Grant Vortex Blue Supplementary Instructions DOC 0108 Rev 2.1 November 2016

User Manual: Pdf

Open the PDF directly: View PDF .
Page Count: 32

Contents
1 - User Instructions
2 - Introduction
3 - Technical Data
4 - Installation
- 4.1 - General
5 - Electrical
6 - Commissioning
7 - Servicing
- 7.1 - General
8 - Burner
9 - Fault Finding
10 - Spare Parts
- 10.1 - Riello RDB BLU Burner Parts List
- 10.2 - Exploded View of Riello RDB BLU Burner

UK | DOC 0108 | Rev 2.1 | November 2016

Grant UK VortexBlue

21, 26 and 36kW Blue Flame Oil Boiler Range

Supplementary User, Installation and Servicing Instr

uctions

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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances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

Contents Page 3

Contents

1 User Instructions 4

1.1 VortexBlue Kitchen/Utility, Kitchen/Utility 4

System Boilers and External Modules

1.2 VortexBlue Combi Boilers (Internal and 4

External models)

1.3 Control Panels 5

2 Introduction 6

2.1 Update to Main Installation Instructions 6

2.2 General 6

2.3 Low NOx Technology 6

2.4 Boiler Controls 6

2.5 Fuel Type 6

3 Technical Data 7

3.1 Boiler Technical Data 7

3.2 Boiler Clearances 8

3.3 Burner Settings 9

3.4 Boiler Dimensions 10

4 Installation 13

4.1 General 13

5 Electrical 13

5.1 General 13

5.2 Frost Protection 13

5.3 VortexBlue Kitchen Utility and 13

Kitchen/Utility System models

5.4 VortexBlue External Modules 14

5.5 VortexBlue Combi Boilers and 20

External Combi Boilers

6 Commissioning 22

6.1 General 22

6.2 Ignition Electrode Setting 22

6.3 Air Damper Adjustment 22

6.4 Air Adjuster Disc - 21kW only 22

7 Servicing 23

7.1 General 23

8 Burner 24

8.1 General 24

8.2 Burner Features 24

8.3 Digital Control Box 25

8.4 Burner Operation 27

9 Fault Finding 28

9.1 Burner Fault Indication 28

9.2 Burner Fault Diagnostics 28

9.3 Riello RDB BLU Fault Finding Chart 29

10 Spare Parts 30

10.1 Riello RDB BLU Burner Parts List 30

10.2 Exploded View of Riello RDB BLU Burner 31

Page 3

User InstructionsPage 4

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.

1.1 VortexBlue Kitchen/Utility, Kitchen/Utility

System Boilers and External Modules

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.

The Grant VortexBlue Kitchen/Utility (and Kitchen/Utility

System) boilers differ 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.

NOTE

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/Off 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.

If the ON/OFF switch is set to off 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.

NOTE

• Service Switch (External Modules only)

A Service switch is fitted to the control panel to allow the Service

Engineer to test-fire the boiler.

1 User Instructions

• 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.

• 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.

• 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.

To operate the reset push-button it must be pressed in and

briefly held (for at least one second) before releasing.

NOTE

1.2 VortexBlue Combi Boilers (Internal and External

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.

User Instructions Page 5

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

1.3 Control Panels

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 left with the User on

completion of Installation and Commissioning.

NOTE

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

2.2 General

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.

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 maximum 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.

Internal and External Combi boilers must be left at the factory

set output and not de-rated to a lower output.

NOTE

2.3 Low NOx Technology

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.

2 Introduction

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 External 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.

A service switch is fitted to the control panel of the external

modules to allow the service engineer to test-fire the boiler.

When set to 'ON' the switch temporarily by-passes the

external control system to operate the boiler.

This is a 'momentary' or non-latching switch that cannot be

left set to 'ON'. The boiler will automatically revert to normal

operation when 15 minutes have elapsed since it was last

operated.

If required, this 15 minute override period can be stopped by

switching the boiler ON/OFF switch 'OFF' and then back to

'ON'.

The boiler will then operate as normal under control of the

external heating/hot water controls (timer, room thermostat

or programmer).

NOTE

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.

Section 2: IntroductionPage 6

Section 3: Technical Data Page 7

3.1 Boiler Technical Data

3.1.1 Kitchen/Utility, Kitchen/Utility System and External Modules

Table 3-1: Kitchen/Utility, Kitchen/Utility System and External Modules Technical Data

Units Kitchen/Utility and System External Module

21kW 26kW 36kW 21kW 26kW 36kW

Water content

litres 19 19 21 19 19 21

gall 4.2 4.2 4.7 4.2 4.2 4.7

Weight (dry)*

kg 130 130 144 143 143 162

lbs 287 287 318 315 315 357

Maximum heat output (Kerosene)**

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

Maximum static head m 28

Minimum circulating head m 1

Boiler thermostat range °C 65 to 78

Limit (safety) shut off temperature °C 111±3

Maximum 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 ¼" BSP male (on end of flexible fuel hose)

Conventional flue draught

N/m² Minimum: 8.7 - maximum: 37

in wg Minimum: 0.035 - maximum: 0.15

Maximum operating pressure - sealed/open system bar 2.0

Maximum operating pressure - pressure relief valve bar 2.5

* Weight includes burner but excludes flue.

** Factory setting (maximum output). Refer to Section 3.3 for other boiler outputs.

3 Technical Data

Section 3: Technical DataPage 8

3.1.2 Combi and External Combi

Table 3-2: Combi and External Combi Technical Data

Units Combi External Combi

21kW 26kW 36kW 21kW 26kW 36kW

Water content (including 32 litre primary store)

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

Weight (dry)*

kg 160 177 200 181 206 225

lbs 353 390 441 399 454 496

Maximum heat output (Kerosene)

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

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

Maximum 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 ¼" BSP male (on end of flexible fuel hose)

Conventional flue draught

N/m² Minimum: 8.7 - maximum: 37

in wg Minimum: 0.035 - maximum: 0.15

Maximum operating pressure - pressure relief valve 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.

Section 3: Technical Data Page 9

3.3 Burner Settings

Table 3-3: Burner settings

Boiler models

(burner type)

Heat output

Nozzle

Oil

pressure

(bar)

Smoke

No.

Burner

head type

Burner

head/disc

setting

Fuel

flow rate

(kg/h)

Flue gas

temp.

(°C)

CO2

(%)

(kW) (Btu/h)

Kitchen/Utility 21

Kitchen/Utility System 21

External Module 21

(RDB2.2 BG1 BLU)

* 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

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 DataPage 10

3.4 Boiler Dimensions

All dimensions in the following diagrams are in millimetres.

Alternative

condensate

drain outlets

FRONT VIEW

470

860

LEFT SIDE

VIEW

813

759

709

587

352

110

30 Flue centre line

RIGHT SIDE VIEW

PLAN VIEW

470

603 11 0

Safety valve

Cold fill

Flow - 22mm push-fit

170

Flue

spigot

Figure 3-4: 21 and 26kW Kitchen/Utility and System dimensions

Safety valve

Flow - 28mm push-fit

Cold fill

170 61

LEFT SIDE VIEW

455

555

311

115

63 63

Flue centre line

RIGHT SIDE VIEW

PLAN VIEW

470

603 150

FRONT VIEW

470

900

205

Flue

spigot

Alternative

condensate

drain outlets

Figure 3-5: 36kW Kitchen/Utility and System dimensions

Section 3: Technical Data Page 11

Pre-cut hole

for side flue exit

if required

4 pre-cut

holes 50 mm dia.

in sidesboth

1005

509

797

269

908

117

757

660

418

179

21 and 26kW: A = 804

36kW: A = 824

Plan View

132

180

3 pre-cut holes

76 mm dia. in base

of boiler enclosure

Figure 3-6: 21, 26 and 36kW External Module dimensions

RIGHT SIDE VIEW

LEFT SIDE VIEW

PLAN VIEW

REAR VIEW

202210

760

690 140

614

307

105

110

155

227

588

100

699125

444

609

INTERNAL DRAIN

TRAP EXIT

(LEFTSIDE

PANEL ONLY)

858

Figure 3-7: 21 and 26kW Internal Combi dimensions

Section 3: Technical DataPage 12

RIGHT SIDE VIEW

LEFT SIDE VIEW

PLAN VIEW

REAR VIEW

182250

779

694 170

614

307

106

110

185

190

556

100

695170

445

106

609

INTERNAL DRAIN

TRAP EXIT

(LEFTSIDE

PANEL ONLY)

900

Figure 3-8: 36kW Internal Combi dimensions

966

239

Combi 21e, 26e

Combi 36e

Side flue exit

if required

Pre-cut hole 75 x 150mm in

each side of boiler enclosure

2 pre-cut holes in base

of boiler enclosure

115mm dia.

754

836

150

7533

945

150

658

Plan View

Figure 3-9: 21, 26 and 36kW External Combi dimensions

Section 4: Installation and Section 5: Electrical Page 13

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

4 Installation

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

For total system protection against freezing, particularly

during extended 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.

NOTE

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.

Do not interrupt the permanent mains supply to the boiler

with any external control, e.g. a timer, programmer, or room

thermostat.

NOTE

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

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.

NOTE

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)

Section 5: ElectricalPage 14

• 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 External 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.

Do not interrupt the permanent mains supply to the boiler

with any external control, e.g. a timer, programmer, or room

thermostat.

NOTE

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.

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.

NOTE

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.

Section 5: Electrical Page 15

1 2 3

E N L

4 5 6

E N L

7 8 9

E N L

10 11 12

E N L

18 20 21 22

15 1613 14 25 26

23 24

17 19 27 28

PUMP EARTH

PUMP NEUTRAL

PUMP LIVE

DO NOT CONNECT

BURNER EARTH

BURNER NEUTRAL

BURNER LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

DO NOT

REMOVE

LINK

DO NOT CONNECT

SWITCHED

LIVE SUPPLY

TIMER NEUTRAL

TIMER LIVE

STORE

THERMISTOR

(TO FRONT POCKET)

FLOW

THERMISTOR

(TO TOP POCKET)

MAINS

1A 2A

4B 5B

Boiler

On/Off

Off Off

Constant

Timed Timed

Constant

Central

Heating

Switch

Domestic

Hot Water

Switch

2 C

Limit

Thermostat

Earth connection

boiler top bracket

Printed Circuit Board

FUSE 5 X 20

N L

230V 5A Fused

Supply

Flow

Thermistor

Black shroud

indicates

Flow

Thermistor

Link Link Link

Burner

Resistor

BURNER

PERMANENT LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

Figure 5-1: VortexBlue Kitchen/Utility control panel wiring diagram

Section 5: ElectricalPage 16

1 2 3

E N L

4 5 6

E N L

7 8 9

E N L

10 11 12

E N L

18 20 21 22

15 1613 14 25 26

23 24

17 19 27 28

PUMP EARTH

PUMP NEUTRAL

PUMP LIVE

DO NOT CONNECT

BURNER EARTH

BURNER NEUTRAL

BURNER LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

DO NOT

REMOVE

LINK

DO NOT CONNECT

SWITCHED

LIVE SUPPLY

TIMER NEUTRAL

TIMER LIVE

STORE

THERMISTOR

(TO FRONT POCKET)

FLOW

THERMISTOR

(TO TOP POCKET)

MAINS

1A 2A

4B 5B

Boiler

On/Off

Off Off

Constant

Timed Timed

Constant

Central

Heating

Switch

Domestic

Hot Water

Switch

2 C

Limit

Thermostat

Earth connection

boiler top bracket

Printed Circuit Board

FUSE 5 X 20

E N L

N L

Black

Cable

230V 5A Fused

Supply

Flow

Thermistor

Black shroud

indicates

Flow

Thermistor

Link Link Link

Pump Burner

Resistor

BURNER

PERMANENT LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

Figure 5-2: VortexBlue Kitchen/Utility System control panel wiring diagram

Section 5: Electrical Page 17

1 2 3

E N L

4 5 6

E N L

7 8 9

E N L

10 11 12

E N L

18 20 21 22

15 1613 14 25 26

23 24

17 19 27 28

PUMP EARTH

PUMP NEUTRAL

PUMP LIVE

DO NOT CONNECT

BURNER EARTH

BURNER NEUTRAL

BURNER LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

DO NOT

REMOVE

LINK

DO NOT CONNECT

SWITCHED

LIVE SUPPLY

TIMER NEUTRAL

TIMER LIVE

STORE

THERMISTOR

(TO FRONT POCKET)

FLOW

THERMISTOR

(TO TOP POCKET)

MAINS

1A 2A

4B 5B

Boiler

On/Off

2 C

Limit

Thermostat

Earth connection

boiler top bracket

Service Switch

Printed Circuit Board

FUSE 5 X 20

N L

230V 5A Fused

Supply

Flow

Thermistor

Black shroud

indicates

Flow

Thermistor

Link Link Link

Burner

Resistor

BURNER

PERMANENT LIVE

DO NOT CONNECT

DO NOT REMOVE LINK

Link

Figure 5-3: VortexBlue External Module control panel wiring diagram

Section 5: ElectricalPage 18

Cylinder

Stat

Grant 2-Channel

Wall Mounted

Programmer ESKIT

L N E

240V

50HZ

1 2 345 6 78 9 10

L 1 2 34

Frost

Stat

Pipe Stat

(If fitted)

Wiring Centre

OFF OFF ON ON

HW HT HW HT

2 1 3

Room

Stat

1 2 3 4 5 6 7 8 9 10 11 12 18 20 21 2215 1613 14 25 2623 2417 19

N L

- -

- - - - -

4 Core cable from

Controls Wiring

Centre to Boiler

Brown

Blue

Green/Yellow

Brown

Blue

Green/Yellow

Red (Switch Live)

2-Port Zone Valve

Motor HW

HTG

Link Link

Blue

Green/Yellow

Motor

Blue

Green/Yellow

Grey

Orange

Brown

Pump

Brown

Blue

Green/Yellow E

Remove Link from

terminals 19 & 20

Brown Red

Figure 5-4: VortexBlue Kitchen/Utility, Kitchen/Utility System and External Module with S-plan type control system wiring diagram

Earth and some Neutral connections have

been excluded for clarity.

All switches are shown in the closed

position.

NOTE

Section 5: Electrical Page 19

Cylinder

Stat

Grant 2-Channel

Wall Mounted

Programmer ESKIT

L N E

240V

50HZ

1 2 345678 9 10

L 1 2 34

Frost

Stat

Pipe Stat

(If fitted)

Wiring Centre

Link

OFF OFF ON ON

HW HT HW HT

3-Port Mid Position

Zone Valve

2 1 3

Room

Stat

1 2 3 4 5 6 7 8 9 10 11 12 18 20 21 2215 1613 14 25 2623 2417 19

N L

- -

- - - - -

4 Core cable from

Controls Wiring

Centre to Boiler

Motor

13k

270k

0.25W

Brown

Blue

Green/Yellow

Brown

Blue

Green/Yellow

Orange

Grey

White

Blue

Green/Yellow

Red (Switch Live)

Link Link

Remove Link from

terminals 19 & 20

Brown

Blue

Green/Yellow E

1 2 345

RB1 Relay

Figure 5-5: VortexBlue Kitchen/Utility, Kitchen/Utility System and External Module with Y-plan type control system wiring diagram

Earth and some Neutral connections have

been excluded for clarity.

All switches are shown in the closed

position.

NOTE

Section 5: ElectricalPage 20

5.5 VortexBlue Combi and External Combi Boilers

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.

Figure 5-6: VortexBlue Internal Combi control panel wiring diagram

Figure 5-6 below replaces Figure 8-1 in the Combi boiler

Installation Instructions.

NOTE

1 2 3

E N L

4 5 6

E N L

7 8 9

E N L

10 11 12

E N L

18 20 21 22

15 16

13 14 25 26

23 24

17 19 27 28

CH PUMP EARTH

CH PUMP NEUTRAL

CH PUMP LIVE

DHW PUMP EARTH

DHW PUMP NEUTRAL

DHW PUMP LIVE

BURNER EARTH

BURNER NEUTRAL

BURNER LIVE

FLOW SWITCH

DHW TIMED ON

CH TIMED ON

TIMER NEUTRAL

TIMER LIVE

EXT. FROST STAT

ROOM STAT

STORE

THERMISTOR

(TO FRONT POCKET)

FLOW

THERMISTOR

(TO TOP POCKET)

MAINS

1A 2A

4B 5B

Boiler

On/Off

Off Off

Constant

Timed Timed

Constant

Central

Heating

Switch

Domestic

Hot Water

Switch

2 C

Limit

Thermostat

Earth connection

boiler top bracket

Printed Circuit Board

FUSE 5 X 20

E N L E N L

Pump

DHW

Pump

N L

Black

Cable

230V 5A Fused

Supply

White

Cable

Flow

Switch

Store

Thermistor

Flow

Thermistor

Black shroud

indicates

Flow

Thermistor

Link Link Link

BURNER

PERMANENT LIVE

Link

Section 5: Electrical Page 21

Figure 5-7: VortexBlue External Combi control panel wiring diagram

1 2 3

E N L

4 5 6

E N L

7 8 9

E N L

10 11 12

E N L

18 20 21 22

15 16

13 14 25 26

23 24

17 19 27 28

CH PUMP EARTH

CH PUMP NEUTRAL

CH PUMP LIVE

DHW PUMP EARTH

DHW PUMP NEUTRAL

DHW PUMP LIVE

BURNER EARTH

BURNER NEUTRAL

BURNER LIVE

FLOW SWITCH

DHW TIMED ON

CH TIMED ON

TIMER NEUTRAL

TIMER LIVE

EXT. FROST STAT

ROOM STAT

STORE

THERMISTOR

(TO FRONT POCKET)

FLOW

THERMISTOR

(TO TOP POCKET)

MAINS

1A 2A

4B 5B

Boiler

On/Off

2 C

Limit

Thermostat

Earth connection

boiler top bracket

Printed Circuit Board

FUSE 5 X 20

E N L E N L

Pump

DHW

Pump

N L

Black

Cable

230V 5A Fused

Supply

White

Cable

Flow

Switch

Store

Thermistor

Flow

Thermistor

Black shroud

indicates

Flow

Thermistor

Link Link Link

Service Switch

BURNER

PERMANENT LIVE

Link

Figure 5-7 below replaces Figure 8-1 in the External Combi

boiler Installation Instructions.

NOTE

Section 6: CommissioningPage 22

6.1 General

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.

6.2 Ignition Electrode Setting

Before first firing the boiler ensure that the burner ignition electrodes

are correctly set.

The ignition electrode details given in Figure 6-1 below

replaces that given in the Installation Instructions supplied

with the boiler.

NOTE

Figure 6-1: Riello RDB BLU ignition electrode setting

±0.5

6 3

±0.5

6 Commissioning

6.3 Air Damper Adjustment

Use a 3mm Allen key to adjust the air damper. Refer to Figure 6-2.

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:

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 6-3: Fitting the air adjuster disc

Section 7: Servicing Page 23

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.

7 Servicing

Section 8: BurnerPage 24

8.1 General

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.

From September 2018 the maximum 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.

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.

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.

8 Burner

Figure 8-1: Burner components

Table 8-2: Burner components key

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 Page 25

8.3 Digital Control Box

The digital control box fitted to this burner has several different

features compared to the more commonly used 'analogue' control

box.

8.3.1 Reset Push-button

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.

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 push-

button.

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.

To operate the reset push-button 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, after

which the mains power supply has to be switched off and

then back on for a further 5 reset attempts to be available.

NOTE

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.

8.3.3 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.

8.3.4 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 push-

button 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 push-

button 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 Reset push-button colour Seconds Notes

OFF OFF - -

Pre-purge ORANGE blinking 0.5 0.5

Safety time GREEN blinking 0.5 0.5

Normal operating position GREEN - - Steady ON

Table 8-4: Burner operating status indicator

Status Reset push-button colour Seconds Notes

Extraneous light (false flame signal) GREEN, RED blinking alternately 0.5 0.5

Frequency supply error ORANGE - - Steady ON

Voltage monitor error ORANGE, GREEN fast blinking alternately 0.2 0.2

Reset push-button / remote reset anomaly GREEN, RED fast blinking alternately 0.2 0.2

Lockout for no flame after safety time RED - - Steady ON

Go to box A*

Lockout for false flame signal RED blinking 0.5 0.5 Go to box B*

Lockout for maximum number of re-cycles RED fast blinking 0.2 0.2 Go to box C*

Lockout for fan motor error 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*

* Refer to the fault finding chart - Section 8.3.

Section 8: BurnerPage 26

8.3.5 Removal of Control Box

Before removing the control box from the burner, or opening

the control box cover, isolate the electrical supply to the

boiler.

!WARNING

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.

Figure 8-5: Removal of control box

Section 8: Burner Page 27

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

Re-cycles: Max. no. 3 repetitions of complete

start-up sequence if there is a flame failure

during

operation; the final action at the last attempt fol-

lowing flame failure is a lock-out

3 re-cycles

tpp

Post-purge time: additional purge time at the end

of a heat request. Can be interrupted by a new

heat request

8.4.2 Presence of Extraneous 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 maximum 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.

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.

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).

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.

In the case of continuous ignition sequence recycling

after flame failure, or heat demands close to one another,

the maximum number of cycle repetitions of the ignition

transformer is one attempt every minute.

NOTE

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.

After 8½ minutes of continuous burner operation the control

box regains one attempt to re-fire (should it be required).

If the power supply to the boiler is disconnected and then

reconnected, when the next heat demand is applied to the

burner all three possible attempts to re-fire are restored.

NOTE

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 pre-

purge 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.

Section 9: Fault FindingPage 28

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 •Faultyinternalmemory

9.2 Burner Fault Diagnostics

Table 9-2: Burner faults

Faults Possible cause Fault

diagnostics Solutions

The burner does not start when there

is heat demand

Lack of electrical supply OFF

Check presence of voltage in the L - N the pin plug

Check the conditions of the fuses.

Check that safety thermostat is not in lockout

The UV sensor sees an extraneous

light

GREEN, RED

blinking Eliminate the extraneous light.

The connections in the control box are

wrongly inserted OFF Check and connect all the plugs and sockets

properly.

The burner goes into lockout mode

before or during the pre-purging The UV sensor sees extraneous light RED blinking Eliminate the extraneous light.

Burner runs normally in the pre-purge

and ignition cycle and locks out after

about 5 seconds

The UV sensor is dirty

RED steady ON

Clear it

The UV sensor is faulty Replace it

Flame moves away or fails

Check pressure and output of the fuel

Check air output

Change nozzle

Check the coil of solenoid valve

Burner starts with an ignition delay

The ignition electrodes are wrongly

positioned

GREEN blinking

Adjust them according to the instructions of this

manual

Air output is too high Set the air output according to the instructions of this

manual

Nozzle dirty or worn Replace it

9 Fault Finding

Section 9: Fault Finding Page 29

9.3 Riello RDB BLU Fault Finding Chart

Figure 9-3: Riello RDB BLU Fault Finding

Contaminated

fuel

filters?

Control box

is supplied

with heat

demand

Fan runs for

less than

12 seconds

Burner locks

out after

25 seconds

Washing

pressure

1 - 2 bar

Ignition

spark

present

Coil releases

working

pressure?

Nozzle

atomising

the fuel?

Combustion

head set

correctly?

Motor starts

after initialisation

Check time 3.5sec?

Check boiler

and system

controls

Fan motor

or oil

pump seized?

Motor gives

50V AC across

white and

black wire?

Burner

fires when

UV sensor is

covered?

Check oil

supply to

oil pump

Are electrodes

OK and

set correctly?

Clean or

replace

filters

Nozzle

new?

Adjust

combustion air

setting

Reset

combustion

head

Replace

seized

component

Replace

fan

motor

Is the UV sensor

faulty?

Drive

coupling

broken?

Replace or

reset

electrodes

Replace

nozzle

Flame goes

out then

relights?

230V to motor

across blue and

black wire?

Remove

extraneous

light

Replace

pump

coupling

Check oil pipe

from pump to

nozzle holder

Clear

blockage

Boiler or

flue

blocked?

Approx.

35 Ω across blue

and black motor

wire?

DCoil

lead

OK?

Replace

UV sensor

Replace

oil

pump

Ignition

leads

OK?

Replace

coil

Clean or replace

pump and fuel

line filters

If balanced flue:

remove snorkel

and test - now OK?

Coil

resistance

90 to 110Ω?

Coil

resistance

90 to 110 Ω?

Replace

ignition

leads

After 15 seconds

25-30V DC to coil?

(coil connected)

Is the UV sensor

faulty?

Balanced flue can

recirculate gases

causing recycling

Replace

motor

capacitor

Replace

coil

lead

Replace

coil

Replace

oil

pump

Replace

UV sensor

Check flue

position

and seals

YAir

set

correctly?

Y N N Y Y Y Y Y N

Y N Y N Y N

N Y

N N Y Y N N N N N Y

Y Y

Y N Y

N Y

Y N

FReplace

control

box

Replace fan

motor and check

control box

Section 10: Spare PartsPage 30

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 ü20117411 RBS200

2 4-pin connector üN/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 ü20117437 RBS204

4 Ignition electrodes üüü 20117455 RBS205

5 Pre-heater jumper üüü 20045862 RBS206

6 Nozzle holder ü ü N/A 20117459 RBS207

6 Nozzle holder N/A N/A ü20117461 RBS208

7 Collar (including o-rings) ü ü N/A 20117472 RBS209

7 Collar (including o-rings) N/A N/A ü20117476 RBS210

8 Ignition HT lead üüü 20105111 RBS211

9 Air damper assembly üN/A N/A 3008647 RBS116

9 Air damper assembly N/A ü ü 3008839 RBS166

10 Fan üüü 3005788 RBS151

11 UV sensor üüü 20095126 RBS212

12 Capacitor 4.5 μF üüü 20071576 RBS149A

13 Solenoid valve üüü 3007871 RBS213

14 Pump pressure regulator üüü 20032135 RBS214

15 Air adjuster disc üN/A N/A 20094349 RBS215

16 Oil pump üüü 20030953 RBS101

17 O-ring (pump filter) - 10 pack üüü 3007175 RBS216

18 Pump filter and o-ring üüü 3020436 RBS217

19 Oil hose connector - 3/8 x 1/4 üüü 3009068 RBS218

20 Flexible oil hose üüü 3007621 RBS219

21 Oil pipe üüü 20117488 RBS220

22 Pressure gauge connector üüü 3008876 RBS138

23 Oil pump drive coupling - 10 pack üüü 3000443 RBS16

24 Solenoid coil üüü 3008648 RBS117

25 Motor and capacitor 4.5 μF üüü 20071577 RBS102A

26 Control box cover üüü 20094351 RBS221

27 Control box üüü 20117694 RBS222

28 Solenoid coil lead üüü 3008682 RBS223

29 Cover üüü 20117497 RBS224

30 O-ring kit üüü 3008878 RBS140

31 Front shield üüü 3020306 RBS225

32 Air intake - balanced flue üüü 3020281 RBS226

33 Air baffle ü ü N/A 20117504 RBS227

33 Air baffle N/A N/A ü20117506 RBS228

34 Flange ü ü N/A 3006384 RBS119

34 Flange N/A N/A ü20094352 RBS229

35 Air intake - conventional flue üüü 20012046 RBS230

10 Spare Parts

Section 10: Spare Parts Page 31

Figure 10-2: Exploded view of Riello RDB BLU burner

10.2 Exploded View of Riello RDB BLU Burner

33 10

25 12

21 29

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

Grant Vortex Blue Supplementary Instructions DOC 0108 Rev 2.1 November 2016

Navigation menu

Versions of this User Manual:

Views

Navigation