out' indicator neon (on thecontrol panel) will light. Usually suchmalfunctions are short lived and pressingthe reset button will restore normaloperation.

!NOTE

Figure 3 shows the Lockout Resetbutton along with other main burnercomponents.

Make the following checks:

1.Check that the boiler On/Off switchis ON.

2.Check that the programmer isworking and is in an 'on' period.

3.Check that all thermostats are set tothe desired setting and are callingfor heat.

4.Check if the burner 'Lock-out'indicator neon on the control panelis lit. If it is, locate the lockout resetbutton on the burner behind thecontrol panel. See Figure 3.

5.Press the Reset button on theburner. If the burner fails to light andgoes to 'Lock-out' again, check thatyou have sufficient fuel in thestorage tank and that the fuelsupply valve is open.

6.Check that the fire valve in the oilsupply line has not tripped.

7.Ensure that a fuse has not blown orthat the electricity supply has notfailed.

8.Check to see if the overheat safetythermostat has operated. See thesection Overheat thermostat.

If the burner still fails to light aftercarrying out these checks then a faultexists or the fuel supply is low. If youhave sufficient fuel, switch off theelectricity supply to the boiler andcontact your Service engineer.

Burner head (blast tube)

Combustion air inlet

Combustionair adjuster

Lockout reset buttonMotor

Control box

Oil pump

Ignition sparkgenerator

Photocell

Fan housing

4

User Instructio

ns

Figure 1:Boiler lower front panel in down positionFigure 2:Boiler controls

User InstructionsLighting your BoilerThe lighting procedure is:

1.Ensure that there is sufficient fuel, ofthe correct type, in the supply tankand all fuel supply valves are open.The water supply is on. Theelectricity supply to the boiler is off.The boiler On/Off switch is set toOFF. The room thermostat (if fitted)is at the desired setting. The boilerthermostat is set to the requiredsetting.

2.Switch on the electricity supply tothe boiler.

3.Set the On/Off switch to ON, withthe remote programmer (CH or HW)also ON.

4.The boiler will now lightautomatically.

5.Set the HW and CH functions toTIMED. The boiler will now operateduring the 'on' periods set on theprogrammer.

IntroductionThis User Guide is intended to assistthe user in the operation of the GrantCONDENSING Wall Hung boilers.The engineers manual for theinstallation and maintenance of thisboiler is attached to the reverse ofthese instructions.

The following special text formats areused in this manual for the purposeslisted below:

Warning of possible human injury asa consequence of not following theinstructions in the warning.

About your BoilerThe boiler is fully automatic onceswitched on, providing central heating(and also heating your domestic hotwater if you have a hot water cylinderfitted). The boiler has a 'mains on' neon,see Figure 1, which lights when theboiler is switched on, but does notnecessarily indicate the burner is firing.

If your model is controlled by a remoteprogrammer and a room thermostat, itwill provide hot water and centralheating during the periods as set on theprogrammer, when either the roomthermostat and/or the hot waterthermostat are calling.

Boiler Controls1.To access the controls, open the

lower front panel by pulling it downas shown in Figure 1

The controls are shown in Figure 2.Note text. Used for emphasis orinformation not directly concernedwith the surrounding text but ofimportance to the reader.

!WARNING

!NOTE

Contents

Co

ntents

3

Overheat Thermostat6

Remote Programmer6

Ventilation6

Flue Terminal6

Frost Protection6

Cleaning and Servicing6

Failure of Electricity Supply6

Electricity Supply6

Introduction4

About your Boiler4

Boiler Controls4

Lighting your Boiler4

If your Boiler Fails to Light5

Turning off your Boiler5

About your Fuel5

General Notes and Careof your System5

Boiler Thermostat5

Burner Lock-out Indicator andReset Button5

2

Service Lo

g

For use with Kerosene only.

After installing the boiler leave theseinstructions with the User.

Service LogIt is recommended that the boiler shouldbe regularly serviced, at least once ayear, and the details entered in theBoiler Handbook by the serviceengineer.

GRANT ENGINEERING (IRELAND) LIMITEDCrinkle, Birr, Co. Offaly, IrelandTel: (057) 91 20089 Fax: (057) 91 21060 Email: info@grantengineering.ie www.grantengineering.ie

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/orappearances are changed in the interests of continued product improvement.All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.© Grant Engineering (Ireland) Limited 2008. No part of this manual may be reproduced by any means without prior writtenconsent.

Grant CondensingWall Hung Condensing Oil Boiler Range

User Instructions

Part No. DOC 84. Rev 0. November 2008