Grant Vortex Blue Supplementary Instructions DOC 0108 Rev 2.1 November 2016
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Grant UK VortexBlue 21, 26 and 36kW Blue Flame Oil Boiler Range Supplementary User, Installation and Servicing Instructions UK | DOC 0108 | Rev 2.1 | November 2016 Grant Engineering (UK) Limited Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: info@grantuk.com www.grantuk.com This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement. However, no responsibility of any kind for any injury, death, loss, damage or delay however caused resulting from the use of this manual can be accepted by Grant Engineering (UK) Limited, the author or others involved in its publication. All good sold are subject to our official Conditions of Sale, a copy of which may be obtained on application. © Grant Engineering (UK) Limited 2016. No part of this manual may be reproduced by any means without prior written consent. Contents 1 User Instructions 1.1 1.2 1.3 VortexBlue Kitchen/Utility, Kitchen/Utility System Boilers and External Modules VortexBlue Combi Boilers (Internal and External models) Control Panels 2 Introduction 2.1 2.2 2.3 2.4 2.5 Update to Main Installation Instructions General Low NOx Technology Boiler Controls Fuel Type 3 Technical Data 3.1 3.2 3.3 3.4 Boiler Technical Data Boiler Clearances Burner Settings Boiler Dimensions 4 Installation 4.1 5 4 5 6 6 6 6 6 6 13 13 Electrical 13 General Frost Protection VortexBlue Kitchen Utility and Kitchen/Utility System models VortexBlue External Modules VortexBlue Combi Boilers and External Combi Boilers Contents 7 8 General Burner 8.1 8.2 8.3 8.4 9 General Ignition Electrode Setting Air Damper Adjustment Air Adjuster Disc - 21kW only Servicing 7.1 7 7 8 9 10 Commissioning 6.1 6.2 6.3 6.4 4 General 5.1 5.2 5.3 5.4 5.5 6 4 General Burner Features Digital Control Box Burner Operation Fault Finding 9.1 9.2 9.3 Burner Fault Indication Burner Fault Diagnostics Riello RDB BLU Fault Finding Chart 10 Spare Parts 10.1 Riello RDB BLU Burner Parts List 10.2 Exploded View of Riello RDB BLU Burner 22 22 22 22 22 23 23 24 24 24 25 27 28 28 28 29 30 30 31 13 13 13 14 20 Page 3 1 User Instructions These User Instructions are intended to assist the user in the operation of the Grant VortexBlue range of high efficiency oil fired boilers. Please refer to the section that applies to your particular boiler model. • Heating Thermostat This control allows the temperature of the water leaving the boiler to heat the radiators (and domestic hot water) to be adjusted. This will be set by the installer to the optimum temperature for efficient operation of the boiler. It should be left set in this position. 1.1 VortexBlue Kitchen/Utility, Kitchen/Utility System Boilers and Ex ternal Modules • Boiler Indicator Lights These five red LEDs, located on the boiler control panel, indicate the operating situation of the boiler as below: PUMP Power to the system circulating pump POWER Mains power to the boiler is switched on DEMAND Demand for heating (and/or hot water) from the heating system controls. OVERHEAT Boiler overheat thermostat has operated and switched the boiler off. BURNER Power to the burner for it to operate. The boiler is fully automatic once switched on, providing central heating (and also heating your domestic hot water if you have a hot water cylinder fitted). For guidance on how to use your Grant VortexBlue Kitchen/Utility boiler (or Kitchen/Utility System boiler) please refer to the User Instructions for the Grant Vortex Kitchen/Utility boiler. These are to be found at the back of the Installation Instructions supplied with the boiler. ! NOTE The Grant VortexBlue Kitchen/Utility (and Kitchen/Utility System) boilers dif fer from the standard version of the Grant Vortex, as follows: a) The use of the Riello RDB BLU blue flame burner – refer to Section 7 (installer section) of these Supplementary Instructions for details. b) A new boiler control system with electronic temperature control and LED boiler function indication. 1.1.1 Boiler Controls Please refer to the following for details of the boiler control panels. For all other details refer to the User Instructions supplied with the boiler. To access the control panel, pull off the front door panel from the boiler. The controls on the panel are as follows (refer to Figures 1-1 to 1-3 as appropriate). • Boiler On/Of f switch This switches the boiler on and off. The boiler ON/OFF switch incorporates a 'mains on' neon which lights when the boiler is switched on. Please note that the 'mains on' neon does not necessarily indicate that the burner if firing. See Boiler Indicator Lights information in the next column. When the ON/OFF switch is set to on, the POWER indicator LED on the control panel will also light. This also does not necessarily indicate that the boiler is firing. ! NOTE • Overheat Thermostat (Overheat Reset) The boiler is fitted with a safety overheat thermostat which will automatically switch off the boiler in the case of a control malfunction causing overheating. • System Pressure Gauge (Kitchen/Utility System models only) This is to indicate the water pressure in the sealed heating system. 1.1.2 Lighting the Boiler Please follow the guidance for lighting the boiler given in the User Instructions supplied with the boiler. If the reset push-button LED on the burner indicates a lockout (refer to Section 8.3.3), press the reset button to attempt to re-start the burner. If the burner then operates correctly the lockout may have been caused by a temporary fault that has now cleared. If the lockout persists the cause of the fault should be diagnosed and rectified. ! NOTE To operate the reset push-but ton it must be pressed in and briefly held (for at least one second) before releasing. 1.2 VortexBlue Combi Boilers (Internal and Ex ternal models) For guidance on how to use your Grant VortexBlue Combi boiler, please refer to the User Instructions for the Grant Vortex Combi boiler (or External Combi boiler). These are to be found at the back of the Installation Instructions supplied with the boiler. If the ON/OFF switch is set to of f the boiler will NOT supply central heating or heat domestic hot water (if a hot water cylinder is connected to the boiler). The built-in frost thermostat will also not operate. • Service Switch (Ex ternal Modules only) A Service switch is fitted to the control panel to allow the Service Engineer to test-fire the boiler. Page 4 User Instructions 1.3 Control Panels Figure 1-1: VortexBlue Kitchen/Utility Control Panel Figure 1-2: VortexBlue Kitchen/Utility System Control Panel Figure 1-3: VortexBlue External Module Control Panel User Instructions Page 5 2 Introduction ! NOTE These supplementary Instructions must be read in conjunction with the Vortex boiler Installation Instructions supplied with the boiler. Both the Vortex boiler Installation Instructions and these Supplementary Instructions must be lef t with the User on completion of Installation and Commissioning. 2.1 Update to Main Installation Instructions These Supplementary Instructions are designed to cover the differences between the Grant Vortex and the new Grant VortexBlue low NOx boilers, as much of the installation, commissioning, servicing and operation is identical to the standard Vortex boilers. The following sections of the Vortex Installation Instructions (supplied with the boiler) have not been changed and should be referred to during the installation and commissioning of this boiler: • Section 3 Oil Supply and Storage • Section 5 Pipe Connections • Section 6 Condensate Disposal • Section 7 Sealed Systems • Section 9 Flues and Air Supply • Section 14 Health and Safety Information • Section 16 Guarantee 2.4 Boiler Controls 2.4.1 Combi Boilers The Grant VortexBlue Combi boilers (internal and external) have the same electronic control system as fitted to the standard Vortex Combi models. All wiring details for external controls (programmers, room thermostats, etc.) are given in Section 8 of the Vortex Combi Installation Instructions provided with the boiler. 2.4.2 Kitchen/Utility boilers and Ex ternal Modules The Grant VortexBlue Kitchen/Utility boilers and External Modules incorporate a new electronic control system based on the one used in the Grant Vortex Combi boilers. This uses an electronic boiler thermostat and has LED lights to indicate the operating status of the boiler. For details on how to operate the boiler please refer to Section 1. Refer to Section 5 of these Supplementary Instructions for further details and electrical connection diagrams. ! NOTE A service switch is fit ted to the control panel of the ex ternal modules to allow the service engineer to test-fire the boiler. 2.2 General When set to 'ON' the switch temporarily by-passes the ex ternal control system to operate the boiler. The new Grant VortexBlue range of high efficiency low NOx oil fired boilers consists of 15 models including Kitchen/Utility, Kitchen/Utility System and External Modules as well as both Internal and External Combi boilers. This is a 'momentary' or non-latching switch that cannot be lef t set to 'ON'. The boiler will automatically revert to normal operation when 15 minutes have elapsed since it was last operated. All models are available in three outputs – 21kW, 26kW and 36kW. The Kitchen/Utility, Kitchen/Utility System and External Modules are supplied factory set at the ma ximum outputs of 21kW, 26kW and 36kW but can be de-rated to a lower output on commissioning if required. Refer to Section 3.3 of these Supplementary Instructions for a full list of all models and outputs. If required, this 15 minute override period can be stopped by switching the boiler ON/OFF switch 'OFF' and then back to 'ON'. ! NOTE Internal and Ex ternal Combi boilers must be lef t at the factory set output and not de-rated to a lower output. 2.3 Low NOx Technology The boiler will then operate as normal under control of the ex ternal heating/hot water controls (timer, room thermostat or programmer). 2.5 Fuel Type All VortexBlue boilers are designed for use with Kerosene (Class C2) only. The use of any other fuel, e.g. Gas Oil (Class D), is not permitted with any of the VortexBlue boilers and may invalidate the product guarantee. Grant VortexBlue boilers are designed to meet both the forthcoming European Ecodesign (ErP) emissions limits due to be introduced in September 2018, and to maintain the high efficiencies expected of Grant Vortex oil fired boilers. They combine the proven Grant condensing boiler technology with the Riello RDB BLU compact low NOx blue flame burners. Grant VortexBlue boilers can be used with all the Grant flue system options available for the standard Vortex boilers. Refer to the Installation Instructions supplied with the boiler for details. Page 6 Section 2: Introduction 3 Technical Data 3.1 Boiler Technical Data 3.1.1 Kitchen/Utility, Kitchen/Utility System and Ex ternal Modules Table 3-1: Kitchen/Utility, Kitchen/Utility System and External Modules Technical Data Kitchen/Utility and System Units Water content Weight (dry)* Ma ximum heat output (Kerosene)** litres Ex ternal Module 21kW 26kW 36kW 21kW 26kW 36kW 19 19 21 19 19 21 gall 4.2 4.2 4.7 4.2 4.2 4.7 kg 130 130 144 143 143 162 lbs 287 287 318 315 315 357 kW 21 26 36 21 26 36 Btu/h 71 650 88 700 122 840 71 650 88 700 122 840 Flow connection 22mm 22mm 28mm 22mm 22mm 28mm Return connection 22mm 22mm 28mm 22mm 22mm 28mm Minimum flow rate (∆T=10°C) l/h 1 800 2 200 3 000 1 800 2 200 3 000 Minimum flow rate (∆T=20°C) l/h 900 1 100 1 500 900 1 100 1 500 Condensate connection 22 mm plastic pipe Flue diameter (conventional) 100 mm (4 inches) Waterside resistance (∆T=10°C) mbar 26 Waterside resistance (∆T=20°C) mbar 9.5 Ma ximum static head m 28 Minimum circulating head m 1 Boiler thermostat range °C 65 to 78 Limit (safety) shut off temperature °C 111±3 Ma ximum hearth temperature °C Less than 50 Electricity supply 230/240V 1ph 50Hz fused at 5A Burner motor power W 90 Absorbed motor power W 0.15 Starting current A 2.0 Running current A 0.85 Oil connection Conventional flue draught ¼" BSP male (on end of flexible fuel hose) N/m² Minimum: 8.7 - ma ximum: 37 in wg Minimum: 0.035 - ma ximum: 0.15 Ma ximum operating pressure - sealed/open system bar 2.0 Ma ximum operating pressure - pressure relief valve bar 2.5 * Weight includes burner but excludes flue. ** Factory setting (ma ximum output). Refer to Section 3.3 for other boiler outputs. Section 3: Technical Data Page 7 3.1.2 Combi and Ex ternal Combi Table 3-2: Combi and External Combi Technical Data Units Water content (including 32 litre primary store) Weight (dry)* Combi Ex ternal Combi 21kW 26kW 36kW 21kW 26kW 36kW litres 48.5 48.5 53.5 48.5 48.5 53.5 gall 10.7 10.7 11.8 10.7 10.7 11.8 kg 160 177 200 181 206 225 lbs 353 390 441 399 454 496 kW 21 26 36 21 26 36 Btu/h 71 650 88 700 122 840 71 650 88 700 122 840 Flow and return connections mm 22 22 28 22 22 28 Minimum flow rate ∆T=10°C l/h 1 800 2 200 3 000 1 800 2 200 3 000 Minimum flow rate ∆T=20°C l/h 900 1 100 1 500 900 1 100 1 500 Ma ximum heat output (Kerosene) Condensate connection 22 mm plastic pipe Flue diameter (conventional) 100 mm (4 inches) Waterside resistance ∆T=10°C mbar 28.5 28.5 26 28.5 28.5 26 Waterside resistance ∆T=20°C mbar 10.0 10.0 9.5 10.0 10.0 9.5 Boiler stat range °C 65 to 78 Limit stat shut off temperature °C 111±3 Ma ximum hearth temperature °C Electricity supply Less than 50 230/240V 1ph 50Hz fused at 5A Burner motor power W 90 Absorbed motor power W 0.15 Starting current A 2.0 Running current A 0.85 Oil connection Conventional flue draught Ma ximum operating pressure - pressure relief valve ¼" BSP male (on end of flexible fuel hose) N/m² Minimum: 8.7 - ma ximum: 37 in wg Minimum: 0.035 - ma ximum: 0.15 bar 2.5 * Weight includes burner but excludes flue 3.2 Boiler Clearances Adequate clearance must be left for servicing the boiler. For guidance on the clearances required, please refer to the 'Boiler Location' information given in the 'Installation Information' section of the Installation Instructions supplied with the boiler. Page 8 Section 3: Technical Data 3.3 Burner Set tings Table 3-3: Burner settings Boiler models (burner type) Heat output (kW) (Btu/h) Nozzle Oil pressure (bar) Smoke No. Burner head type Burner head/disc set ting Fuel flow rate (kg/h) Flue gas temp. (°C) CO2 (%) * 21 * 71 650 0.60/80°ES 8.5 0-1 BG1 N/A 1.78 75 - 85 12.0 18 61 400 0.55/80°ES 8 0-1 BG1 N/A 1.53 70 - 80 12.0 16 54 600 0.40/80°ES 10.5 0-1 BG1 B 1.36 65 - 75 12.0 15 51 200 0.40/80°ES 9 0-1 BG1 B 1.28 65 - 75 12.0 Kitchen/Utility 26 Kitchen/Utility System 26 External Module 26 (RDB2.2 BG1 BLU) * 26 * 88 700 0.65/80°ES 10 0-1 BG1 N/A 2.19 75 - 80 12.0 23 78 475 0.65/80°ES 8.5 0-1 BG1 N/A 1.94 70 - 75 12.0 21 71 650 0.60/80°ES 8.5 0-1 BG1 N/A 1.78 65 - 70 12.0 Kitchen/Utility 36 Kitchen/Utility System 36 External Module 36 (RDB2.2 BG3 BLU) * 36 * 123 000 0.85/80°ES 11 0-1 BG3 N/A 2.99 75 - 80 12.0 31.5 107 500 0.85/80°ES 9 0-1 BG3 N/A 2.62 70 - 75 12.0 26 88 700 0.65/80°ES 10 0-1 BG3 N/A 2.19 65 - 70 12.0 Combi 21 External Combi 21 (RDB2.2 BG1 BLU) 21.0 71 650 0.60/80°ES 8.5 0 BG1 N/A 1.8 73 12.0 Combi 26 External Combi 26 (RDB2.2 BG1 BLU) 26.0 88 700 0.65/80°ES 10.0 0 BG1 N/A 2.0 72 12.0 Combi 36 External Combi 36 (RDB2.2 BG3 BLU) 36.0 123 000 0.85/80°ES 11.0 0 BG3 N/A 2.8 78 12.0 Kitchen/Utility 21 Kitchen/Utility System 21 External Module 21 (RDB2.2 BG1 BLU) Notes: 1. The data given above is approximate only. 2. The above settings may have to be adjusted on site for the correct operation of the burner. 3. Gas Oil and Bio Kerosene are NOT suitable for use with Grant VortexBlue boiler range 4. The flue gas temperatures given above are ± 10%. 5. When commissioning, the air damper must be adjusted to obtain the correct CO2 level. 6. * Factory settings: 15/21 - 21kW, 21/26 - 26kW, 26/36 - 36kW 7. When setting the 15/21 to 15kW or 16kW, the burner air adjuster disc requires repositioning. Refer to Section 6 (Commissioning). 8. The installer must amend the boiler data label if the output is changed. Section 3: Technical Data Page 9 3.4 Boiler Dimensions All dimensions in the following diagrams are in millimetres. 603 110 470 PLAN VIEW 352 813 759 709 587 18 Flue centre line 470 170 Flue spigot Alternative condensate drain outlets 17 860 30 110 Safety valve Cold fill Flow - 22mm push-fit FRONT VIEW LEFT SIDE VIEW RIGHT SIDE VIEW Figure 3-4: 21 and 26kW Kitchen/Utility and System dimensions 603 150 470 Safety valve Flow - 28mm push-fit Cold fill PLAN VIEW 63 115 Flue centre line 470 61 170 61 555 455 311 205 Flue spigot Alternative condensate drain outlets LEFT SIDE VIEW 900 24 63 FRONT VIEW RIGHT SIDE VIEW Figure 3-5: 36kW Kitchen/Utility and System dimensions Page 10 Section 3: Technical Data 3 pre-cut holes 76 mm dia. in base of boiler enclosure 132 = 180 180 = Plan View 21 and 26kW: A = 804 36kW: A = 824 1005 509 797 269 Pre-cut hole for side flue exit if required 757 4 pre-cut holes 50 mm dia. in both sides 908 A 660 418 179 50 117 Figure 3-6: 21, 26 and 36kW External Module dimensions 105 614 ø 11 0 307 ø 155 PLAN VIEW 210 90 90 35 75 75 140 227 ø 25 609 17 125 202 699 858 ø 31 ø 99 588 INTERNAL DRAIN TRAP EXIT (LEFTSIDE PANEL ONLY) 31 760 690 100 ø 31 444 REAR VIEW LEFT SIDE VIEW RIGHT SIDE VIEW Figure 3-7: 21 and 26kW Internal Combi dimensions Section 3: Technical Data Page 11 106 614 ø 11 0 307 ø 185 182 PLAN VIEW 250 90 190 90 60 62 609 18 170 170 62 ø 25 ø 31 900 695 ø 106 556 INTERNAL DRAIN TRAP EXIT (LEFTSIDE PANEL ONLY) 31 779 694 100 ø 31 445 RIGHT SIDE VIEW LEFT SIDE VIEW REAR VIEW Figure 3-8: 36kW Internal Combi dimensions 966 239 658 754 75 2 pre-cut holes in base of boiler enclosure 49 150 Side flue exit if required 115mm dia. 150 945 Combi 21e, 26e Combi 36e 836 33 49 Plan View 150 73 33 75 Pre-cut hole 75 x 150mm in each side of boiler enclosure Figure 3-9: 21, 26 and 36kW External Combi dimensions Page 12 Section 3: Technical Data 4 Installation 4.1 General For full details on the installation of this boiler, please refer to the following sections of the Installation Instructions supplied with the boiler: • • • • • Installation Information Pipe Connections Condensate Disposal Sealed Systems Flue System & Air Supply 5 Electrical 5.1 General For details on the electrical installation requirements for this boiler please refer to the Installation Instructions supplied with this boiler in conjunction with the information given below. 5.2 Frost Protection The Kitchen/Utility, Kitchen/Utility System and External Modules are all fitted with pre-set internal frost protection. This will automatically start the circulating pump if either: a) The air temperature (sensed on the boiler control PCB) falls below 5°C, or b) The water temperature (sensed by the boiler control thermistor) falls below 8°C If after fifteen minutes the air temperature exceeds 10°C or the water temperature exceeds 15°C the circulating pump will stop. However, if after fifteen minutes either the air or water temperature is less than 10°C, the burner is automatically fired until the water temperature reaches 30°C, when the burner stops and there is a pump overrun of two minutes. Also, to protect any exposed heating system pipework, it is recommended that an 'external' frost thermostat is also installed. This frost thermostat will operate in parallel with the internal frost protection of the boiler. It should be sited within the house in such a place that it can detect any rise and fall in the ambient air temperature, i.e. in a room with a radiator. Where the frost thermostat is installed outside the house (to protect a boiler installed in an external boiler room or garage) or in an attic, it is recommended that it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property. The pipe thermostat should be located on the boiler return pipe, and set to operate at 30°C. For connection details please refer to Figures 5-4 and 5-5 ! NOTE For total system protection against freezing, particularly during ex tended periods without electrical power, Grant recommend the use of a combined heating system antifreeze and corrosion inhibitor, used in accordance with the manufacturer's instructions. Section 4: Installation and Section 5: Electrical 5.3 VortexBlue Kitchen/Utility and Kitchen/Utility System models 5.3.1 Connecting Power Supply, Pump and Control System The boiler requires both a switched mains power supply, from an external programmer or control system, in addition to a permanent live supply. ! NOTE Do not interrupt the permanent mains supply to the boiler with any ex ternal control, e.g. a timer, programmer, or room thermostat. There is no facility in the Grant VortexBlue Kitchen/Utility and Kitchen/Utility System boilers for the fitting of a plug-in timer or programmer. A 4-core cable (3-core and earth) is required to connect the power supply and heating controls to the boiler. On Kitchen/Utility models a 3-core cable (2-core and earth) is required to connect the circulating pump to the boiler. For control system wiring please refer to Figures 5-4 and 5-5 ! NOTE Ensure that the route and length of the supply and pump cables are such that the boiler control panel can be fully hinged down without needing to disconnect them from the terminal block. The procedure is as follows: 1. Lift off the boiler top front casing panel, if it has not already been removed. 2. Loosen (do not remove) the four screws securing the control panel to the side panels, hinge the panel forward and allow it to drop down to gain access to the top of the panel. 3. Remove the two screws securing the terminal block cover and lift off the cover. 4. Remove the screws securing the cable clamp and open clamp. 5. Route the supply cable through the hole in the rear panel (using the grommet supplied) and up to the control panel 6. Pass the 4-core cable through the cable clamp and connect to the boiler control panel terminals as follows: • Green/Yellow to mains earth (terminal 1) • Blue to mains neutral (terminal 2) • Brown to mains live (terminal 3) Page 13 • Black to switched live (terminal 19) On Kitchen/Utility models - pass the 3-core cable from the pump through the cable clamp and connect to the boiler control panel terminals as follows: • Green/Yellow to pump earth (terminal 4) • Blue to pump neutral (terminal 5) • Brown to pump live (terminal 6) 7. Tighten the cable clamp and refit the terminal block cover 8. Re-connect the electrical supply and check operation of heating system controls (programmer, room thermostats, etc.). 9. Refer to Instructions provided with the programmer for operation and setting. 10. Leave the Programmer and Thermostat Instructions with the user after installation for their future reference. 5.3.2 Circulating Pump On the Kitchen/Utility System models, the circulating pump is factory fitted within the boiler enclosure and the pump is wired to the pump terminals on the control panel terminal block. On Kitchen/Utility models the pump should also be connected directly to the control panel terminal block. Refer to Section 5.3.1. Connected this way allows the pump to be isolated using the Boiler ON/OFF switch, on the boiler control panel, for servicing or maintenance work. Also, the boiler control automatically provides a short pump 'overrun' (two minutes) after the burner is shut down (when the heat demand is interrupted), e.g. when the room thermostat is satisfied. This pump overrun will not occur if the boiler power supply is interrupted, e.g. if the boiler ON/OFF switch is set to off. 5.4 VortexBlue Ex ternal Modules 5.4.1 Connecting Power Supply, Pump and Control System The boiler requires both a switched mains power supply, from an external programmer or control system, in addition to a permanent live supply. ! NOTE Do not interrupt the permanent mains supply to the boiler with any ex ternal control, e.g. a timer, programmer, or room thermostat. There is no facility in the Grant VortexBlue External Module for the fitting of a plug-in timer or programmer. A 4-core cable (3-core and earth) is required to connect the power supply and heating controls to the boiler. A 3-core cable (2-core and earth) is required to connect the circulating pump to the boiler. For control system wiring, refer to Figures 5-8 and 5-9. ! NOTE Ensure that the route and length of the supply cable is such that the boiler control panel can be fully hinged down without disconnecting the supply cable from the terminal block. The procedure is as follows: 1. Remove the module front door panel, if it has not already been removed. 2. Remove the four screws securing the front of the control panel and allow it to drop down to gain access to the top of the panel. 3. Remove the screws securing the cable clamp and open clamp. 4. Route the supply and pump cables up to the control panel. 5. Pass the 4-core cable through the cable clamp and connect to the boiler control panel terminals as follows: • Green/Yellow to mains earth (terminal 1) • Blue to mains neutral (terminal 2) • Brown to mains live (terminal 3) • Black to switched live (terminal 19) 6. Pass the 3-core cable from the pump through the cable clamp and connect to the boiler control panel terminals as follows: • Green/Yellow to pump earth (terminal 4) • Blue to pump neutral (terminal 5) • Brown to pump live (terminal 6) 7. Tighten the cable clamp and refit the front of the control panel. 8. Re-connect the electrical supply and check operation of heating system controls (programmer, room thermostats, etc.). 9. Refer to Instructions provided with the programmer for operation and setting. 10. Leave the Programmer and Thermostat Instructions with the user after installation for their future reference. 5.4.2 Connection of the Circulating Pump The circulating pump should be connected directly to the control panel terminal block. Refer to Section 4.4.1. Connecting the pump in this way allows it to be isolated using the Boiler On/Off switch, on the boiler control panel, for servicing or maintenance work. Also, when the pump is connected this way, the boiler control automatically provides a short pump 'overrun' (2 minutes) after the burner has shut down (when the heat demand is interrupted), e.g. when the room thermostat is satisfied. This pump overrun will not occur if the boiler power supply is interrupted, e.g. if the boiler ON/ OFF switch is set to off. Page 14 Section 5: Electrical 4B 5B N L N L 2 3 230V 5A Fused Supply E 1 MAINS FUSE 5 X 20 PUMP LIVE PUMP NEUTRAL N L 5 6 DO NOT CONNECT N L 8 9 DO NOT CONNECT E 7 BURNER LIVE N SL N L 11 12 BURNER NEUTRAL Burner E L BURNER EARTH E 10 Printed Circuit Board DO NOT CONNECT 13 14 15 16 BURNER PERMANENT LIVE SWITCHED LIVE SUPPLY DO NOT CONNECT Link Link 17 18 19 20 DO NOT CONNECT Figure 5-1: VortexBlue Kitchen/Utility control panel wiring diagram PUMP EARTH E 4 C DO NOT CONNECT 2 DO NOT REMOVE LINK DO NOT REMOVE LINK DO NOT CONNECT Timed 21 22 Timed Off Off Domestic Hot Water Switch Constant Constant Central Heating Switch TIMER NEUTRAL Limit Thermostat TIMER LIVE Earth connection boiler top bracket Link 23 24 25 26 DO NOT CONNECT Boiler On/Off 1A 2A DO NOT REMOVE LINK DO NOT REMOVE LINK DO NOT CONNECT Section 5: Electrical Page 15 Black shroud indicates Flow Thermistor Flow Thermistor Resistor 28 STORE THERMISTOR (TO FRONT POCKET) 27 FLOW THERMISTOR (TO TOP POCKET) 4B 5B Black Cable PUMP LIVE Pump N L 5 6 PUMP NEUTRAL E NL PUMP EARTH E 4 DO NOT CONNECT N L 8 9 DO NOT CONNECT E 7 BURNER LIVE N SL N L 11 12 BURNER NEUTRAL Burner E L BURNER EARTH E 10 Printed Circuit Board DO NOT CONNECT 13 14 15 16 DO NOT CONNECT DO NOT CONNECT Link Link 17 18 19 20 BURNER PERMANENT LIVE SWITCHED LIVE SUPPLY Figure 5-2: VortexBlue Kitchen/Utility System control panel wiring diagram N L N L 2 3 230V 5A Fused Supply E 1 MAINS FUSE 5 X 20 C DO NOT CONNECT 2 DO NOT REMOVE LINK DO NOT REMOVE LINK DO NOT CONNECT Timed 21 22 TIMER NEUTRAL Timed Off Off Domestic Hot Water Switch Constant Constant Central Heating Switch TIMER LIVE Limit Thermostat Link 23 24 25 26 DO NOT CONNECT Earth connection boiler top bracket DO NOT CONNECT Boiler On/Off 1A 2A DO NOT REMOVE LINK DO NOT REMOVE LINK Page 16 Section 5: Electrical Black shroud indicates Flow Thermistor Flow Thermistor Resistor 28 STORE THERMISTOR (TO FRONT POCKET) 27 FLOW THERMISTOR (TO TOP POCKET) Section 5: Electrical Page 17 Boiler On/Off 2A 5B 1A 4B N L N L 2 3 230V 5A Fused Supply E 1 MAINS FUSE 5 X 20 Earth connection boiler top bracket N L 5 6 E 7 N L 8 9 C 2 DO NOT CONNECT Limit Thermostat L E N SL N L 11 12 Burner E 10 13 14 15 16 Printed Circuit Board Link Link 17 18 19 20 Link Figure 5-3: VortexBlue External Module control panel wiring diagram E 4 PUMP EARTH PUMP NEUTRAL PUMP LIVE DO NOT CONNECT DO NOT CONNECT BURNER EARTH BURNER NEUTRAL BURNER LIVE DO NOT CONNECT DO NOT CONNECT DO NOT REMOVE LINK DO NOT REMOVE LINK DO NOT CONNECT BURNER PERMANENT LIVE SWITCHED LIVE SUPPLY DO NOT CONNECT 21 22 TIMER NEUTRAL TIMER LIVE Link Link 23 24 25 26 DO NOT CONNECT DO NOT CONNECT DO NOT REMOVE LINK DO NOT REMOVE LINK 28 Flow Thermistor Resistor 27 STORE THERMISTOR (TO FRONT POCKET) FLOW THERMISTOR (TO TOP POCKET) Black shroud indicates Flow Thermistor Service Switch Page 18 Section 5: Electrical NOTE All switches are shown in the closed position. Earth and some Neutral connections have been excluded for clarity. ! 5A Pipe Stat (If fitted) Brown Blue Green/Yellow N L 1 2 4 2 1 3 Room Stat 3 1 2 3 4 OFF OFF ON ON HW HT HW HT Grant 2-Channel Wall Mounted Programmer ESKIT 5 1 2 7 Cylinder Stat C 6 L N E 8 Link 13 14 15 16 9 10 Brown Blue Green/Yellow Brown Blue Green/Yellow Orange Orange Red HTG 17 18 19 20 Motor HW 2-Port Zone Valve Motor 4 Core cable from Controls Wiring Centre to Boiler Red (Switch Live) Pump 10 - 11 12 Brown Brown Blue Green/Yellow 7 - 8 9 21 22 Remove Link from terminals 19 & 20 Link 23 24 25 26 2-Port Zone Valve Grey Grey Figure 5-4: VortexBlue Kitchen/Utility, Kitchen/Utility System and External Module with S-plan type control system wiring diagram 240V 50HZ 4 - 5 6 Brown Blue Green/Yellow Wiring Centre L N E Frost Stat N L - 1 - 2 3 -- Section 5: Electrical Page 19 NOTE All switches are shown in the closed position. Earth and some Neutral connections have been excluded for clarity. ! 5A Pipe Stat (If fitted) Brown Blue Green/Yellow N L 1 2 4 2 1 3 Room Stat 3 1 2 3 4 OFF OFF ON ON HW HT HW HT Grant 2-Channel Wall Mounted Programmer ESKIT 5 1 2 7 L N E 8 Link 13 14 15 16 9 Link 1 10 3 4 RB1 Relay 2 4 Core cable from Controls Wiring Centre to Boiler Red (Switch Live) 10 - 11 12 Cylinder Stat C 6 Brown Blue Green/Yellow 7 - 8 9 5 13k 2W 270k 0.25W Link 23 24 25 26 Motor 21 22 Blue Green/Yellow Orange Grey White 17 18 19 20 Remove Link from terminals 19 & 20 3-Port Mid Position Zone Valve Figure 5-5: VortexBlue Kitchen/Utility, Kitchen/Utility System and External Module with Y-plan type control system wiring diagram 240V 50HZ 4 - 5 6 Brown Blue Green/Yellow Wiring Centre L N E Frost Stat N L - 1 - 2 3 -- 4B 5B N L Black Cable E DHW PUMP LIVE DHW Pump N L N L 8 9 DHW PUMP EARTH E 7 L E BURNER EARTH E 10 BURNER LIVE BURNER NEUTRAL N SL N L 11 12 Flow Switch Link 13 14 15 16 CH TIMED ON DHW TIMED ON Link Link 17 18 19 20 BURNER PERMANENT LIVE Figure 5-6: VortexBlue Internal Combi control panel wiring diagram CH Pump E NL White Cable N L 5 6 E 4 Timed 21 22 Timed Off Off Link 27 Black shroud indicates Flow Thermistor Flow Thermistor FLOW THERMISTOR (TO TOP POCKET) 28 STORE THERMISTOR (TO FRONT POCKET) Store Thermistor ROOM STAT 23 24 25 26 ! 230V 5A Fused Supply N L 2 3 CH PUMP EARTH Printed Circuit Board FLOW SWITCH Constant Constant TIMER NEUTRAL Domestic Hot Water Switch 5.5.1 Connecting the Power Supply and Control System For details on the electrical installation requirements for the Combi or External Combi, please refer to Section 8 of the Installation Instructions supplied with this boiler. E 1 MAINS CH PUMP LIVE CH PUMP NEUTRAL FUSE 5 X 20 C DHW PUMP NEUTRAL 2 FLOW SWITCH Central Heating Switch TIMER LIVE Limit Thermostat EXT. FROST STAT Earth connection boiler top bracket EXT. FROST STAT Page 20 ROOM STAT Boiler On/Off 1A 2A 5.5 VortexBlue Combi and Ex ternal Combi Boilers NOTE Figure 5-6 below replaces Figure 8-1 in the Combi boiler Installation Instructions. Section 5: Electrical 4B 5B N L N L 2 3 230V 5A Fused Supply E 1 MAINS Black Cable CH Pump E NL E DHW PUMP LIVE DHW Pump N L N L 8 9 DHW PUMP EARTH E 7 L E BURNER EARTH E 10 Printed Circuit Board BURNER LIVE BURNER NEUTRAL N SL N L 11 12 FLOW SWITCH FLOW SWITCH Flow Switch Link 13 14 15 16 Link Link Link 17 18 19 20 TIMER NEUTRAL 21 22 TIMER LIVE Figure 5-7: VortexBlue External Combi control panel wiring diagram White Cable N L 5 6 CH PUMP EARTH E 4 CH PUMP LIVE CH PUMP NEUTRAL FUSE 5 X 20 C DHW PUMP NEUTRAL 2 DHW TIMED ON Limit Thermostat CH TIMED ON BURNER PERMANENT LIVE Earth connection boiler top bracket EXT. FROST STAT Link Link 23 24 25 26 EXT. FROST STAT Boiler On/Off 1A 2A ROOM STAT Section 5: Electrical 27 Black shroud indicates Flow Thermistor Flow Thermistor FLOW THERMISTOR (TO TOP POCKET) 28 STORE THERMISTOR (TO FRONT POCKET) Store Thermistor ROOM STAT Service Switch ! NOTE Figure 5-7 below replaces Figure 8-1 in the Ex ternal Combi boiler Installation Instructions. Page 21 6 Commissioning 6.1 General 6.3 Air Damper Adjustment To commission the boiler and burner follow the procedure given in the Section 10 of the Vortex (or Vortex Combi ) Installation Instructions supplied with the boiler. Use a 3mm Allen key to adjust the air damper. Refer to Figure 6-2. 6.2 Ignition Electrode Set ting Before first firing the boiler ensure that the burner ignition electrodes are correctly set. ! NOTE The ignition electrode details given in Figure 6-1 below replaces that given in the Installation Instructions supplied with the boiler. 5 ±0.5 Figure 6-2: Air damper adjustment 6.4 Air Adjuster Disc – 21kW only The boiler is supplied with an air adjuster disc loose in the accessories bag. To fit and position the air adjuster disc when downrating the 21kW boiler to 15 or 16kW output: 63 ±0.5 1. Ensure the boiler is isolated from the electrical supply. 2. Remove the burner from the boiler. 3. Undo the two screws (1) and remove the air damper assembly from the side of the burner. 4. Remove the screw (2) from the centre of where the air adjuster disc will be fitted. 5. Position the disc such that the disc setting ‘B’ (corresponding to 15 or 16kW output setting – refer to Section 3.3) is located against the cast boss on the fan housing. 6. Replace the screw in the centre of the air adjuster disc and tighten. 7. Re-fit the air damper assembly to the side of the burner and reassemble in reverse order. Air adjuster disc Air damper assembly Figure 6-1: Riello RDB BLU ignition electrode setting 2 1 Figure 6-3: Fitting the air adjuster disc Page 22 Section 6: Commissioning 7 Servicing 7.1 General To service the boiler and burner follow the procedure given in the Section 11 of the Vortex boiler (or Vortex Combi boiler) Installation Instructions supplied with the boiler. Section 7: Servicing Page 23 8 Burner 8.1 General 3 All Grant VortexBlue boilers are fitted with a Riello RDB BLU blue flame burner. This has been designed to operate with reduced NOx emissions that meet the forthcoming European Ecodesign emissions regulations. 6 9 From September 2018 the ma ximum permissible NOx level for oil fired boilers is 120mg/kWh. All Grant VortexBlue boilers, fitted with the Riello RDB BLU burner, will operate well below this minimum level and thus fully comply with these emissions regulations when they come into effect. 5 8.2 Burner Features The Riello RDB BLU blue flame burner fitted to the Grant VortexBlue boilers is very similar to the Riello RDB 'yellow flame' burners, such as those fitted to the Vortex range of oil fired boilers. 10 The main differences with the blue flame burner are as follows: • An Ultra Violet (UV) sensor is used – the blue flame cannot be detected by the usual photocell. • A digital control box is used – the UV cell cannot be used with the usual 'analogue' control box. • A clear reset button (on the control box) with burner status and fault identification by different coloured indicator lights. • A longer combustion head – to allow the necessary recirculation of the combustion gases. • A post purge following flame shut off – requiring a permanent live to the burner in addition to the usual switched live. 2 7 8 4 1 Figure 8-1: Burner components Table 8-2: Burner components key Page 24 Key Description 1 Oil pump 2 Digital control box 3 Reset push-button with lockout lamp 4 Flange with insulating gasket 5 Air damper adjustment screw 6 Snorkel (balanced flue) 7 Pump pressure adjustment screw 8 Pressure gauge port 9 UV sensor 10 Combustion head Section 8: Burner The digital control box fitted to this burner has several different features compared to the more commonly used 'analogue' control box. 8.3.2 Operating Status Indication From start up the operating status of the burner is displayed via the reset push-button indicator LED on the control box. Refer to Table 8-3. 8.3.1 Reset Push-but ton This is a clear (transparent) button that will indicate the operating status of the burner and also burner faults depending on the colour of the indicator LED visible through the reset button. 8.3.3 Burner Fault Indication Whenever a burner lockout occurs the cause is displayed via the reset push-button indicator LED on the control box. Refer to Table 8-4. 8.3 Digital Control Box If there is no heat demand to fire the burner, the indicator LED will be off, i.e. no colour visible though the reset push button. Refer to Figure 8-1 for the location of the control box and reset pushbutton. If the reset push-button LED is indicating a lockout (refer to Section 8.3.3), press the reset button to attempt to re-start the burner. If the burner then operates correctly the lockout may have been caused by a temporary fault that has now cleared. If the lockout persists the cause of the fault should be diagnosed and rectified. ! NOTE To operate the reset push-but ton it must be pressed in and briefly held (for at least one second) before releasing. ! NOTE The burner can only be reset 5 times consecutively, af ter which the mains power supply has to be switched of f and then back on for a further 5 reset at tempts to be available. 8.3.4 Last Lockout Display The control box memorises the details of the last lockout that occurred and this information can be recalled and displayed by the reset push-button indicator LED. To operate this function: • Press and hold the reset push-button for 25 seconds • During this time the reset push button indicator LED will first flash RED (twice) and then flash GREEN (once) and then GREEN again (three times) • As soon as it flashes GREEN four times release the reset pushbutton immediately • The reset push-button indicator LED will then display the last lockout indication, e.g. constant red. • Refer to the Fault Diagnostics table (Table 9-2) in Section 9 of these Supplementary Instructions to identify the fault from the indicator LED sequence. The lockout fault will only be displayed for a period of 10 seconds. If required, this period can be extended by re-pressing the reset pushbutton during the display of the lockout. The lockout display will then be extended by a further 10 seconds. Table 8-3: Burner operating status indicator Status OFF Reset push-but ton colour Seconds OFF - - Pre-purge ORANGE blinking 0.5 0.5 Safety time GREEN blinking 0.5 0.5 GREEN - - Normal operating position Notes Steady ON Table 8-4: Burner operating status indicator Status Extraneous light (false flame signal) Frequency supply error Voltage monitor error Reset push-but ton colour Seconds GREEN, RED blinking alternately 0.5 0.5 ORANGE - - Notes Steady ON ORANGE, GREEN fast blinking alternately 0.2 0.2 GREEN, RED fast blinking alternately 0.2 0.2 RED - - Steady ON Go to box A* RED blinking 0.5 0.5 Go to box B* RED fast blinking 0.2 0.2 Go to box C* RED, ORANGE blinking inverted 2.5 0.5 Go to box D* Lockout for oil valve error RED, GREEN blinking inverted 2.5 0.5 Go to box E* Lockout for eeprom error ORANGE, GREEN blinking alternately 0.5 0.5 Go to box F* Reset push-button / remote reset anomaly Lockout for no flame after safety time Lockout for false flame signal Lockout for ma ximum number of re-cycles Lockout for fan motor error * Refer to the fault finding chart - Section 8.3. Section 8: Burner Page 25 8.3.5 Removal of Control Box ! WARNING 2 Before removing the control box from the burner, or opening the control box cover, isolate the electrical supply to the boiler. 4 To remove the control box proceed as follows (referring to Figure 8-5): • Unscrew and remove screw (1) and open control box cover (2). • Disconnect all plugs from the control box terminals. • Unscrew the retaining finger nut and remove the solenoid coil (3) from the oil pump. • Unscrew and remove the two screws (4) and remove the control box from the burner. • Disconnect the two ignition leads from the ignition connections on rear of control box. • Refit the control box to the burner using the reverse of the above procedure. 3 1 4 Figure 8-5: Removal of control box Page 26 Section 8: Burner 8.4.3 Spark Ignition Duration The 'pre-ignition' spark time starts 2 seconds before the oil valve opens (the start of the 5 second 'safety time' period). 8.4 Burner Operation 8.4.1 Burner Operating Times Table 8-6: Burner operating times Symbol Description Value (seconds) t0 Standby: the burner is waiting for a heat request - t1 Standby time for an input signal: reaction time, control box remains in waiting status for t1 ≤1 t2 Initialisation standby time: check time following the main power start-up 3.5 t2l Checks extraneous light during t2: waiting mode for t2l, then lockout: the motor does not start 25 t3 Pre-purge time: the fan motor is working 15 t3l Checks extraneous light during pre-purging: control box goes into lockout at the end of t3l 25 t3i Spark pre-ignition time 2 ts Safety time 5 t4i Total spark ignition time 10 t4l Reaction time to achieve safety shut-down due to flame failure ≤1 t5i Spark post-ignition time 3 tr Re-cycles: Ma x. no. 3 repetitions of complete start-up sequence if there is a flame failure during operation; the final action at the last attempt following flame failure is a lock-out 3 re-cycles Post-purge time: additional purge time at the end of a heat request. Can be interrupted by a new heat request 60 tpp The 'post-ignition' spark time ends 3 seconds after the end of the safety time period, i.e. 8 seconds after the oil valve opens. The ignition spark is present throughout the 'safety time' period (5 seconds) making a total spark ignition period of 10 seconds. ! NOTE In the case of continuous ignition sequence recycling af ter flame failure, or heat demands close to one another, the maximum number of cycle repetitions of the ignition transformer is one at tempt every minute. 8.4.4 Burner Recycle Function In event of flame failure during burner operation the control box will allow the burner to recycle and repeat the start-up sequence for the burner to attempt to re-fire. This can occur up to a total of three attempts to re-fire the burner. If it fails a fourth time in operation it will cause a burner lockout and the reset push-button indicator LED will be RED. ! NOTE Af ter 8½ minutes of continuous burner operation the control box regains one at tempt to re-fire (should it be required). 8.4.2 Presence of Ex traneous light or Flame On burner start up, when the fan starts to pre-purge the burner/ boiler, if an extraneous light or flame is detected in the combustion chamber by the UV sensor the burner fan continues to run until either: a) The extraneous light or flame disappears, or b) 25 seconds elapses, a burner lockout occurs and the fault indicator LED flashes Green/Red If an extraneous light or flame is detected after the fan has started (i.e. at some time during the pre-purge period) the pre-purge time of 15 seconds is reset, and the 25 second time for checking for the presence of extraneous light or flame starts and the fan continues to run. As above, if the extraneous light or flame does not disappear after 25 seconds a burner lockout occurs. This function is cumulative and can operate a ma ximum of two times during the burner pre-purge period. If the extraneous light or flame disappears after 24 seconds (or less) the pre-purge period and the 25 second countdown for checking for extraneous light or flame re-starts. If the extraneous light or flame re-appears the process is repeated. If the extraneous light or flame appears for a third time, the burner goes into lockout. If during a burner recycle operation due to Flame failure (refer to Section 8.4.4 – Burner Recycle Function) an extraneous light or flame is detected, the 25 second countdown starts for checking for extraneous light or flame. If the power supply to the boiler is disconnected and then reconnected, when the nex t heat demand is applied to the burner all three possible at tempts to re-fire are restored. 8.4.5 Post Purge Function This function allows air flow through the burner for a pre-set time after the burner flame is switched off (on the loss of demand for the burner to fire). The loss of demand from either the heating system controls, or boiler temperature control, interrupts the switched live to the burner resulting in the fuel supply being shut off and the flame stopped. The permanent supply to the burner maintains the fan operation for a short period to provide the post purging of the burner and boiler prior to the burner re-firing again. The post-purge function does not operate: e) After a burner lockout has occurred f) If the heat demand is interrupted during the pre-purge period However, the post-purge function will operate if the heat demand is interrupted: g) During the safety time period (i.e. immediately after burner ignition) h) During normal operation of the burner If the UV cell detects any extraneous light or flame during the prepurge period the burner will go to 'lockout' after 25 seconds. If there is a new heat demand during the post-purge period, the post-purge function is halted (the fan stops) and a new burner operating cycle starts. The presence of extraneous light or flame can also be detected when the burner is in: c) The standby condition waiting for a heating demand to start the burner. d) The Initialisation period (t2) after the heating demand but before the burner fan starts. Section 8: Burner Page 27 9 Fault Finding 9.1 Burner Fault Indication Whenever a burner lockout occurs the cause is displayed via the reset push button indicator LED on the control box. The colour, sequence and speed of the indicator LED flashes identify the specific lockout type and the possible causes are listed in Table 8-1. Table 9-1: Burner fault indication Lockout description Lockout time LED colour Probable cause Presence of extraneous light during standby After 25 seconds RED blinking • Presence of a false flame signal before the heat request Presence of extraneous light detected during pre-purging After 25 seconds RED blinking • Presence of false flame signal during pre-purging Extraneous light detected during post-purging After 25 seconds RED blinking • Presence of false flame signal during post-purging (or pre-heating if the short-circuit socket is not connected The flame is not detected after the safety time After 5 seconds from oil-valve starts RED steady ON • UV sensor defective or dirty • Oil valve defective or dirty • Faulty ignition transformer • Badly regulated burner • Oil fuel not present Flame failure during operation After 3 recycles RED blinking • Badly adjusted burner • Oil valve defective or dirty • UV sensor defective or dirty Fan motor error Immediate (during pre-purge) RED, ORANGE blinking inverted • Faulty fan motor • Fan motor not connected Malfunction in the internal control circuit that drives the oil valve Immediate (during pre-purge) RED, GREEN blinking inverted • Faulty oil valve • Internal control circuit that drives the oil valve faulty Eeprom error Immediate (during pre-purge) ORANGE, GREEN blinking inverted Possible cause Fault diagnostics • Faulty internal memory 9.2 Burner Fault Diagnostics Table 9-2: Burner faults Faults Solutions Check presence of voltage in the L - N the pin plug The burner does not start when there is heat demand The burner goes into lockout mode before or during the pre-purging Burner runs normally in the pre-purge and ignition cycle and locks out after about 5 seconds Lack of electrical supply OFF The UV sensor sees an extraneous light GREEN, RED blinking The connections in the control box are wrongly inserted OFF The UV sensor sees extraneous light RED blinking Check the conditions of the fuses. Check that safety thermostat is not in lockout Eliminate the extraneous light. Check and connect all the plugs and sockets properly. Eliminate the extraneous light. The UV sensor is dirty Clear it The UV sensor is faulty Replace it RED steady ON Flame moves away or fails Check pressure and output of the fuel Check air output Change nozzle Check the coil of solenoid valve The ignition electrodes are wrongly positioned Burner starts with an ignition delay Air output is too high Nozzle dirty or worn Page 28 Adjust them according to the instructions of this manual GREEN blinking Set the air output according to the instructions of this manual Replace it Section 9: Fault Finding Section 9: Fault Finding Check boiler and system controls N Control box is supplied with heat demand Y N Replace motor capacitor Y N N Replace fan motor Y Replace coil lead N Coil lead OK? Y Y Y N N Burner fires when UV sensor is covered? Y Burner locks out after 25 seconds Replace coil Y Replace UV sensor Y Is the UV sensor faulty? B Remove extraneous light N Coil resistance 90 to 110 Ω? Motor gives 50V AC across white and black wire? Y Fan runs for less than 12 seconds Replace fan motor and check control box Approx. 35 Ω across blue and black motor wire? D Y 230V to motor across blue and black wire? N Fan motor or oil pump seized? N Motor starts after initialisation Check time 3.5sec? A Replace seized component Y N N Replace ignition leads N Replace pump coupling Y Y F Replace control box Y Ignition leads OK? Y Are electrodes OK and set correctly? N Ignition spark present E Replace or reset electrodes N Y N Replace coil N Y Clean or replace filters Y Y Clean or replace pump and fuel line filters Check oil pipe from pump to nozzle holder Replace oil pump Y Y Nozzle new? N Nozzle atomising the fuel? After 15 seconds 25-30V DC to coil? (coil connected) Coil resistance 90 to 110Ω? N Contaminated fuel filters? N Coil releases working pressure? Figure 9-3: Riello RDB BLU Fault Finding Replace oil pump N Drive coupling broken? Check oil supply to oil pump N Washing pressure 1 - 2 bar N N Air set correctly? N Replace UV sensor Y Is the UV sensor faulty? Clear blockage Adjust combustion air setting C Replace nozzle N Y Y Y Check flue position and seals Balanced flue can recirculate gases causing recycling Y If balanced flue: remove snorkel and test - now OK? N Boiler or flue blocked? N Flame goes out then relights? Y Combustion head set correctly? Y Reset combustion head N 9.3 Riello RDB BLU Fault Finding Chart Page 29 10 Spare Parts 10.1 Riello RDB BLU Burner Parts List Table 10-1: Riello RDB BLU burner parts list Key Description 21kW burner 26kW burner 36kW burner Riello product code Grant UK product code 1 Gasket ü ü N/A 3005787 RBS27 1 Gasket N/A N/A ü 20117411 RBS200 2 4-pin connector ü N/A N/A 20117417 RBS201 2 4-pin connector N/A ü ü 20117432 RBS202 3 Combustion head - BG1 ü ü N/A 20117435 RBS203 3 Combustion head - BG3 N/A N/A ü 20117437 RBS204 4 Ignition electrodes ü ü ü 20117455 RBS205 5 Pre-heater jumper ü ü ü 20045862 RBS206 6 Nozzle holder ü ü N/A 20117459 RBS207 6 Nozzle holder N/A N/A ü 20117461 RBS208 7 Collar (including o-rings) ü ü N/A 20117472 RBS209 7 Collar (including o-rings) N/A N/A ü 20117476 RBS210 8 Ignition HT lead ü ü ü 20105111 RBS211 9 Air damper assembly ü N/A N/A 3008647 RBS116 9 Air damper assembly N/A ü ü 3008839 RBS166 10 Fan ü ü ü 3005788 RBS151 11 UV sensor ü ü ü 20095126 RBS212 12 Capacitor 4.5 μF ü ü ü 20071576 RBS149A 13 Solenoid valve ü ü ü 3007871 RBS213 14 Pump pressure regulator ü ü ü 20032135 RBS214 15 Air adjuster disc ü N/A N/A 20094349 RBS215 16 Oil pump ü ü ü 20030953 RBS101 17 O-ring (pump filter) - 10 pack ü ü ü 3007175 RBS216 18 Pump filter and o-ring ü ü ü 3020436 RBS217 19 Oil hose connector - 3/8 x 1/4 ü ü ü 3009068 RBS218 20 Flexible oil hose ü ü ü 3007621 RBS219 21 Oil pipe ü ü ü 20117488 RBS220 22 Pressure gauge connector ü ü ü 3008876 RBS138 23 Oil pump drive coupling - 10 pack ü ü ü 3000443 RBS16 24 Solenoid coil ü ü ü 3008648 RBS117 25 Motor and capacitor 4.5 μF ü ü ü 20071577 RBS102A 26 Control box cover ü ü ü 20094351 RBS221 27 Control box ü ü ü 20117694 RBS222 28 Solenoid coil lead ü ü ü 3008682 RBS223 29 Cover ü ü ü 20117497 RBS224 30 O-ring kit ü ü ü 3008878 RBS140 31 Front shield ü ü ü 3020306 RBS225 32 Air intake - balanced flue ü ü ü 3020281 RBS226 33 Air baffle ü ü N/A 20117504 RBS227 33 Air baffle N/A N/A ü 20117506 RBS228 34 Flange ü ü N/A 3006384 RBS119 N/A N/A ü 20094352 RBS229 ü ü ü 20012046 RBS230 34 Flange 35 Air intake - conventional flue Page 30 Section 10: Spare Parts 18 16 1 Section 10: Spare Parts 17 13 5 27 14 34 26 3 28 19 20 6 4 16 24 22 25 2 30 33 12 10 Figure 10-2: Exploded view of Riello RDB BLU burner 23 31 7 8 11 35 21 30 15 32 29 9 10.2 Exploded View of Riello RDB BLU Burner Page 31 Grant Engineering (UK) Limited Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991 Email: info@grantuk.com www.grantuk.com
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