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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances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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