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Transcript of Grant UK VortexBlue · operation of the Grant VortexBlue range of high efficiency oil fired ......
UK | DOC 0108 | Rev 2.5 | June 2018
Grant UK VortexBlueInternal, Internal System, External, Combi and External Combi Blue Flame Oil Boiler Range
Supplementary User, Installation and Servicing Instructions
Grant EnGinEErinG (UK) LimitEd
Hopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EUTel: +44 (0)1380 736920 Fax: +44 (0)1380 736991Email: [email protected] 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This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.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. No part of this manual may be reproduced by any means without prior written consent.
important notE for instaLLErsThese instructions are intended to guide Installers on the installation, commissioning and servicing of the Grant Vortex oil boiler. After installing the boiler, leave these instructions with the user.
spEciaL tExt formatsThe following special text formats are used in these instructions for the purposes listed below:
! WarninG !Warning of possible human injury as a consequence of not following the instructions in the warning.
! caUtion !caution concerning likely damage to equipment or tools as a consequence of not following the instructions in the caution.
! notE !Used for emphasis or information not directly concerned with the surrounding text but of importance to the reader.
prodUct codEs coVErEdThese instructions cover the following product codes:VTXBF21, VTXBF26, VTXBF36, VTXSBF21, VTXSBF26, VTXSBF36, VTXBFCOMBI21, VTXBFCOMBI26, VTXBFCOMBI36, VTXBFOMCOMB21, VTXBFOMCOMB26 and VTXBFOMCOMB36these supplementary instructions must be read in conjunction with the Vortex boiler installation instructions supplied with the boiler.
sErVicinGThe boiler should be serviced at least every twelve months.
fUEL tYpEAll Grant Vortex boilers are suitable for use with Class C2 Kerosene. To use Bio-Kerosene (B30K), refer to the information below:
opEration on Bio-fUELAll Grant Vortex condensing boilers manufactured since May 2011 are suitable for for operation on both standard Kerosene (Class C2 to BS 2869) and also bio-kerosene - up to a 30% blend (B30K).All burner settings and nozzle sizes (as detailed in Section 2.2 of these instructions) are correct for both standard kerosene and bio-kerosene (B30K).In order to operate this boiler on bio-kerosene, it will be necessary to take the following actions:• Useabio-kerosene(B30K)compatibleflexibleoillinein
place of the oil line supplied with the boiler.• Have the oil storage tank and oil supply line (including all
pipework,sightgauges,filters,isolatingvalves,firevalves,de-aeration devices, etc.) checked for their compatibility with bio-kerosene (B30K).Where necessary, some or all of these items may have to be replaced with a bio-kerosene compatible alternative.
• CheckthesuitabilityofthefluesystemwithGrantUK.• Use only bio-kerosne (B30K) that conforms to OPS24.
important:Under no circumstances, should the boiler be used with bio-kerosene without the above actions being taken first.
Contents Page 03
Contents
1 User Instructions 4 1.1 VortexBlue Internal, Internal 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 2.6 Sealed Systems 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 Internal and 13 Internal System models 5.4 VortexBlue External Modules 14 5.5 VortexBlue Combi Boilers and 14 External Combi Boilers 5.6 Wiring Diagrams 15
6 Commissioning 22 6.1 General 22 6.2 Ignition Electrode Setting 22 6.3 Air Damper Adjustment 22 6.4 Air Adjuster Disc - 15-21 model 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 26
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 03
User InstructionsPage 04
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 Internal, Internal System Boilers and External ModulesThe 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 Internal boiler (or Internal System boiler) please refer to the User Instructions for the Grant Vortex Internal boiler.
These are to be found at the back of the Installation Instructions supplied with the boiler.
The Grant VortexBlue Internal (and Internal 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.
NOTE!
1.1.1 Boiler ControlsPlease 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 switchThis 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 ThermostatThis 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 LightsThese five red LEDs, located on the boiler control panel, indicate the operating situation of the boiler as below: PUMP Power to the system circulating pumpPOWER 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(Internal System models only)
This is to indicate the water pressure in the sealed heating system.
1.1.2 Lighting the BoilerPlease 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 05
Figure 1-1: VortexBlue Internal Control Panel
Figure 1-2: VortexBlue Internal 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 lef t with the User on completion of Installation and Commissioning.
NOTE!
2.1 Update to Main Installation InstructionsThese Supplementary Instructions are designed to cover the dif ferences 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 Refer to Section 2.6 of these instructions• Section 9 Flues and Air Supply• Section 14 Health and Safety Information• Section 16 Guarantee
2.2 GeneralThe new Grant VortexBlue range of high efficiency low NOx oil fired boilers consists of 15 models including Internal, Internal 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 Internal, Internal 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.
2.3 Low NOx TechnologyGrant 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 Controls2.4.1 Combi BoilersThe 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 Internal boilers and External ModulesThe Grant VortexBlue Internal boilers and External Modules incorporate a new electronic control system based on the one used in the Grant Vortex Pro 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 fit ted 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 lef t 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 TypeAll 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.
2.6 Sealed SystemsThe following sealed system kits are available for the external modules:
VortexBlue External Grant UK product code
VTXBFOM21VTXOMSSKIT26
VTXBFOM26
VTXBFOM36 VTXOMSSKIT46
Section 2: IntroductionPage 06
Section 3: Technical Data Page 7
3.1 Boiler Technical Data3.1.1 Internal, Internal System and External
Table 3-1: Internal, Internal System and External Technical Data
UnitsInternal and Internal System External
21 26 36 21 26 36
Output (Kerosene)
kW 15-21 21-26 26-36 15-21 21-26 26-36
Btu/h 51,200 - 71,00
71,700 - 88,700
88,700 - 123,000
51,200 - 71,00
71,700 - 88,700
88,700 - 123,000
Water contentlitres 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
Heating system flow connection mm 22 22 28 22 22 28
Heating system return connection 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 (only connect 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 ~230V 1ph 50Hz 5A fused
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 draughtN/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.
3 Technical Data
Section 3: Technical DataPage 8
3.1.2 Internal Combi and External Combi
Table 3-2: Internal Combi and External Combi Technical Data
UnitsInternal Combi External Combi
21 26 36 21 26 36
Output (Kerosene)kW 21 26 36 21 26 36
Btu/h 71,700 88,700 123,000 71,700 88,700 123,000
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 71,700 88,700 123,000 71,700 88,700 123,000
Heating system flow and return connections mm 22 22 28 22 22 28
Cold water mains inlet mm 15 15 22 15 15 22
Domestic hot water outlet mm 15 15 22 15 15 22
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 draughtN/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 ClearancesAdequate 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 outputnozzle
oil pressure
(bar)smoke
no.Burner head type
Burner head/
air disc setting
fuel flow rate
(kg/h)
flue gas temp. (°c)
co2(%)
flue gas
Vfr ‡(m³/hr)
(kW) (Btu/h)
Internal 21Internal System 21
External 21(RDB2.2 BG1 BLU 21)
15.0 51,200 0.40/80°ES 9.0 0 - 1 BG1 B 1.25 65 - 75 12.0 16.0
18.0 61,400 0.55/80°ES 8.0 0 - 1 BG1 N/A 1.50 65 - 75 12.0 20.0
21.0 * 71,700 0.60/80°ES 8.5 0 - 1 BG1 N/A 1.75 70 - 80 12.0 23.0
Internal 26Internal System 26
External 26(RDB2.2 BG2 BLU 26)
21.0 71,700 0.60/80°ES 8.5 0 - 1 BG2 N/A 1.75 60 - 65 12.0 23.0
23.0 78,500 0.65/80°ES 8.5 0 - 1 BG2 N/A 1.91 65 - 70 12.0 25.5
26.0 * 88,700 0.65/80°ES 10.0 0 - 1 BG2 N/A 2.16 75 - 80 12.0 28.5
Internal 36Internal System 36
External 36(RDB2.2 BG3 BLU 36)
26.0 88,700 0.65/80°ES 10.0 0 - 1 BG3+ N/A 2.16 67 - 70 12.0 28.5
31.5 * 107,500 0.85/80°ES 9.0 0 - 1 BG3+ N/A 2.62 70 - 75 12.0 34.5
36.0 123,000 0.85/80°ES 11.0 0 - 1 BG3+ N/A 2.99 75 - 80 12.0 39.5
Internal Combi 21External Combi 21
(RDB2.2 BG1 BLU 21)21.0 71,700 0.60/80°ES 8.5 0 - 1 BG1 N/A 1.75 70 - 80 12.0 23.0
Internal Combi 26External Combi 26
(RDB2.2 BG2 BLU 26)26.0 88,700 0.65/80°ES 10.0 0 - 1 BG2 N/A 2.16 75 - 80 12.0 28.5
Internal Combi 36External Combi 36
(RDB2.2 BG3 BLU 36)
31.5* 107,500 0.85/80°ES 9.0 0 - 1 BG3+ N/A 2.62 70 - 75 12.0 34.5
36.0 123,000 0.85/80°ES 11.0 0 - 1 BG3+ N/A 2.99 75 - 80 12.0 39.5
Notes: † Refer to Section 10.2 (Burner Settings: RDB2.2 BX burners) ‡ FluegasVFR:Fluegasvolumetricflowrate
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 range4. 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 - 31.5kW, Combi 36 - 31.5kW7. When setting the 15-21 to 15kW, the burner air adjuster disc (Grant UK product code: RBS215) must be fitted and positioned to disc setting B. Refer to
Section 6.4. This disc is NOT supplied with the boiler but can be obtained free-of-charge by contacting Grant UK.8. The installer must amend the boiler data label if the output is changed.
Section 3: Technical DataPage 10
3.4 Boiler DimensionsAll dimensions in the following diagrams are in millimetres.
Alternativecondensatedrain outlets
FRONT VIEW
470
860
LEFT SIDEVIEW
813
759
709
587
352
18
17
11030 Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
470
603
110
Safety valveCold fillFlow - 22mm push-fit
170Fluespigot
Figure 3-4: VortexBlue Internal 21, Internal 26, Internal System 21 and Internal System 26 dimensions
Safety valveFlow - 28mm push-fitCold fill
61170 61
LEFT SIDE VIEW45555
5
311
24
11563 63Flue centre line
RIGHT SIDE VIEW
PLAN VIEW
470
603
150
FRONT VIEW
470
900
205Fluespigot
Alternativecondensatedrain outlets
Figure 3-5: VortexBlue Internal 36 and Internal System 36 dimensions
Section 3: Technical Data Page 11
Pre-cut holefor side flue exitif required
4 pre-cutholes 50 mm dia.in sidesboth
1005509797
269
908
11750
757A
660
418179
21 and 26kW: A = 80436kW: A = 824
Plan View
132
180
180
=
=
3 pre-cut holes76 mm dia. in baseof boiler enclosure
Figure 3-6: VortexBlue External 21, External 26 and External 36 dimensions
RIGHT SIDE VIEWLEFT SIDE VIEW
PLAN VIEW
REAR VIEW
90
7575
90
202 210
760
690
140
614
307
105
ø 110
ø 155
17
35
227
588
100
699
125
444
99
609
ø 31
ø 31
ø 31
INTERNAL DRAIN TRAP EXIT (LEFTSIDE PANEL ONLY)
ø 25
858
Figure 3-7: VortexBlue Internal Combi 21 and 26 dimensions
Section 3: Technical DataPage 12
RIGHT SIDE VIEWLEFT SIDE VIEW
PLAN VIEW
REAR VIEW
90
6262
90
182 250
779
694
170
614
307
106
ø 110
ø 185
18
60
190
556
100
695
170
445
106
609
ø 31
ø 31
ø 31
INTERNAL DRAIN TRAP EXIT (LEFTSIDE PANEL ONLY)
ø 25
900
Figure 3-8: VortexBlue Internal Combi 36 dimensions
966
239
Combi 21e, 26eCombi 36e
Side flue exitif required
Pre-cut hole 75 x 150mm ineach side of boiler enclosure
2 pre-cut holes in baseof boiler enclosure
115mm dia.
754
836
150
73
7533
945
33
75
150
49
49
150
658
Plan View
Figure 3-9: VortexBlue External Combi 21, 26 and 36 dimensions
Section 4: Installation and Section 5: Electrical Page 13
4.1 GeneralFor 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 GeneralFor 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 ProtectionThe Internal, Internal 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, orb) The water temperature (sensed by the boiler control thermistor)
falls below 8°C
If after fif teen minutes the air temperature exceeds 10°C or the water temperature exceeds 15°C the circulating pump will stop.
However, if af ter fif teen 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 Internal and Internal System models5.3.1 Connecting Power Supply, Pump and Control SystemThe boiler requires both a switched live, from an external programmer or control system AND a permanent live power supply.
This permanent live supply is essential for the fan post purge operation.
Failure to fit BOTH a switched live and permanent live may cause damage to the burner.
Do not interrupt the permanent mains supply to the boiler with any external control, e.g. a timer, programmer, or room thermostat.
NOTE!
The boiler must be wired as shown in Figures 5-4 and 5-5, i.e. with both a permanent live supply AND a separate switched live (from the heating system controls).
No permanent live supply to the boiler can result in damage to the burner.
This will not be covered by the boiler product guarantee.
! WARNING
There is no facility in the Grant VortexBlue Internal and Internal 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 Internal 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. Lif t 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
Section 5: ElectricalPage 14
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 lif t 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 panel6. 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)On Internal 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 cover8. 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 PumpOn the Internal 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 Internal 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 Modules5.4.1 Connecting Power Supply, Pump and Control SystemThe boiler requires both a switched live, from an external programmer or control system, in addition to a permanent live power supply.
Do not interrupt the permanent mains supply to the boiler with any external control, e.g. a timer, programmer, or room thermostat.
NOTE!
The boiler must be wired as shown in Figures 5-4 and 5-5, i.e. with both a permanent live supply AND a separate switched live (from the heating system controls).
No permanent live supply to the boiler can result in damage to the burner. This will not be covered by the boiler product guarantee.
! WARNING
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 5-4 and 5-5.
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 PumpThe 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.
5.5 VortexBlue Internal Combi and External Combi Boilers5.5.1 Connecting the Power Supply and Control SystemFor 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.
Section 5: Electrical Page 15
12
3E
NL
45
6E
NL
78
9E
NL
1011
12E
NL
1820
2122
1516
1314
2526
2324
1719
2728
PUMP EARTH
PUMP NEUTRAL
PUMP LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
BURNER EARTH
BURNER NEUTRAL
BURNER LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINKDO NOTREMOVELINK
DO NOT CONNECT
SWITCHED LIVE
TIMER NEUTRAL
TIMER LIVE
STORETHERMISTOR(TO FRONT POCKET)
FLOWTHERMISTOR(TO TOP POCKET)
MAI
NS
1A
2A
4B
5B
Boile
rO
n/O
ff
Off
Off
Cons
tant
Tim
edTi
med
Cons
tant
Cent
ral
Hea
ting
Switc
h
Dom
estic
Hot
Wat
erSw
itch
2
C
Lim
itTh
erm
osta
tEa
rth c
onne
ctio
nbo
iler t
op b
rack
et
Prin
ted
Circ
uit B
oard
FUSE
5 X
20 N
L23
0V 5
A Fu
sed
Supp
ly
N
E
Flow
Ther
mist
or
Blac
k sh
roud
indi
cate
sFl
owTh
erm
istor
Link
Link
Burn
er
Resis
tor
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINK
DO NOT REMOVE LINK
SLL
Link
BURNERPERMANENT LIVE
PERMANENT LIVE
Fig
ure
5-1:
Vor
texB
lue
Inte
rnal
con
trol p
anel
wiri
ng d
iagr
am
5.6 Wiring Diagrams
Section 5: ElectricalPage 16
12
3E
NL
45
6E
NL
78
9E
NL
1011
12E
NL
1820
2122
1516
1314
2526
2324
1719
2728
PUMP EARTH
PUMP NEUTRAL
PUMP LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
BURNER EARTH
BURNER NEUTRAL
BURNER LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINKDO NOTREMOVELINK
DO NOT CONNECT
SWITCHED LIVE
TIMER NEUTRAL
TIMER LIVE
STORETHERMISTOR(TO FRONT POCKET)
FLOWTHERMISTOR(TO TOP POCKET)
MAI
NS
1A
2A
4B
5B
Boile
rO
n/O
ff
Off
Off
Cons
tant
Tim
edTi
med
Cons
tant
Cent
ral
Hea
ting
Switc
h
Dom
estic
Hot
Wat
erSw
itch
2
C
Lim
itTh
erm
osta
tEa
rth c
onne
ctio
nbo
iler t
op b
rack
et
Prin
ted
Circ
uit B
oard
FUSE
5 X
20
EN
L
NL
Blac
kCa
ble
230V
5A
Fuse
dSu
pply
N
E
Flow
Ther
mist
or
Blac
k sh
roud
indi
cate
sFl
owTh
erm
istor
Link
Link
Pum
pBu
rner
Resis
tor
BURNERPERMANENT LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINK
DO NOT REMOVE LINK
SLL
Link
PERMANENT LIVE
Fig
ure
5-2:
Vor
texB
lue
Inte
rnal
Sys
tem
con
trol p
anel
wiri
ng d
iagr
am
Section 5: Electrical Page 17
12
3E
NL
45
6E
NL
78
9E
NL
1011
12E
NL
1820
2122
1516
1314
2526
2324
1719
2728
PUMP EARTH
PUMP NEUTRAL
PUMP LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
BURNER EARTH
BURNER NEUTRAL
BURNER LIVE
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINKDO NOTREMOVELINK
DO NOT CONNECT
SWITCHED LIVE
TIMER NEUTRAL
TIMER LIVE
STORETHERMISTOR(TO FRONT POCKET)
FLOWTHERMISTOR(TO TOP POCKET)
MAI
NS
1A
2A
4B
5B
Boile
rO
n/O
ff
2
C
Lim
itTh
erm
osta
tEa
rth c
onne
ctio
nbo
iler t
op b
rack
et
Serv
ice
Switc
h
Prin
ted
Circ
uit B
oard
FUSE
5 X
20 N
L23
0V 5
A Fu
sed
Supp
ly
N
E
Flow
Ther
mist
or
Blac
k sh
roud
indi
cate
sFl
owTh
erm
istor
Link
Link
Burn
er
Resis
tor
DO NOT CONNECT
DO NOT CONNECT
DO NOT CONNECT
DO NOT REMOVE LINK
DO NOT REMOVE LINK
SLL
Link
Link
Link
BURNERPERMANENT LIVE
PERMANENT LIVE
Fig
ure
5-3:
Vor
texB
lue
Ext
erna
l Mod
ule
cont
rol p
anel
wiri
ng d
iagr
am
Section 5: ElectricalPage 18
Cyl
inde
rS
tat
NGra
nt 2
-Cha
nnel
Wal
l Mou
nted
Pro
gram
mer
ES
KIT
L N
E
240V
50H
Z
5A
12
34
56
78
910
L1
23
4
Fros
tS
tat
Pip
e S
tat
(If fi
tted)
Wiri
ng C
entre
OFF
OFF
ON
ON
HW
H
T H
W H
T
2C
1
2 1
3
Roo
mS
tat
12
34
56
78
910
1112
1820
2122
1516
1314
2526
2324
1719
NPL
- - --
--
-
4 C
ore
cabl
e fro
mC
ontro
ls W
iring
Cen
tre to
Boi
ler
Bro
wn
Blu
eG
reen
/Yel
low
Bro
wn
Blu
eG
reen
/Yel
low
Red
(Sw
itch
Live
)
2-P
ort Z
one
Valv
e
2-P
ort Z
one
Valv
e
Mot
orH
W
HTG
Link
Link
Blu
eG
reen
/Yel
low
Mot
orB
lue
Gre
en/Y
ello
w
Gre
yG
rey
Ora
nge
Ora
nge
Bro
wn
Bro
wn
Pum
p
Bro
wn
Blu
eG
reen
/Yel
low
ENL
Bro
wn
Red
SL
Fig
ure
5-4:
Vor
texB
lue
Inte
rnal
, Int
erna
l Sys
tem
and
Ext
erna
l Mod
ule
with
S-p
lan
type
con
trol s
yste
m w
iring
dia
gram
The
bo
iler
mus
t be
wir
ed a
s sh
ow
n in
this
wir
ing
dia
gra
m,
i.e. w
ith b
oth
a p
erm
anen
t liv
e (P
L) s
upp
ly A
ND
a s
epar
ate
switc
hed
live
(S
L) f
rom
the
heat
ing
sys
tem
co
ntro
ls.
No
per
man
ent l
ive
(PL)
sup
ply
to th
e b
oile
r ca
n re
sult
in
dam
age
to th
e b
urne
r.
This
will
no
t be
cove
red
by
the
bo
iler
pro
duc
t gua
rant
ee.
!W
AR
NIN
G
Ear
th a
nd s
om
e N
eutr
al c
onn
ectio
ns h
ave
be
en e
xclu
ded
fo
r cl
arit
y.
All
switc
hes
are
sho
wn
in th
e cl
ose
d p
osi
tion.
NO
TE!
Section 5: Electrical Page 19
Cyl
inde
rS
tat
NGra
nt 2
-Cha
nnel
Wal
l Mou
nted
Pro
gram
mer
ES
KIT
L N
E
240V
50H
Z
5A
12
34
56
78
910
L1
23
4
Fros
tS
tat
Pip
e S
tat
(If fi
tted)
Wiri
ng C
entre
Link
OFF
OFF
ON
ON
HW
H
T H
W H
T
3-P
ort M
id P
ositi
onZo
ne V
alve
2C
1
2 1
3
Roo
mS
tat
12
34
56
78
910
1112
1820
2122
1516
1314
2526
2324
1719
NPL
- - --
--
-
4 C
ore
cabl
e fro
mC
ontro
ls W
iring
Cen
tre to
Boi
ler
Mot
or
13k
2W27
0k0.
25W
Bro
wn
Blu
eG
reen
/Yel
low
Bro
wn
Blu
eG
reen
/Yel
low
Ora
nge
Gre
yW
hite Blu
eG
reen
/Yel
low
Red
(Sw
itch
Live
)
Link
Link
Bro
wn
Blu
eG
reen
/Yel
low
ENL
12
34
5
RB
1 R
elay
SL
Fig
ure
5-5:
Vor
texB
lue
Inte
rnal
, Int
erna
l Sys
tem
and
Ext
erna
l Mod
ule
with
Y-p
lan
type
con
trol s
yste
m w
iring
dia
gram
Ear
th a
nd s
om
e N
eutr
al c
onn
ectio
ns h
ave
be
en e
xclu
ded
fo
r cl
arit
y.
All
switc
hes
are
sho
wn
in th
e cl
ose
d p
osi
tion.
NO
TE!
The
bo
iler
mus
t be
wir
ed a
s sh
ow
n in
this
wir
ing
dia
gra
m,
i.e. w
ith b
oth
a p
erm
anen
t liv
e (P
L) s
upp
ly A
ND
a s
epar
ate
switc
hed
live
(S
L) f
rom
the
heat
ing
sys
tem
co
ntro
ls.
No
per
man
ent l
ive
(PL)
sup
ply
to th
e b
oile
r ca
n re
sult
in
dam
age
to th
e b
urne
r.
This
will
no
t be
cove
red
by
the
bo
iler
pro
duc
t gua
rant
ee.
!W
AR
NIN
G
do
no
t co
nnec
t the
ora
nge
wire
from
the
3-po
rt v
alve
di
rect
ly to
term
inal
19
(sL)
on
the
boile
r con
trol
pan
el (v
ia
term
inal
s 9
and
10 in
the
wiri
ng c
entr
e).
Whe
n th
e he
atin
g de
man
d is
sat
isfie
d, a
vol
tage
of b
etw
een
50-1
50V
can
rem
ain
on th
e or
ange
wire
from
the
3-po
rt v
alve
. if
conn
ecte
d to
term
inal
19
(sL)
of t
he b
oile
r con
trol
pan
el,
the
boile
r will
con
tinue
to o
pera
te in
the
heat
ing
mod
e, a
s if
a he
atin
g de
man
d is
stil
l pre
sent
.fo
r cor
rect
ope
ratio
n, th
e or
ange
wire
from
the
3-po
rt v
alve
m
Ust
be
conn
ecte
d to
the
coil
of th
e re
lay,
as
show
n in
the
wiri
ng d
iagr
am. s
ee f
igur
e 5-
5.th
is re
quire
men
t doe
s n
ot
appl
y to
s-p
lan
type
sys
tem
s us
ing
2-po
rt z
one
valv
es. r
efer
to f
igur
e 5-
4.
NO
TE!
Section 5: ElectricalPage 20
Fig
ure
5-6:
Vor
texB
lue
Inte
rnal
Com
bi c
ontro
l pan
el w
iring
dia
gram
12
3E
NL
45
6E
NL
78
9E
NL
1011
12E
NL
1820
2122
1516
1314
2526
2324
1719
2728
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
FLOW SWITCH
DHW TIMED ON
CH TIMED ON
TIMER NEUTRAL
TIMER LIVE
EXT. FROST STAT
EXT. FROST STAT
ROOM STAT
ROOM STAT
STORETHERMISTOR(TO FRONT POCKET)
FLOWTHERMISTOR(TO TOP POCKET)
MAI
NS
1A
2A
4B
5B
Boile
rO
n/O
ff
Off
Off
Cons
tant
Tim
edTi
med
Cons
tant
Cent
ral
Hea
ting
Switc
h
Dom
estic
Hot
Wat
erSw
itch
2
C
Lim
itTh
erm
osta
tEa
rth c
onne
ctio
nbo
iler t
op b
rack
et
Prin
ted
Circ
uit B
oard
FUSE
5 X
20
EN
LE
NL
CH Pum
pDH
WPu
mp
NL
Blac
kCa
ble
230V
5A
Fuse
dSu
pply
Whi
teCa
ble
SLN
EFl
owSw
itch
Stor
eTh
erm
istor
Flow
Ther
mist
or
Blac
k sh
roud
indi
cate
sFl
owTh
erm
istor
Link
Link
Link
L
BURNERPERMANENT LIVE
Link
Fig
ure
5-6
bel
ow
rep
lace
s Fi
gur
e 8-
1 in
the
Co
mb
i bo
iler
Inst
alla
tion
Inst
ruct
ions
.
NO
TE!
Section 5: Electrical Page 21
Fig
ure
5-7:
Vor
texB
lue
Ext
erna
l Com
bi c
ontro
l pan
el w
iring
dia
gram
12
3E
NL
45
6E
NL
78
9E
NL
1011
12E
NL
1820
2122
1516
1314
2526
2324
1719
2728
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
FLOW SWITCH
DHW TIMED ON
CH TIMED ON
TIMER NEUTRAL
TIMER LIVE
EXT. FROST STAT
EXT. FROST STAT
ROOM STAT
ROOM STAT
STORETHERMISTOR(TO FRONT POCKET)
FLOWTHERMISTOR(TO TOP POCKET)
MAI
NS
1A
2A
4B
5B
Boile
rO
n/O
ff
2
C
Lim
itTh
erm
osta
tEa
rth c
onne
ctio
nbo
iler t
op b
rack
et
Prin
ted
Circ
uit B
oard
FUSE
5 X
20
EN
LE
NL
CH Pum
pDH
WPu
mp
NL
Blac
kCa
ble
Switc
hed
live
CH
Whi
teCa
ble
SLN
EFl
owSw
itch
Stor
eTh
erm
istor
Flow
Ther
mist
or
Blac
k sh
roud
indi
cate
sFl
owTh
erm
istor
Link
L
Serv
ice
Switc
h
BURNERPERMANENT LIVE
Link
Link
Link
YORG/YBLRD
Switc
hed
live
DHW
~23
0V 5
A fu
sed
supp
ly
Fig
ure
5-7
bel
ow
rep
lace
s Fi
gur
e 8-
1 in
the
Ex
tern
al C
om
bi b
oile
r In
stal
latio
n In
stru
ctio
ns.
NO
TE!
Section 6: CommissioningPage 22
6.1 GeneralTo 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 SettingBefore 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 . 56 3
± 0 . 55
6 Commissioning
6.3 Air Damper AdjustmentUse 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 – 15-21 models onlyIf the 15-21 boiler is to be down-rated to the minimum output of 15kW, an air adjuster disc (Grant UK product code: RBS215) must be fitted as described below.
This disc is NOT supplied with the boiler but is available free-of-charge by contacting Grant UK.
To fit and position the air adjuster disc, proceed as follows:
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 15kW 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 re-assemble in reverse order.
Air adjuster disc
Air damper assembly
12Figure 6-3: Fitting the air adjuster disc
Section 7: Servicing Page 23
7.1 GeneralTo 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
The burner and flange are matched.
If the burner is changed, the correct flange for the replacement burner MUST be fit ted.
Refer to Section 10 (spare parts).
! WARNING
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 FeaturesThe 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 dif ferences 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 dif ferent 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
3 9
5
6
10
4
1
7
8
2
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 BoxThe digital control box fitted to this burner has several dif ferent features compared to the more commonly used 'analogue' control box.
8.3.1 Reset Push-buttonThis 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, af ter 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 IndicationFrom 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 IndicationWhenever 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 DisplayThe 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 ONGo 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 9.3.
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.
4
4
3
12
8.4 Burner Operation8.4.1 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: Max. no. 3 repetitions of complete start-up sequence if there is a flame failure
duringoperation; the final action at the last attempt fol-
lowing flame failure is a lock-out
3 re-cycles
tppPost-purge time: additional purge time at the end
of a heat request. Can be interrupted by a newheat request
60
8.4.2 Presence of Extraneous light or FlameOn 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, orb) 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.
Figure 8-5: Removal of control box
Section 8: Burner Page 27
8.4.3 Spark Ignition DurationThe '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 af ter 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 FunctionIn 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 Burner LockoutIn the event of a burner lockout:If the reset button is pressed four times in succession, without the burner being restarted, pressing the reset a fif th time will 'lock' the reset button. The reset button will flash red and will not respond to being pressed, i.e. it will no longer operate to attempt to restart the burner. This is intended to stop the burner reset from being repeatedly pressed and does not necessarily indicate a fault with the control box.If this condition occurs, switch the boiler ON/OFF switch (located on the boiler control panel) to OFF. Wait for 5 seconds and then switch it back to ON. The burner reset button should now function as expected.Before continuing to press the reset button, the cause of the original burner lockout, e.g. lack of fuel, no ignition, etc. must be identified and rectified.
8.4.6 Post Purge FunctionThis 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 occurredf) 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 IndicationWhenever 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 9-1.
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•Presenceofafalseflamesignalbeforetheheatrequest
Presence of extraneous light detected during pre-purging After 25 seconds RED
blinking •Presenceoffalseflamesignalduringpre-purging
Extraneous light detected during post-purging After 25 seconds RED
blinking
•Presenceoffalseflamesignalduringpost-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
•UVsensordefectiveordirty•Oilvalvedefectiveordirty•Faultyignitiontransformer•Badlyregulatedburner•Oilfuelnotpresent
Flame failure during operation After 3 recycles REDblinking
•Badlyadjustedburner•Oilvalvedefectiveordirty•UVsensordefectiveordirty
Fan motor error Immediate (during pre-purge) RED, ORANGEblinking inverted
•Faultyfanmotor•Fanmotornotconnected
Malfunction in the internal control circuit that drives the oil valve Immediate (during pre-purge) RED, GREEN
blinking inverted•Faultyoilvalve•Internalcontrolcircuitthatdrivestheoilvalvefaulty
Eeprom error Immediate (during pre-purge) ORANGE, GREENblinking inverted •Faultyinternalmemory
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
Fig
ure
9-3:
Rie
llo R
DB
BLU
Fau
lt Fi
ndin
g
Con
tam
inat
edfu
elfil
ters
?
Con
trol b
oxis
sup
plie
dw
ith h
eat
dem
and
Fan
runs
for
less
than
12 s
econ
ds
Bur
ner l
ocks
out a
fter
25 s
econ
ds
Was
hing
pres
sure
1 - 2
bar
Igni
tion
spar
kpr
esen
t
Coi
l rel
ease
sw
orki
ngpr
essu
re?
Noz
zle
atom
isin
gth
e fu
el?
Com
bust
ion
head
set
corr
ectly
?
Mot
or s
tarts
afte
r ini
tialis
atio
nC
heck
tim
e 3.
5sec
?
A
Che
ck b
oile
ran
d sy
stem
cont
rols
BFa
n m
otor
or o
ilpu
mp
seiz
ed?
Mot
or g
ives
50V
AC
acr
oss
whi
te a
ndbl
ack
wire
?
Bur
ner
fires
whe
nU
V se
nsor
isco
vere
d?
Che
ck o
ilsu
pply
tooi
l pum
p
Are
ele
ctro
des
OK
and
set c
orre
ctly
?
Cle
an o
rre
plac
efil
ters
Noz
zle
new
?
Adj
ust
com
bust
ion
air
setti
ng
Res
etco
mbu
stio
nhe
ad
Rep
lace
seiz
edco
mpo
nent
Rep
lace
fan
mot
or
Is th
e U
V se
nsor
faul
ty?
Driv
eco
uplin
gbr
oken
?
Rep
lace
or
rese
tel
ectro
des
Rep
lace
nozz
le
Flam
e go
esou
t the
nre
light
s?
230V
to m
otor
acro
ss b
lue
and
blac
k w
ire?
Rem
ove
extra
neou
slig
ht
Rep
lace
pum
pco
uplin
g
Che
ck o
il pi
pefro
m p
ump
tono
zzle
hol
der
Cle
arbl
ocka
ge
Boi
ler o
rflu
ebl
ocke
d?
App
rox.
35 Ω
acr
oss
blue
and
blac
k m
otor
wire
?
DC
oil
lead
OK
?
Rep
lace
UV
sens
or
Rep
lace
oil
pum
p
Igni
tion
lead
sO
K?
Rep
lace
coil
Cle
an o
r rep
lace
pum
p an
d fu
ellin
e fil
ters
If ba
lanc
ed fl
ue:
rem
ove
snor
kel
and
test
- no
w O
K?
Coi
lre
sist
ance
90 to
110
Ω ?
E
Coi
lre
sist
ance
90 to
110
Ω?
Rep
lace
igni
tion
lead
s
Afte
r 15
seco
nds
25-3
0V D
C to
coi
l?(c
oil c
onne
cted
)
Is th
e U
V se
nsor
faul
ty?
Bal
ance
d flu
e ca
nre
circ
ulat
e ga
ses
caus
ing
recy
clin
g
Rep
lace
mot
orca
paci
tor
Rep
lace
coil
lead
Rep
lace
coil
Rep
lace
oil
pum
p
Rep
lace
UV
sens
or
Che
ck fl
uepo
sitio
nan
d se
als
YA
irse
tco
rrec
tly?
CY
NN
YY
YY
YN
Y
Y
N
NN
N
YN
NYN
YN
YN
Y
NY
Y
N N
Y Y
N N
N N
N Y N N Y
Y Y
N
Y
Y N
Y
N Y
Y N Y Y
N
N
N
FR
epla
ceco
ntro
lbo
x
Rep
lace
fan
mot
or a
nd c
heck
cont
rol b
ox
Section 10: Spare PartsPage 30
10.1 Riello RDB BLU Burner Parts List
Key Description
Internal 21, Internal
System 21, External 21
andCombi 21
Internal 26, Internal
System 26 and
Combi 26
Internal 36, Internal
System 36 and
Combi 36
Riello product code Grant UK product code
1 Gasket - refer to item 34 ü ü ü N/A N/A
24-pin connector ü N/A N/A 20117417 RBS201
4-pin connector N/A ü ü 20117432 RBS202
3
Combustion head - BG1 ü N/A N/A 20117435 RBS203
Combustion head - BG2 N/A ü N/A 20120985 Z20120985
Combustion head - BG3+ N/A N/A ü 20133762 Z20133762
4 Ignition electrodes ü ü ü 20117455 RBS205
5 Pre-heater jumper ü ü ü 20045862 RBS206
6Nozzle holder ü ü N/A 20117459 RBS207
Nozzle holder N/A N/A ü 20117461 RBS208
7Collar (including o-rings) ü ü N/A 20117472 RBS209
Collar (including o-rings) N/A N/A ü 20117476 RBS210
8 Ignition HT lead ü ü ü 20105111 RBS211
9Air damper assembly ü N/A N/A 3008647 RBS116
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 and gasket* ü ü ü 20116712 Z20116712
35 Air intake - conventional flue ü ü ü 20012046 RBS230
* The flange and gasket are supplied as a combined pack.
10 Spare Parts
Section 10: Spare Parts Page 31
Fig
ure
10-1
: Exp
lode
d vi
ew o
f Rie
llo R
DB
BLU
bur
ner
10.2 Exploded View of Riello RDB BLU Burner
2
134
3
4
8
7
30
3310
30
15
32
9
6
31
26
23
2512
24
2216
11
2129
20 19
5 27
28
1413
18
17
35
16
Grant EnGinEErinG (UK) LimitEdHopton House, Hopton Industrial Estate, Devizes, Wiltshire, SN10 2EU
Tel: +44 (0)1380 736920 Fax: +44 (0)1380 736991Email: [email protected] www.grantuk.com