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Misc/1522 Wood Pellet Manual May 2013::

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1. Product Bulk Auger Auger Code Lengthm Weight kg WPAUG25 22 Sin PES WPAUGS0 3 0m 22 WPAUGS35 3 5m 26 9 WPAUG40 4 0m 29 7 WPAUG45 4 5m O2 WPAUG50 5 0m 35 3 WPAUG55 Som 38 1 WPAUG60 6 0m 40 9 GRANT To determine the length of auger required the following factors must be determined a Difference in height between the ground floor level on which the store will stand and the floor level on which the hopper will stand b Horizontal distance between the back of the hopper and the store If the store is to be situated outside this will be a the distance from the rear of the hopper to the inner face of the wall b the thickness of the wall c the distance to the store from the outside face of the wall Refer to Figure 3 3 for further details New dimensioned diagram of store amp hopper here showing key dimensions Figure 3 3 Bulk store and auger dimensions Using the following table select the required length of auger based on the above dimensions Always select the next size up of auger New table of store and bulk auger dimensions here O O Q Q Q dp o Storage amp Delivery O SO o i Information 4 Boller Installation Information 4 1 Introduction For the 6 26 and 9 36 models the appliance comes supplied on two pallets a Pallet 1 contains the intermediate hopper and auger
2. Check that sufficient permanent ventilation is present in the room containing the boiler s Refer to Section 7 1 for guidance Lack of ventilation will lead to incomplete combustion and an increased temperature in the pellet feed tube that will activate the burn back thermostat Note 10 Is the wash system operating correctly Check the water supply to the wash System is connected and turned on Operate the CLEANING switch and check the solenoid valve is opening and the water jets are all clear and spraying into heat exchanger tubes Refer to Section 10 3 3 If necessary remove clean and refit the wash system manifold Refer to Section 11 6 2 In hard water areas an anti scale device should be fitted on the cold water supply to the wash system to prevent scale build up in the manifold and jets Note 11 Is the boiler cleaning period correct Go to the CLEAN sub menu of the burner control settings and check that both TIME CLEAN PERIOD and TIME CLEAN BOILER are correctly set If not re set to the correct value Refer to 9 7 1 3 12 6 Failed Pellet Lighting H20 60 C SET 75 C 5 FAILED PEL Is there a sufficient quantity of pellets in the hopper Fill hopper with correct grade of pellets Is the required lux level being detected by photocell Is the ignition element operational Does the ignition element on period exceed 360 seconds Contact GRANT for assistance
3. Is it fitted correctly at both ends with an air tight fit onto both pellet feed pipe and pellet auger outlet Rectify as necessary A damaged or incorrectly fitted pellet delivery hose can allow a back draught through the boiler resulting in the pellet tube burn back thermostat operating and shutting down the burner Note 4 Is the ash pan overflowing An overflowing ash pan and ash build up on the baffle can block the passage of the combustion gases from the burner causing them to back up through the burner into the pellet feed tube This will activate the pellet feed tube burn back thermostat The ash pan must be periodically emptied and also any ash build up on the baffle removed by the user at MONTHLY intervals for the FIRST THREE MONTHS After this the ash pan should be emptied and ash on the baffle removed regularly on at least a monthly basis or as indicated by the amount of ash found during the first three months cleaning Refer to Section 120 Note 5 Is combustion chamber draught correct Check combustion chamber draught Hefer to Section 10 9 for procedure If it is incorrect BEFORE making any adjustment to the draught stabiliser carry out the following checks as per the flow chart e 5 condensate trap or pipework blocked or frozen Defrost remove blockage as necessary e 5 ash pan overflowing Empty and clean ash pan as necessary e 5 the flue system incorrectly installed or
4. IViaterials 9 6 Burner Menu Navigation Information 80 4 8 Pipe Connections 17 Chart and Factory Default 4 0 Wash System Manifold 17 setting 43 15 EC Declaration of 4 10 Fan Box and Flue Starter 17 9 Burner Menu ad Conformity 81 4 11 Pellet Hoppers 18 T ER 10 Commissionin 47 16 Warrant 82 4 12 Pellet Feed Auger 18 0 10 Eau ies py uipment Require 4 13 Before you Commission 19 102 5 M da A m 4 14 Completion 19 M E E 10 3 Boiler 47 5 Condensate disposal 20 10 4 Pellet Hopper 48 5 1 General Requirements 20 10 5 Safety Device Checks 46 5 2 Connections 20 10 6 Burner Setting 49 5 3 Pipework 20 10 7 Priming the Pellet Feed Auger 49 5 4 External Pipework 20 DE 10 8 Lighting the Boiler 50 5 5 Condensate Soakaway 20 10 9 Combustion Chamber 5 6 Condensate Trap 2 Draught 50 5 Inspection and Cleaning 10 10Flue Gas Analysis 51 of Trap 2 9 10 11 Customer Handover 51 e 6 Sealed Systems 20 10 12 Commissioning Report 6 1 Sealed Syst id sa ealed System sali Requirements 22 10 13 Commissioning Check List 52 O 6 2 Filling the Sealed System 22 6 3 Venting the Pump 23 6 4 Pressure Relief Safety Valve Operation 23 1 Introduction Intermediate Hopper Wood Pellet Boiler Boiler Controls Pellet Feed Auger Pellet Delivery Hose Pellet Delivery Tube rner Controls Q1 o Wood Pellet Burner Grant SPIRA Condensing Wood Pellet Boiler amp Intermediate Hopper This manual is intended
5. If the ON STANDBY switch is set to STANDBY during the start up sequence but AFTER the pre load is finished then the burner will immediately enter and complete the shut down sequence before it can start up again even if the ON STANDBY switch is reset to ON After completing the start up sequence the burner should be firing at maximum output and the display on the burner control shows BURNER FIRING 100 10 9 Combustion Chamber Draught 10 9 1 Burn Back Thermostat The combustion chamber draught must be checked and adjusted where necessary as follows e Allow the boiler to run for a period of 15 minutes until the boiler and flue system are warmed up e Ensure the burner display is showing BURNER FIRING 100 e Remove the screw from the draught test point located to the left of the burner on the combustion chamber door Refer to Figure 10 12 e After setting the zero on the draught gauge insert the end of the draught gauge sample tube into the test point on the door Ensure that it is pushed through the door insulation and into the combustion chamber e draught reading of between 0 1 and 0 15mbar is required 0 04 and 0 06 in wg RIVER EE j Figure 10 12 Draught test point 10 9 2 Draught Stabiliser Adjustment To adjust the combustion chamber draught reading re position the weight on the stabiliser door arm as follows e To increase draught move the weight away from th
6. b Pallet 2 contains the boiler burner and combined fan box amp flue starter For the 12 52 15 62 and 18 72 models double boiler installations the appliance comes supplied on two pallets a Pallet 1 contains the intermediate hopper and augers b Pallet 2 contains both boilers each with burner and combined fan box amp flue starter An accessories box is packed with each boiler and this contains the following a fan box which comes complete with exhaust fan and draught stabiliser b condensate drain trap items c wash pipe manifold assembly d auger feed tube Check the packing list supplied in the accessories carton to ensure all items have been delivered The Grant Black flue system comes separately and its configuration will depend on the installation requirements 4 2 Boiler Location The boiler must be installed in a damp free environment Refer to Section 2 4 for boiler and hopper clearances These clearances are to allow for access during servicing Also if fitting a bulk hopper system refer to Section 3 2 2 as the location of the bulk hopper can influence the boiler location 4 3 Preparation for Installation With the units on the pallet remove all outer packaging from the units Unpack the accessories box supplied with the boiler and check the packing list against all items present 4 4 Installing the Boiler The boiler and hopper must be positioned on a level solid n
7. e Terminal L2 Switched live from heating system controls e Terminal N Mains neutral e Terminal earth Mains earth e Terminal L1 Mains permanent live 4 Replace the cover ensuring outer sheath of the flex is held in the cable grip of the plug and secure using the screws previously removed 8 Electrical 5 Connect the other end of the 4 core flex to the either the heating Ai WAR N N system controls wiring centre or In the event of an electrical fault after installation of the boiler the following electrical system checks must be junction box Refer to either Figures carried out 8 9 or 8 10 as appropriate for The Grant wood pellet boiler and so details of the connections required intermediate hopper contains electrical switching equipment and e Polarity 6 Fit the two parts of the 4 way must be earthed also any bulk connector back together Ensure hopper system fitted should also be the plug and socket are fully earthed e Resistance to earth pushed together until the small catch clicks into place 8 6 Wiring Diagrams CONNECTED TO BURNER PLUG NO 1 PLUG NO 2 PLUG NO 3 CONNECT TO SIDE OF BURNER CONNECT TO SIDE OF BURNER CONNECT TO SIDE OF BURNER HARUTAN d rH EB B4 S3 Te Ti N 11 Li N Ti Te S3 B4 dy JL THERMISTOR N ON SWITCH OMENTARY 1 SIDE LIMIT THERMOSTAT ON OFF SWITCH BL BOILER CLEANI
8. eS 1 Ia ee Quantity 9 36 1 A A 1 Rove A A 4 6 A 3 1 o ud gt O Q LO gt O Q V 13 Spare Parts 13 6 Pellet Hopper 110kg Figure 13 4 110kg Pellet Hopper Components Exploded View ne gt O LO gt O V 13 7 Pellet Hopper 110kg Parts List Description Quantity 6 26 amp 9 36 m al eme eal kad CA AJ O OINJ O Castor Wheel c w brake Caster wheel flange Right side panel Pellet feed Auger shield Base Front panel Grid Top front panel Door hinge Top rear panel Left side panel Castor Wheel Rubber diaphragm flange Rubber diaphragm Wiring centre Pellet damper Rear panel Wiring centre access cover Low level limit switch Limit switch bracket WP146 WP147 WP148 WP149 WP150 WP151 WP152 WP153 WP154 WP155 WP156 WP157 WP158 WP159 WP160 WP161 WP162 WP163 WP164 WP165 HA N o md gt O LO gt O V Information 2 p o Nga V c 9 ic O 14 Health and Safety Information Under the Consumer Protection Act 1987 and Section 6 of the Health amp safety at Work Act 1974 we are required to provide information on substances hazardous to health
9. 1 I I I I HOPPER l MEE I E nin MEN gt l 6 CORE MULTICORE CABLE xi ci EARTH amp 5 BLACK S gt gt NUMBER 1 5 nw E El a sa wt Se N L uo EM nr 00O go E ne n 2 IlI pa Soe ae ie ao T gt gt Dea gt E m DI gt un 6 DO 526 Du gg us O amp zm gE O gt u 252 Wy i E ti P E Colour code BR Brown BLK Black RD Red BL Blue Y Yellow OR Orange G Y Green Yellow Figure 8 7 Hopper wiring diagram single boiler hopper HOPPER LIMIT Rd SWITCH Or with CH valve fitted connect pipe stat between L4 amp L7 without CH valve fitted connect SA eA HO 0 A ddng HOPPER ONLY Pipe Stat option EARTH amp 5 BLACK NUMBER 1 5 thermostat option Frost 6 CORE MULTICORE CABLE AINO NHISAS YADNV NINA WHLSAS NNNOVA OL AGOW A INO 3IHddOH NI ASN AINO dI AV I ONINUVM LATTAd MOT OL ATddNS QHHOLLIAS ATddNS SNIVIN INANVINUHd GIN TIOS JO UVAW OL LIJ VATION OJ LL JAI ININVNYAA WATIOd JO AVAW OL LA NATIOE BR Brown BLK Black RD Red BL Blue Y Yellow OR Orange G Y Green Yellow Colour code Hopper wiring diagram double hopper Figure 8 8 8 Electrical Green Yellow Green Yellow Orange
10. 6 Ifa bulk pellet store is to be used connect the 6 way plug to the corresponding connection on the flying lead from either the Grant SPIRA VAC system or Grant bulk pellet store auger Ensure that the plug and socket are fully pushed together until the small catch clicks into place Refer to instructions supplied with either the Grant SPIRA VAC or Grant bulk store auger for further details 8 4 Heating System Controls The boiler can be used in conjunction with typical heating control system e g S Plan or Y Plan type controls Refer to Figures 8 9 and 8 10 and for typical control system wiring diagrams As the electrical connection permanent mains supply and switched live from the heating control system to the boiler is made via the flying lead with 4 way plug connection it will be necessary to provide a 4 core flying lead either a Directly from the heating controls wiring centre if suitable located adjacent to the boiler hopper or b Via a junction box situated adjacent to the boiler hopper The length of 4 core flex required between the wiring centre or junction box and the 4 way plug connection must be sufficient to allow the hopper to be moved out enough to allow disconnection the 4 way plug Frost Protection For additional protection of either the entire heating system or the boiler and localised pipework it is recommended that a frost thermostat be installed It is also recommended that
11. Ensure TIME CLEAN BRAZIER is then reset to its original setting or the brazier cleaning operation will be repeated every time the burner shuts down Note 5 Is the servo motor correctly set The stroke of the servo motor is factory set and should not be adjusted Check with Grant UK for correct setting Note 6 Is the boiler cleaning interval correct Go to the CLEAN sub menu of the burner control settings and check that TIME CLEAN BRAZIER and TIME CLEAN BOILER are correctly set Refer to 9 7 1 3 5 TE 5 Tw D TE Tw 12 Fault Finding 12 8 Probe Fault Is the heating thermistor damaged Are all three burner plugs correctly fitted Correctly fit Replace plugs push thermistor fully into sockets Notes 1 Are burner plugs correctly fitted Check that all three plugs are fully pushed into sockets on the left side of the burner in particular plug No 2 Refer to Section 8 and Figure 8 5 Is thermistor Replace connected to thermistor control PCB Check thermistor connections from burner plug socket to control PCB Note 2 Is heating thermistor damaged Isolate electrical supply to boiler and remove boiler control panel cover Check the condition of the thermistor for any damage and replace if necessary Check that the heating thermistor is correctly fitted into the pocket inside the boiler
12. Hectify as necessary Note 2 Is the pellet auger fully primed Refer to Section 10 7 for procedure to prime the auger Note 3 Is there clinker in the burner brazier Clinker is the hard deposits of solidified ash containing sand particles which the automatic burner cleaning system is unable to remove Clinker is caused by using unsuitable pellets See note 4 If there is no clinker but brazier is full of unburnt pellets remove all pellets and clean brazier Note 4 Are the correct pellets being used Check the pellets being used Only EN Plus Grade A1 pellets conforming to EN14961 must be used with the Grant opira boilers Refer to Section 3 1 for details pellet specification Check the brazier cleaning setting TIME CLEAN BRAZIER Refer to oection 9 7 1 3 for settings Note 5 Is the ignition element operational To check isolate electrical supply and disconnect the two leads from the element cable Grasp the black grommet and pull the complete element and cable from the tube Check the condition of the ceramic element and that it is correctly fitted into the ceramic Socket Also check it is correctly positioned inside the tube Refer to Section 10 8 3 for details Check across the two terminals for electrical continuity Resistance of element 89Q If no continuity is found then replace the element Note 6 Is the burner cleaning interval correct Go to the CLEAN sub menu of the
13. Replace element if faulty Is the pellet auger fully primed Fully prime pellet Is photocell operational Check that photocell amp tube are clear Replace photocell if faulty gt Primary Fault Are there unburnt pellets in the brazier Are pellets being delivered to the burner Is the auger operating Is hopper outlet blocked or full of dust Check auger motor power amp coupling Clean out hopper amp re prime auger Is the flame stabilisation time 45 correct Contact GRANT for assistance Is pre load quantity of pellets correct Contact GRANT for assistance to set pre load Secondary follow on checks Is there clinker in the brazier Is the correct grade of pellets being used Empty hopper amp refill with correct grade pellets Is the required lux level being detected by photocell in LIGHTING CYCLE REDUCED 42 In burner menu reset TIME CLEAN BRAZIER amp TIME CLEAN BOILER settings No _ s the ignition element operational 1 Check power to element Check is element Replace element ff if faulty Is the TIME LOAD LIGHTING time 4 seconds Contact GRANT for assistance es Is the burner cleaning interval correctly set Yes In burner menu reset TIME CLEAN BRAZIER amp TIME CLEAN BOILER settings Is the TIME PAUSE LIGHTING time 15 sec
14. 22 Ignition element mounting plate WP22 1 1 29 Photocell back plate WP23 1 1 24 Burner fan gasket WP24 1 1 29 Boiler water thermistor WP25 1 1 26 Controls chassis left gable WP26 1 1 20 Controls chassis back plate amp base WP27 1 1 28 Main burner cover WP28 1 1 29 Flame hood 6 26 WP29A 1 29b Flame hood 9 36 WP29B 1 30 Brazier flame plate set WP130 1 al M6 x 15 Coach bolt WP31 8 8 32a Grate enclosure 6 26 WP32A 1 32b Grate enclosure 9 36 WP32B 1 39a Brazier base assembly 6 26 WP33A 1 39b Brazier base assembly 9 36 WP33B 1 ne gt O LO pus O V 13 4 Boller o md gt O Dv gt O V Figure 13 3 Boiler Components Exploded View ne gt O LO gt O Q V 13 Spare Parts 13 5 Boiler Parts List O O0 NT ODO a AJOINJ 13 14 15 16 We 18 TE 20 21 22 23 24 25 26 ed 28 29 30 31 Description Rear lower panel 5 way mains connection male fixed Rear upper panel 5 way mains connection female detachable WP34 WP 35 WP36 WP37 5 way flue fan cleaning solenoid connection detachable 5 way flue fan cleaning solenoid connection female fixed WP39 Flue fan sealing gasket Fan box Cleaning door sealing gasket Secondary 6 26 Cleaning door sealing gasket Secondary 9 26 Cleaning door secondary 6 26 Cleaning door secondary 9 26
15. ALL the Grant pellet hoppers are for indoor use only and must be positioned in a dry environment Hopper contents switch All hoppers are fitted with a contents switch This detects when the level of pellets in the hopper falls to a pre set minimum value and triggers the operation of either a bulk store auger or vacuum system to delivery pellets from the bulk pellet store If no bulk store is used the contents switch will stop the burner operating when the minimum pellet level is reached Topping up the hopper with more pellets will automatically operate the contents switch and the burner will restart if there is a demand for the boiler to run The minimum quantity of pellets required to restart the boiler is 20kg for the single boiler hoppers and 3kg for the double boiler hoppers All boiler pellet hoppers are for indoor use only and MUST be positioned in a dry environment free from dampness They must be located on the same floor level as the boiler or boilers they are supplying All hoppers are mounted on four castors with the two front castors lockable to allow it to be easily moved when required Allow sufficient area in front of the hopper for it to be moved out and away from the boiler s during servicing The electrical connections to the boiler s are all made to the 4 way electrical plug on one of the three factory fitted flying leads at the rear of the hopper Refer to Section 7 for details Al
16. CO gt 16 VVarranty The Spira Wood Pellet Boiler Warranty Dear Customer You are now the proud owner of a Grant Spira Wood Pellet Boiler from Grant Engineering UK Ltd which has been designed to give years of reliable trouble free operation Grant Engineering UK Ltd guarantees the manufacture of the boiler including all electrical and mechanical components for a period of twelve months from the date installation unless the installation was more than six months from the date of purchase in which case the warranty period will commence six months from the date of purchase provided the boiler is installed in full accordance with the installation instructions provided This will be extended to a period of two years if the boiler is registered with Grant UK within thirty days of installation and it is serviced at twelve month intervals See Main Terms and Conditions below IMPORTANT Please register your Grant Spira Wood Pellet boiler with Grant UK within thirty days of installation To do so visit www grantuk com and follow the links to the Householder Zone where you can register your boiler for a further one year warranty giving two years from the date of purchase This does not affect your statutory rights Breakdown during the Manufacturer s Warranty If your Grant boiler should fail within the warranty period you must contact Grant Engineering UK Ltd who will arrange for the repair un
17. Using a digital manometer set for positive pressure check the pressure generated by the burner fan is the minimum of 0 8mbar required to activate the air pressure switch Refer to Figure 12 7 If fan pressure is incorrect replace fan If correct pressure is still not achieved replace burner PCB 5 TE 5 Tw 71 13 Spare Parts 13 1 Burner Figure 13 1 Burner Control Components Exploded View sued 13 2 Burner Brazier sued Figure 13 2 Burner Brazier Components Exploded View 13 Spare Parts 13 3 Burner Parts List Description Quantity 6 26 Quantity 9 36 1 Pressure switch WP111 1 1 2a Primary printed circuit board 6 26 WP112A 1 2b Primary printed circuit board 9 36 WP112B 1 Burner fan WPOS 1 1 4 Servomotor WP04 1 1 5 LED display unit c w enclosure WPO5 1 1 6 Mounting bracket set LED display WPO6 1 1 7 Electrical connector 7 way female WP07 1 1 8 Electrical connector 7 way male WP08 1 1 9 Photocell WPO9 1 1 10 Ignition element WP10 1 1 1 Pellet feed tube thermostat WP11 1 1 12 Pellet feed tube thermostat cover WP12 1 1 13 Pellet feed tube WP13 1 1 14 Pellet feed tube gasket WP14 1 1 NG Burner mounting gasket WP15 1 1 16 Ignition element housing WP16 1 1 Jf Photocell tube WP17 1 1 18 Electrical connector 6 way male WP18 1 1 19 Brazier chassis WP19 1 1 20 M6 washer WP20 8 8 21 6 nut WP21 8 8
18. burner control settings and check that TIME CLEAN BRAZIER and TIME CLEAN BOILER are correctly set Refer to 9 7 1 3 Note 7 Is the pellet pre load time correct Measure the duration of the pellet pre load period i e whilst the STEP AUTO function is 40 in the VIEW menu at the beginning of the burner lighting sequence Refer to Section 9 3 for burner operating sequence and also Section 9 7 3 for VIEW menu folder Pre load should be 65 seconds If not contact Grant UK for technical advice on how to agjust the pre load period Note 8 Is the required LUX level being detected by the photocell In the WAIT LIGHTING IGNITION period of the burner lighting sequence i e whilst the STEP AUTO function is 41 in the view menu if the LUX value fails to reach 2 after a time of 360 seconds then the error message FAILED PELLET LIGHTING is displayed Refer to Section 9 7 3 for procedure to access LUX value in View menu Note 9 Is the preload quantity of pellets correct When the pre load operation is complete the pellets should cover the heating element but not cover the opening at the end of the photocell tube Note 10 Is the flame stabilization period correct The FLAME STABILISATION period i e step auto function 45 in the VIEW menu is an over run of the ignition element on period AFTER the 2 lux has been detected This is factory set at 3
19. f A Y gt ke E LL Pre r I f gt n 2125 2125 2180 0180 TIR Straight Pipe Length mm Effective Nominal Length Part Length mm Number F D 1000 960 WP EXT1000 lt F i 500 460 WP EXT500 E F 333 293 WP EXT333 amp 200 1600 WP EXT200 e Mg gia _ Double 30 Bend and Straight Pipe Double 45 Bend and Straight Pipe Length mm Length mm Effective Effective Length Dimension Length Length Dimension Length 960 A 1061 960 A 933 B 542 B 784 460 628 460 580 Adjustable Pipe 75 250mm B 292 B 431 Part no WP ADJ250 293 483 293 462 Complete with locking band B 208 B 313 Telescopes over pipe below Minimum engagement should nog i be half the diameter This component is NOT load bearing Air Supply c O z o Pe dp o LL 7 8 Typical Flue Systems 2300 MINIMUM RAIN CAP TERM NAL LIP SEAL amp BAND EXTENSION 1000MM IP SEAL amp BAND LIP SEAL amp BAND 45 BEND LIPSEAL amp LIP SEAL amp BAND CLEANING EYE s e l Figure 7 5 Typical flue installations details a si 19 POOR lt 600 EXTENSION 1000N IP SEAL amp BAND BEND 45 LIP SEAL 8 BAND EXTENSION 9004M ADJUSTABLE EXTENSION 250 EXTENSION 500MM 50MM WALL BRACKET 300MM WALL BRA RAIN CAP TERMINA a AM
20. factory fitted flying leads at the rear of the hopper Refer to Section 7 for details Electrical connection for either a bulk auger or Grant SPIRA VAC system if required is made using the 6 way electrical plug and flying lead supplied factory fitted on the hopper Figure 3 1 Bulk auger inlet in hopper 3 2 2 Bulk Hopper It is advisable to fit a bulk pellet store to take advantage of the lower cost of pellets purchased in bulk The pellet hopper must still be used situated between the bulk hopper and the boiler as the auger fitted to the hopper delivers the precise quantity of pellets required by the burner The pellet hopper also allows any problems with bulk pellet quality to be isolated and the intermediate hopper can be used temporarily as the source of pellets for the boiler It is essential to only use a bulk storage unit that is a Waterproof b Specifically designed to store wood pellets c Supplied with appropriate connections for pellet delivery which are within the drivers reach d Fitted with a vent connection for dust extraction during filling e Permanently vented if located outside or unvented if installed indoors f Fitted with a rubber arrester mat or similar to limit pellet damage during filling 9 ls electrically earthed A range of suitable bulk pellet stores are available from Grant UK These are supplied flat packed for on site assembly Refer to assemble instructi
21. panel and check Go to the BOILER OVERHEAT STAT fault necessary finding chart Note 1 Is there a permanent mains live supply connected to the hopper boiler Check that the permanent live from the fused spur is correctly connected to terminal L1 on the 4 way plug at the rear of the hopper Also check that 4 way plug is fully pushed into the socket on the flying lead at the rear of the hopper Refer to Sections 8 4 and 8 5 for further details Also check that 5 way plug from hopper is fully pushed into the socket at the top left rear of the boiler Check that the fused spur is switched ON and if necessary check the fuse is OK gt Primary Fault ansa Secondary follow on checks Has the pellet Is the Is the power feed tube stat combustion to terminal L1 tripped Unclip chamber door of burner plug amp remove lead closed amp the No 1 from stat and door catch fully engaged Is door catch microswitch Operational Close door amp fully engage door catch PELLET TUBE STAT fault finding chart Replace faulty door microswitch Note 2 Is there a permanent mains live supply connected to the burner Check that the two 7 way plugs are fully pushed into the two lower sockets on the left side of the burner Also check for permanent live on terminal L1 of burner plug No 1 Refer to Figure 8 5 Note 3 Has the boiler overheat thermostat tripped Unscrew and
22. 1 4 2 sub folder contains three parameters stored within this folder lt TO STEP BACK Bo View folder Displays the function or status of the boiler See Section 9 7 3 a TEMP DELTA Defines the boiler temperature either side of the Set point in which the boiler will modulate Units Celsius Default setting 6 26 amp 9 36 5 5 C b TEMP OFF H2o Temperature the User folder Allows the user to change the language burner shuts down See Section 9 7 4 Units Celsius Default setting 6 26 amp 9 36 80 80 C c DELTA RESTART Temperature drop below the set point before burner re starts Units Celsius Default setting 6 26 amp 9 36 545 C 4h CAUTION Settings in the burner menu s below are based on the boiler using the Grant fixed angle pellet feed auger at 45 and an auger motor fixed speed of 8 1 rpm Only ENplus A1 EN14961 2 pellets MUST be used with the Grant SPIRA boilers These pellets must be bark and sand free AND approved by Grant UK BEFORE being used in the Spira boilers Failure to use approved pellets will invalidate the product warranty 9 7 1 2 menu 2 4 POWER PELLET The parameters stored within this folder are a TIME LOAD MAX Time the pellet feed auger operates to deliver pellets to the brazier when the burner is in max flame mode Adjusting this time adjusts the boiler input in max flame i e the larger the load time th
23. 11 8 3 Ignition Element Remove and check the condition of the ceramic heating element Replace if damaged To remove the element from the tube grasp the black grommet and pull out of the tube Do NOT pull on the element power cable Unscrew and remove the single screw securing the ignition element tube and pull it out of the burner Check the condition and thoroughly clean the inside of the tube Replace the tube in the burner and secure with the screw Check that the ceramic element is correctly fitted into the ceramic socket Heplace the ignition element in the tube ensuring that the element is correctly positioned inside the tube Refer to Figure 11 16 Figure 11 17 Ceramic ignition element 11 8 4 Pellet Feed Tube Unscrew the three fixing screws and remove the feed pipe and gasket from the top of the burner Check the condition of the gasket and replace if necessary Check the condition of the feed tube and thoroughly clean the inside Check that the burn back thermostat is correctly mounted and fixed to the top of the tube Heplace on burner ensuring gasket is correctly fitted and secure with the three screws 11 9 Re fitting Burner Before re fitting the burner check the condition of the burner door gasket Replace if necessary With the gasket correctly located re fit the burner to the combustion chamber door Carefully insert the burner brazier through the opening and locate the holes in
24. 141 616 1160 1120 15 62 with double hopper 1 92 616 697 324 241 616 1260 1220 18 72 with double hopper 1 92 616 697 324 241 616 1260 1220 If the measurement from the flue centre line to the rear wall is increased shown as 134 in the plan view then the dimensions D E amp G will have to be increased by the same increment All units in millimeters Figure 2 3 Boiler and hopper dimensions and clearances double boiler with central hopper 3 Pellet Specification Storage amp Delivery 3 1 Pellet Specification Grant SPIRA boilers are designed to run on EN Plus A1 wood pellets that comply with EN 14961 and meet the following of criteria Limits Key Parameter Category as per EN 14961 Diameter Average length DOG Minimum and maximum length Moisture Content 50 05 Mechanical durability DU 97 5 Amount of fines F1 0 Nitrogen NO 3 Nett calorific value 4 8 to 5 2 kWh kg Bulk density 650 kg m Chlorine 0 03906 CL 0 03 The following terms are commonly used when describing the properties of wood pellets Additives Ash Average Length Bulk Density Chlorine Diameter Fines Mechanical Durability Moisture Content Net Calorific Value Nitrogen Sulphur Additives are used to improve the stability of the pellets If manufactured correctly and of a sufficiently low moisture content quality pellets will require no additives Ash represents the non combustible content of the pellet Higher ash
25. 8 3 Boiler Plug Connections Before making any electrical connections to the hopper by connecting the 4 way plug and socket together ensure that all the plug connections have been correctly made between the hopper boiler and if fitted the bulk pellet supply system as follows 1 Fit the 5 way plug from the flue fan and solenoid valve into the socket at the top right rear of the boiler See Figure 8 2 Ensure it is fully pushed home Figure 8 2 Flue fan solenoid valve plug connection 2 Fit the 5 way plug from the hopper into the socket at the top left rear of the boiler See Figure 8 3 Ensure it is fully pushed home Figure 8 3 Hopper plug connection 3 On a double boiler installation fit the second 5 way plug from the double hopper into the top right rear of the second boiler Ensure it is fully pushed home 4 Fit the two 7 way plugs No 1 and No 2 from the boiler control panel into the two lower connections on the left side of the burner These plugs are male and female and cannot be fitted into the wrong connections Refer to Figure 8 3 Ensure that both plugs are fully pushed home until the small catch on each of them clicks into place 5 Fit the 6 way plug No 3 from the pellet feed auger motor into the upper connection on the left side of the burner Refer to Figure 8 4 Ensure that the plug is fully pushed home until the small catch it clicks into place Figure 8 4 Auger plug connection
26. COSHH Regulations 1988 Adhesives sealants and paints used in the manufacture of the product are cured and present no known hazards when used in the manner for which they are intended The following other materials are present in the product 14 1 Insulation Materials Material types Ceramic fibre board mineral wool Description Rigid board slabs sleeves gaskets ropes Known Hazards May cause temporary irritation or rash to skin High dust levels may irritate eyes and upper respiratory system Precautions Avoid unnecessary or rough handling or harsh abrasion of boards Normal handling and use of material should not produce high dust levels Avoid inhalation and contact with skin and eyes After handling always follow normal good hygiene practices Protection Use disposable gloves face mask and eye protection First Aid Eyes If irritation occurs wash eyes with copious amounts of water If symptoms persist seek immediate medical advice Skin If irritation occurs wash under running water before washing with soap and water Inhalation Remove to fresh air drink water to clear throat and blow nose to remove dust fibres Ingestion Drink plenty of water 14 2 Sealant and Adhesive Material Types Silicone elastomer Description Sealant and adhesive Known Hazards Irritation to eyes Precautions Avoid inhalation of vapour contact with eyes and prolonged or repeated contact with s
27. Figure 11 8 e Remove and inspect the baffle and clean off any remaining deposits using a brush and vacuum e Check the baffle condition and replace if necessary e Clean the underside of upper rear section of the primary heat exchanger at the rear of combustion chamber BEFORE replacing baffle Figure 11 9 Combustion chamber baffle 7 CAUTION Extreme care is required when empting the ash pan as smouldering ash could be present and cause serious damage to persons or property Ensure the ash is disposed of in a safe manner e Clean down the combustion chamber side back and base surfaces removing all ash deposits e Clean any ash deposits from the top of the burner hood and the inner face of the combustion chamber door e Clean out the burner brazier to remove as much loose ash as possible using a vacuum e Refit the combustion chamber baffle in position ensuring it is seated correctly on the fixing brackets Refer to Figure 11 8 e Refit the ash pan in the base of the combustion chamber e Grease the front cleaning door latch mechanism and close the door 11 7 Burner Brazier WARNING Ensure that electrical supply to the hopper and boiler is isolated by disconnected at the 4 way plug from the socket on the flying lead at the rear of the hopper before proceeding 11 7 1 Removal of Burner To clean the burner thoroughly it will be necessary to remove it from the boiler as follows
28. Flue fan Air vent Air vent manifold 22mm Secondary to primary pipe 6 26 22mm Secondary to primary pipe 9 36 Heturn assembly 6 26 Heturn assembly 9 36 1 BSP Flow pipe 6 26 1 1a BSP Flow pipe 9 36 Draught Stabilizer Fan box secondary gasket Secondary heat exchanger spiral baffle Cleaning door sealing gasket Primary 6 26 Cleaning door sealing gasket Primary 9 36 Secondary heat exchanger 6 26 Secondary heat exchanger 9 36 Shaker arm assembly 6 26 Shaker arm assembly 9 36 opring anchor fixed Shaker chamber 6 26 Shaker chamber 9 36 Primary secondary gasket Top panel 6 26 Top panel 9 36 Cleaning pipe manifold 6 26 Cleaning pipe manifold 9 36 Cleaning door shaker chamber 6 26 Cleaning door shaker chamber 9 36 Fibre rope shaker chamber door 6 26 Fibre rope shaker chamber door 9 36 Solenoid valve Secondary heat exchanger spiral baffle WP40 WP41 WP42 WP43 WP44 WP145 WP46 MPCBS29 WP48 WP49 WP50 WP51 WP52 WP53 WP54 WP55 WP56 WP57 WP58 WP59 WP60 WP61 WP62 WP63 WP64 WP65 WP66 WP67 WP68 WP69 WP70 WP71 WP72 WP73 WP74 WP75 WP76 WP77 Quantity 6 26 Quantity 9 36 LT ang A A a WP38 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 30 40 1 2 1 1 1 1 1 1 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 18 24 13 5 Boiler Parts List continued 32 3
29. Health amp Safety information given in Section 13 4 6 Heating System Design Considerations To achieve the maximum efficiency possible from the Grant SPIRA wood pellet boiler the heating system should be designed to the following parameters Radiators e Flow temperature 70 C e Return temperature 50 e Differential 20 Size the radiators using a mean water temperature of 60 C Design system controls with programmable room thermostats or use weather compensating controls to maintain return temperatures below o5 C NOTE The boiler should not be allowed to operate with a return temperature of less than 40 C when the system is up to operating temperature The use of a pipe thermostat is recommended to control the return water temperature when using weather compensating controls Underfloor Heating e Flow temperature 50 C e Return temperature 40 C e Differential 10 C In underfloor systems it is essential that the return temperature must be maintained at or above 40 C to prevent internal corrosion of the boiler water jacket 4 7 Pipework Materials Grant SPIRA boilers are compatible with both copper and plastic pipe Where Plastic pipe is used it must be of the oxygen barrier type and be the correct class to BS 7291 Part 1 2001 for the application concerned WARNING On either sealed or open vented systems where plastic pipe is used a minimum of ONE metre of copper pipe M
30. Range Y Switched Live de Of 138 Pellet Burner Firing _ n Min Flame Temp gt Temp Off H20 Y ies Turning Off Brazier Flash Cleaning 0 i Auger Run Time gt Time Clean 4r n i t 1 1 Wait Brazier is Openin Auger Rurglime gt _ Wa Brazier i Opening gt gt gt Time Clean Braz Y Auger Run Time Y 1 Time Clean Boiler 19 j 2 2 L Wait Brazier is Closing gt gt gt Watt Cleaning Boiler Lux lt Flame On Y Y lu gt e Wait Post Purge For STEP AUTO function the two digit code allocated to each function Refer to Section 9 7 3 41 9 Burner 9 4 Burner Display Screen H20 60 C SET 75 C PELLET BU Active symbols Boiler thermostat calling Burner fan operational Pressure switch closed Ignition element operational s Feed auger operational Photocell lux reading gt Flame On setting E 9 5 Burner Control Buttons The burner has six control buttons these perform the following tasks Button No 1 Normal Mode Increase temperature set point by 1 C Menu mode Scroll up UJ utton No 2 Normal mode Decrease temperature set point by 1 C Menu mode Scroll down UJ 5 Z CO utto Menu mode Scroll forwar
31. TE 5 Tw 12 Fault Finding 12 4 Boiler Overheat Thermostat HO a A gt Primary Fault nna Secondary follow on checks BLANK DISPLAY SCREEN BOILER OVERHEAT STAT TRIPPED Is the central Isthe heating Is overheat stat WAR Press reset Vos Isthesystem Isthere any M Remove any heating system thermistor correctly capillary in good Isthere now circulating pump restriction to restriction e g amp boiler full of fitted in the pocket condition amp not continuity between operational water flow from open any valves water amp vented of inside the boiler damaged kinked the overheat stat the boiler or remove any air locks control panel or broken terminals blockage Unclip amp remove lt 1 preventing flow lead from stat amp check Fill amp vent i Correctly fit Repalcefaulty MEME Repalce faulty system heating thermistor g overheat stat circulating pump 8 in pocket amp reset overheat stat Note 1 Is heating system and boiler Also check the condition of the Note 4 is the circulating pump full of water and vented thermistor and the overheat thermostat operational The central heating system must be capillary for any damage replace if With tne burner ON STANDBY switch free of any air locks Ensure auto air necessary set to STANDBY reconnect the vent on secondary heat exchanger at Note 3 Is there continuity between power s
32. amp shaker mechanism Is the condensate trap and or discharge pipe blocked or frozen Clean condensate trap amp pipe to clear blockage Is the boiler cleaning interval correctly set In burner menu reset TIME CLEAN BRAZIER amp TIME CLEAN BOILER settings No Is the flue used the correct type Is it correctly installed amp not blocked Rectify or replace flue if necessary Remove any flue blockage Is the duration of the boiler cleaning period correctly set In burner menu reset TIME CLEAN PERIOD setting Is the flue fan in flue fan box operational amp clean Rectify fan fault or replace if necessary Clean fan if required 5 TE 5 LL D o TE Tw 12 Fault Finding 12 5 Pellet Tube Thermostat Note 1 Is the fault cleared by pressing the reset button Is the pellet feed tube less than 60 C If not then allow it to cool before proceeding When cool remove the steel retaining clip and disconnect the lead from the pellet feed tube burn back thermostat Press the reset button on the thermostat Note 2 Is feed pipe thermostat burn back sensor damaged or faulty Check the electrical continuity and condition of the thermostat Replace if necessary Note 3 Is the pellet delivery hose damaged correctly fitted Check the condition of the hose Is it damaged If so replace it
33. blocked Rectify as necessary e 5 the flue fan operational e 3 the room ventilation adequate If all the above are OK then adjust the draught stabiliser as necessary to achieve the required combustion chamber draught Refer to Section 10 9 for procedure Note 6 Is condensate trap pipe blocked Thoroughly check the entire condensate disposal system including all the pipework and the trap s to ensure that it is not blocked or frozen even partially If the condensate backs up into the condensing heat exchanger it can block the passage of the combustion gases from the burner causing them to back up through the boiler and burner into the pellet feed tube This will activate the pellet feed tube burn back thermostat Note 7 Is the flue correct type and correctly installed Only the Grant Black flue system can be used with the Grant Spira wood pellet boilers Check that the flue has been correctly assembled and that the terminal position complies with the requirements of The Building Regulations Approved Document J Refer to Sections 7 2 for guidance Note 8 Is flue fan operational and clean If the flue fan is not running or is coated with ash the draught in the combustion will be reduced causing the combustion gases from the burner to back up through the burner into the pellet feed tube This will activate the pellet feed tube burn back thermostat Note 9 Is the room ventilation adequate
34. box between junction Use four core flex at least 0 75 mm box and hopper Pressure Switch Four way plug comes fitted to four way socket on rear of Grant Spira hopper SL Wall mounted Junction box Use four core flex at least 0 75 mm between junction box and hopper IVE NEUTRAL SWITCHED Four way plug comes fitted to four way socket on rear of Grant Spira hopper OF PERMANENT LIVE Figure 8 11 Connection of Grant low water pressure switch ref MPCBS62 9 Burner 9 1 Burner Operation The burner controls the pellet feed auger flue fan boiler temperature and also the boiler and brazier cleaning systems The burner comes with a display screen and six control buttons These buttons are to access the menus and control the burner functions The burner is equipped with a brazier where the combustion of the wood pellets takes place within the boiler The self cleaning device on the brazier is automatically activated after the pellet feed auger run time has exceeded a predetermined set time The pellet feed auger run time for brazier and boiler cleaning is pre set in the burner menu The temperature of the water within the boiler is controlled via a thermistor to the burner The thermistor is inserted into the boiler water jacket and is used by the burner to control the modulation of the boiler output The boiler has a set point temperat
35. brackets should be fitted with a maximum spacing of 3m on straight runs of flue and at any offset to ensure the system is rigidly supported Similarly the Roof Support Band Grant ref WP RS is not load bearing and is designed to give lateral support only Where the flue is free standing above the roof and its height exceeds 1 5m beyond the last support of the roof e g Hoof Support Bang a Guy Wire Bracket Grant ref WP GB MUST be used and at every 1 5m thereafter Grant do not supply the guy wires or tie rods to use with this bracket Extended Locking Band A height of up to 3m above the last support at the roof can be achieved without the need for guy wires by using an extended locking band Grant ref WP LBEXT at the joint immediately below and at every joint above the last flue support 7 3 6 Elbows Two elbows are available 30 and 45 To allow for alignment the female collars of these elbows do NOT have the twist lock flutes but the locking band MUST still be used to secure the two flue components together The Building Regulations Approved Document J requires a flue system to have the means to be inspected and cleaned as required To allow for this there should be no more than 2 elbows of maximum angle 45 from the vertical fitted between the boiler fan box clean out hatch and the terminal This can be increased to a maximum of four elbows maximum 45 between the boiler and terminal
36. connected to this boiler must be suitable for use on mains voltage 8 2 Hopper Electrical Connections 7 2 1 Single Boiler Hopper with a single auger in either a left hand or right hand version as required to supply a single boiler This hopper is fitted with three pre wired flying leads with factory fitted plugs e 4 way plug for connection of the permanent live earth and neutral and also the switched live from the heating controls system e 5 way plug to connect the hopper to the boiler e 6 way plug to connect either a bulk pellet store auger or Grant SPIRA VAC vacuum system to the hopper and boiler Refer to Figure 8 7 for hopper wiring diagram 8 2 2 Double Boiler Hopper with two augers to supply two boilers in a double boiler installation This hopper is fitted with four pre wired flying leads with factory fitted plugs e 4 way plug for connection of the permanent live earth and neutral and also the switched live from the heating controls system e Two 5 way plugs one to connect to each of the two boilers e 6 way plug to connect either a bulk pellet store auger or Grant SPIRA VAC vacuum system to the hopper and boiler Refer to Figure 8 8 for double hopper wiring diagram 8 2 3 For Installations with a Bulk Pellet Store only Both single boiler and double boiler hoppers are supplied with the 6 way plug parked inside the wiring enclosure See Figure 8 1 If a b
37. each boiler must have a separate flue system Refer to Section 7 Description WPS626RH110 6 26 WPS626LH110 6 26 WPS626RH200 6 26 WPS626LH200 6 26 WPS936RH110 9 36 WPS936LH110 9 36 WPS936RH200 9 36 WPS936LH200 9 36 WPS1252 12 52 WPS1562 15 62 WPS1872 18 72 1 x 6 26kW boiler 110kg right hand hopper 1 x 6 26kW boiler 110kg left hand hopper 1 x 6 26kW boiler 200kg right hand hopper 1 x 6 26kW boiler 200kg left hand hopper 1 x 9 36kW boiler 110kg right hand hopper 1 x 9 36kW boiler 110kg left hand hopper 1 x 9 36kW boiler 200kg right hand hopper 1 x 9 36kW boiler 200kg left hand hopper 2 x 6 26kW boilers 140kg double boiler hopper 1 x 6 26kW boiler and 1 x 9 36kW boiler 140kg double boiler hopper 2 x 9 36kW boilers 140kg double boiler hopper Q O gt Le pu Q O gt 1 Introduction 1 4 Boiler Components 1 4 1 Burner The burner is supplied factory fitted to the boiler All burners are supplied with factory default settings During commissioning each burner parameter will need to be checked see Section 8 and adjusted if necessary as the flue length can have a significant effect on the boiler performance Refer to commissioning in Section 9 The Burner is equipped with a self cleaning device to prevent a build up of ash and clinker in the burner brazier The burner output is determined by the feed pause ti
38. from this side With hopper located between two boilers in a double boiler installation the right hand boiler will have the wash system manifold fitted from the right hand side and the left hand boiler will have the wash manifold fitted from the left hand side In all cases ensure adequate clearance minimum 400mm is present for removal of the wash system during servicing Refer to Section 2 4 for clearance dimensions The remainder of the washdown cleaning system consists of the pressure gauge and solenoid valve assembly flexible hose isolating valve with integral check valve Fit the gauge valve assembly to the end of the manifold pipe using the 22mm compression elbow Connect the mains water supply to the 15mm compression connection on the isolating check valve inlet Fit the flexible hose between the outlet of the isolating check valve outlet and the inlet to the solenoid valve and leave in place NOTE In hard water areas an anti scale device should be fitted on the cold water supply to the wash system to prevent scale build up in the manifold pipe and jets 4 10 Fan Box and Flue Starter Fit the fan box to the flanged flue outlet on the back of the boiler so that the flue starter outlet is at the top Remove the nuts and washers from the four studs around the fan box inlet With the neoprene gasket in place on the fan box locate the four studs through the corresponding holes in the boile
39. is increased shown as 134 in the plan view then the dimensions D E amp G will have to be increased by the same increment All units in millimeters Figure 2 1 Boiler and hopper dimensions and clearances single boiler with left hand hopper 2 4 2 Single Boiler with Right Hand Hopper 511 256 AIR VENT WASH DOWN MANIFOLD CONDENSATE npe CONNECTION WIRING sf CENTRE Rear View Plan View Spira Wood Pellet Boiler Dimensions Model 6 26 110kg right hand hopper 1056 518 513 177 96 661 1160 1120 6 26 200kg right hand hopper 1256 618 713 129 44 713 1160 1120 9 36 110kg right hand hopper 1056 518 513 Zit 196 661 1260 1220 9 36 200kg right hand hopper 1256 618 713 225 144 713 1260 1220 If the measurement from the flue centre line to the rear wall is increased shown as 134 the plan view then the dimensions D E amp G will have to be increased by the same increment All units in millimeters Figure 2 2 Boiler and hopper dimensions and clearances single boiler with right hand hopper e e 2 4 11 2 LL 2 lechnical Data 2 4 3 Double Boiler with Central Hopper Front View WASH DOWN MANIFOLD A WASH DOWN MANIFOLO CONNECTION RETURN CONNECTION Plan View Rear View Spira Wood Pellet Boiler Dimensions 12 52 with double hopper 1 92 616 697 224
40. operation is complete e Deactivated once photocell lux reading exceeds FLAME ON setting WAIT LIGHTING FLAME STABILISATION operation code 45 Period of time to allow flame stabilise after pellets have ignited e Activated after ignition mode e Deactivated after time exceeds Ma WAIT LIGHTING LIGHTING FEED REDUCED operation code 42 Period of time intermittent quantities of pellets supplied to the brazier to increase the flame e Activated after WAIT LIGHTING flame stabilization mode e Deactivated after time exceeds TOO PELLET BURNER FIRING Power 100 operation code 13 Flame is fully developed and boiler is operating on full power e Activated after WAIT LIGHTING lighting feed reduced mode e Deactivated after temperature is within TEMP DELIA range PELLET BURNER FIRING Power modulating operation code 13 Flame is reduced and boiler output is modulating e Activated once the boiler temperature is within the TEMP DELTA range e Deactivated after temperature exceeds the TEMP DELTA range PELLET BURNER FIRING Power minimum operation code 13 Flame is reduced and boiler is at its minimum output e Activated once the boiler temperature exceeds the TEMP DELTA range e Deactivated after the temperature exceeds TEMP OFF H20 TURNING OFF BRAZIER Operation code 14 Burn down period to remove any pellets rem
41. short as possible less than metres and 38mm 115 waste pipe used to minimise the risk of ice blocking the pipe in freezing conditions The number of bends fitting and joints on external pipes should be kept to a minimum to reduce the risk of trapping condensate NOTE For a boiler installed in an unheated area such as an outhouse or garage all condensate pipework should be considered as an external 5 5 Condensate Soakaway To keep external pipework to a minimum locate the soak away as close as possible to the boiler but ensure it is at least 1 metre from building foundations and away from other services for example gas electricity or other services The condensate pipe may be run above or below ground level and can enter either the top or side of the soakaway tube Refer to Figure 5 1 Ensure that the drainage holes in the soakaway tube face away from the building Backfill the soakaway tube and the hole around it with 10mm limestone chippings Only use a soakaway where the soil iS porous and drains easily Backfill with 10mm Four rows of 3x12mm holes at limestone chippings 32mm waste pipe externasl to the building Cement seal Ground level 100mm plastic tube Sealed end fos fall 2 CLEANING EYE Figure 5 1 25mm centres and 50mm from bottom of the tube Holes facing away from the property Figure 5 1 Purpose made condensate soakaw
42. the burner flange onto the M8 studs on either side of the burner Secure the burner to the door with the two 8 nuts previously removed He connect the three plugs to their corresponding sockets on the left side of the burner Ensure that each plug is fully pushed home until the small catch clicks into place Refer to Figure 11 9 Check the condition of the pellet delivery hose and ensure it forms an air tight seal each end Check for any damage to the hose and replace if necessary A damaged pellet delivery hose can allow a back draught through the boiler resulting in the pellet tube burn back thermostat operating and shutting down the burner 11 10 Condensate Disposal System 11 10 1 Condensate Trap Disconnect the condensate disposal System from the outlet at the back of the boiler Check that the boiler condensate outlet is clear Remove any blockage or ash build up Remove the condensate trap supplied with the boiler from the condensate disposal system Dismantle and check the condition of the trap Thoroughly clean out the trap to remove any deposits and re fit to condensate disposal system Heconnect the disposal system to boiler outlet 1 NOTE The condensate trap s and condensate outlet MUST be checked on EVERY service and cleaned as necessary Failure to regularly check and clean the condensate trap or traps may result in damage to the boiler and this will not be covered by the product
43. the plug is fully pushed home until the small catch it clicks into place See Figure 4 3 Refer to Section 8 3 for all boiler plug connections WARNING Ensure the pellet delivery hose forms an air tight seal at each end and that the pellet delivery hose is not damaged Leakage of air could cause increased temperature in the pellet delivery hose and result in the pellet feed tube burn back thermostat operating and shutting down the burner 4 13 Before you Commission To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly flushed out both before the boiler is connected and then again after the system has been heated and is still hot This is especially important where the boiler is to be installed on an old system For optimum performance after installation the boiler and the associated heating system must be flushed in accordance with the guidelines given in BS 7593 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleaner such as Betz Dearborn s Sentinel x300 or x400 or Fernox Restorer Full instructions are supplied with the products butfor more details visit either www sentinel solutions net for Betz Dearborn products or www fernox com for Fernox products After flushing the system an inhibitor such as Sentinel X100 or Fernox MB 1 should be used in accordance with the guidelin
44. the rear access cover and remove it from top of the secondary condensing heat exchanger Rear flue gas duct LA I Figure 11 8 of heat exchangers Operate the automatic cleaning function in both heat exchangers as follows e Set the ON STANDBY switch to STANDBY e He fit the 5 way plug on the lead from the hopper into the socket at the left rear of the boiler Refer to Figure 11 1 e Replace the 5 fuse in the fused spur and switch on the electrical supply to the hopper and boiler The burner fan should briefly run e Press and hold down the CLEANING switch on the boiler control panel in the TEST position for about 60 seconds e Release switch to automatically reset cleaning function back to AUTO Note that setting this switch to TEST does NOT operate the burner cleaning function but only that of the two heat exchangers Ensure the electrical supply to the hopper and boiler is isolated by disconnecting the 4 way plug from the socket on the flying lead at the rear of the hopper Primary heat exchanger clean as follows e Remove all of the mild steel spirals by lifting them vertically up and out from the primary heat exchanger tubes e Clean down any ash inside tubes using a suitable pipe brush into the combustion chamber and ash pan below e Clean all ash deposits from top chamber of the primary heat exchanger above tubes and shaker mechanism pl
45. to Figure 11 5 e Re fit wash system manifold tube using the two screws previously removed but do not tighten at this stage the wash system manifold needs to be correctly aligned once the boiler power supply is reconnected e Re fit solenoid head to valve body and secure in place with the spring clip Test the automatic cleaning functions as follows e Check the ON STANDBY switch is set to STANDBY e He connect the electrical supply to the hopper and boiler by fitting the 4 way plug into the socket on the flying lead at the rear of the hopper The burner fan should briefly run e Press and hold down the CLEANING TEST switch on the boiler control panel WARNING Ensure that fingers are clear of all moving parts inside the top of the primary heat exchanger BEFORE operating CLEANING TEST switch Primary Heat Exchanger Check the shaker unit located in the top of the primary heat exchanger is operating freely and that the spirals are moving up and down with two intermittent vertical motions If there is no movement of the shaker system isolate the electrical supply and check that e the motor and cam is rotating e the cam follower is in contact with the cam e the condition of the cam follower spring located in the rear of the control panel Replace if necessary Secondary heat exchanger Check the wash system manifold located under the top rear access door is sprayin
46. 0 seconds Note 11 Is the required LUX level being detected by the photocell In the LIGHTING CYCLE REDUCED period of the burner lighting sequence i e whilst the STEP AUTO function is 42 in the view menu if the flame drops below 1 lux then the error message FAILED PELLET LIGHTING is displayed Refer to Section 9 7 3 for procedure to access LUX value in View menu Note 12 TO BE CONFIRMED TII 12 7 Servo Motor Blocked H20 60 C SET 75 C SERVO MO Can the brazier be opened manually Open the combustion chamber door Is the brazier blocked up Is the brazier distorted or damaged Remove the blockage amp close the Combustion chamber door Replace damaged parts amp reset brazier clearance Note 1 Opening the combustion chamber door Before attempting to open the combustion chamber door set the ON STANDBY switch to STANDBY Note 2 Can the brazier be opened manually First clear any blockage clinker ash from the brazier To open the brazier manually operate the release switch on the servo motor Refer to Section 11 7 2 DO NOT FORCE THE BRAZIER OPEN WITHOUT OPERATING THE SERVO MOTOR RELEASE SWITCH OR THE SERVO MOTOR GEARS WILL BE DAMAGED AS A RESULT Note 3 Is the brazier clearance correctly set To check the gap between the fixed and moving part of the brazier use the brazier clearance gauge supplied with the boiler Refer to Section 11
47. 1 4 Boiler Components 6 cla SSN 11 5 Combustion Ventilation 54 1 5 Boiler Cleaning and Servicing 7 7 4 Flue Notice Plate 27 11 6 Boiler 54 2 Technical dat 8 dis e 11 7 Burner Brazier 56 kaaa Di dal n tee 5 11 8 Burner Components or oller opper ue Component i Technical Data 8 Dimensions 30 di 2 2 Boiler Input and 7 8 Typical Flue Systems 31 DIS crete 58 Output Data 9 pue 2 3 Flue Gas Analysis 9 8 Electrical 32 di 2 4 Boiler and Hopper 8 1 General Requirements 32 SUD di Dimensions and Clearances 10 82 Hopper Electrica 11 18 Combustion Checks 59 D Connections Fault Findi 3 Specification 13 8 3 Boiler Plug Connections 32 12 Fault Finding 60 8 4 Heating System Controls 33 n 3 ellet Specification 3 8 5 Connecting the Power 12 2 Normal Screen Display 61 3 2 Pellet Storage 14 Supply na 12 3 No Screen Display 62 8 6 Wiring Diagrams 34 12 4 Boiler Overheat Thermostat 64 4 Installation information 16 ine bale ube thermos 65 4 1 Introduction 16 9 Burner 40 12 6 Failed Pellet Lighting 67 4 2 Boller Location 16 9 1 Burner Operation 40 12 7 Servo Motor Blocked 69 4 3 Preparation for Installation 16 9 2 Burner Operational Modes 40 42 8 Probe Failure Thermostat 70 4 5 Regulations 16 Sequence 41 4 6 Heating System Design 9 4 Burner Display Screen 42 13 Spare Parts 12 Considerations 16 9 5 Burner Control Buttons 42 47 Pi DITE 16 EE 14 Health amp Safety
48. 12 1 If this is the case go to Section 12 2 for fault finding procedure b No display screen is BLANK Refer to Figure 12 2 If this is the case go to Section 12 3 for fault finding procedure c An ERROR message is displayed If this is the case refer to Error Messages below It is essential at this stage to check and identify which of these three displays is shown on the burner control panel screen before proceeding to attempt to diagnose the fault Error Messages There are FOUR possible error messages that can be displayed on the burner control panel screen in the event of a fault In all cases the cursor will be next to the error symbol at the lower left corner of the display Refer to Figure 12 3 The four possible error messages that can be displayed continuously scrolling across the lower part of the screen are listed below Each one identifies a particular fault Refer to the relevant section of this manual for detailed guidance to diagnose and rectify the fault as follows e FAILED PELLET LIGHTING Go to Section 12 6 e SERVO MOTOR BLOCKED Go to Section 12 7 e PROBE FAULT Go to Section 12 8 e AIR PRESSURE ERROR Go to Section 12 9 Figure 12 1 Normal screen display Figure 12 2 Blank screen display Figure 12 3 Error message screen display 12 2 Normal Screen Display Boiler will not fire but NO error message is displayed 6 lY gt
49. 2300 MINIMUM LIP SEAL BAND SECTION 500MM LIP SEAL amp BAND SECTION 1000MM gt mad gt 2 gt e e o NIFLASH N LA FIRE STOP PLATE 52MM WALL BRACKET ROOF SUPPORT LIP SEAL amp BAND FIRE STOP PLATE IP SEAL amp BAND COMBUSTIBLE SHAFT SECTION 1000MM SEAL amp BANO SECTION 1000MM 50MM WALL BRACKET SUPPORT PLATE a IP SEAL amp BAND FIRE STOP PLATE 50MM WALL BRACKET di m SECTION 500MM oe LIP SEAL amp CLEANING EYE SECTION 1092MM ADJUSTABLE EXTENSION IP SEAL amp CLAMP Air Supply o n V o LL 8 Electrical 8 1 General Requirements The Grant SPIRA Condensing Wood Pellet boiler requires a 230 V 50 Hz electrical supply The unit should be connected to a mains power supply that is protected by a RCD For the UK the electrical installation must be carried out by a competent installer in accordance with the requirements of the Electricity at work Regulations 1989 and BS7671 2008 IEE Wiring Regulations 17th Edition including all amendments If installed in the Republic of Ireland the wiring installation must comply with all ETCI rules All the wiring and supplementary earth bonding external to the boiler must be in accordance with the current E E wiring regulations Any heating system controls e g room thermostat frost thermostat etc
50. 3 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 o1 52 53 54 55 56 57 58 59 60 Description Spiral hanger 6 26 Spiral hanger 9 36 Shaker assembly mounting flange Spring anchor movable Cleaning mechanism spring Right side panel 6 26 Right side panel 9 36 Cleaning mechanism cam Cleaning motor mounting flange Cleaning mechanism motor Door interlock Shaker chamber mounting gasket 6 26 Shaker chamber mounting gasket 9 36 Left side panel 6 26 Left side panel 9 36 Brass fitting 1 BSP x 22mm 311 Brass fitting 1 1 4 BSP x 28mm 311 Primary heat exchanger 6 26 Primary heat exchanger 9 36 Combustion chamber baffle 6 26 Combustion chamber baffle 9 36 Ash pan handles Ash pan 6 26 Ash pan 9 36 Combustion chamber cleaning door rope Combustion chamber cleaning door Combustion chamber cleaning door panel Front panel Combustion chamber cleaning door handle On Off switch Limit stat Momentary switch double pole on on Control panel chassis Relay Control panel cover Plug not show Plug not shown Items not indexed are specific to the 9 36 model WP78 WP79 WP80 WP81 WP82 WP83 WP84 WP85 WP86 WP87 WP88 WP89 WP90 WP91 WP92 WP93 WP94 WP95 WP96 WP97 WP98 WP99 WP100 WP101 WP102 WP103 WP104 WP105 WP106 EFBS22 WP107 WP108 WP109 MPCBS72X WP110 Quantity 6 26 1 6
51. 6CO in the flue gases as follows e Ensure the burner display is showing BURNER FIRING 100 e Remove the screw from the combustion test point located at the left rear corner of the rear access cover on the secondary heat exchanger Refer to Figure 10 17 e Insert the analyser probe a minimum of 100mm into the test point e Monitor the 96CO for a few minutes to see the maximum and minimum values reached e The CO measured should range between a maximum of 1296 and a minimum of 1096 Figure 10 17 Combustion test point If necessary the 96CO may have to be adjusted to be within these limits as follows e Access the INSTAL Installer menu in the burner control settings and go to the SETUP FAN sub menu Go to the POWER MAXIMUM value and adjust the burner fan speed using buttons 5 and 6 on the burner control panel Refer to Section 9 4 To decrease the 96CO increase the fan speed using button 6 To increase the CO decrease the fan speed using button 5 To confirm the change in the POWER MAXIMUM fan setting press button 4 twice to exit the SETUP FAN and INSTAL menus and return to the normal control panel display showing H20 and SET temperature Monitor the 96CO for a few minutes to see if the maximum and minimum values are 1296 and 1096 as required If necessary make a further adjustment of the fan speed and check the resulting CO as described ab
52. 7 2 If it is necessary to dismantle the brazier the burner must be removed from the combustion chamber door Refer to Section 11 7 Is the brazier clearance correctly set Reset brazier clearance using Grant brazier clearance guage gt Primary Fault EE Secondary follow on checks Is the boiler cleaning interval correctly set Is the servo motor operating correctly Is the duration of the brazier cleaning period correct 4 to 5 Is the servo In burner menu motor correctly 8 reset TIME set CLEAN BRAZIER amp TIME CLEAN BOILER settings Reset servo motor controls Note 4 Is the servo motor operating correctly oet the ON STANDBY switch to STANDBY Go to the CLEAN sub menu of the burner control settings and set TIME CLEAN BRAZIER to 0 Set the ON STANDBY switch to ON and start the boiler When the burner display shows 100 POWER set the ON STANDBY switch back to STANDBY When the burner has completed the shut down process the brazier cleaning operation will start automatically The burner control screen will first show BRAZIER CLEANING FORWARD for between 2 to 2 minutes Then the burner fan will start and the screen will show BRAZIER CLEANING BACK for between a further 2 to 272 minutes Thus the total time for the brazier cleaning operation is between 4 to 5 minutes mins in total Adjust servo motor setting or replace servo motor if necessary
53. COPY 2 Grant Spira 6 26 kW and 9 36 kW Condensing Wood Pellet Boiler Installation amp Servicing Instructions GRANT Part No DOC 42 Rev 01 May 2013 Pus O 2 cC 9 gt O Q important Note Important Note for Installers After installing the boiler leave these instructions with the Appliance Leave the user manual with the householder This appliance is deemed a controlled service and specific regional statutory requirements may be applicable GRANT ENGINEERING UK LIMITED Hopton House Hopton Industrial Estate Devizes Wiltshire SN10 2EU Tel 01380 736920 Fax 01380 736991 Email sales 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 AII good sold are subject to our official Conditions of Sale a copy of which may be obtained on application Grant Engineering UK Limited 2013 No part of this manual may be reproduced by any means without prior written consent Contents 1 Introduction 4 7 Flue System and 11 Boiler Servicing 59 1 1 How the Condensing Air Supply 24 11 1 General 58 Wood Pellet Boiler Operates 5 7 1 Air Supply 24 11 2 Checks Before Servicing 53 1 2 Boiler Description 5 7 2 Flue Position and 11 3 Heating System 53 1 3 Boiler Models Clearances 24 11 4 Flue System 53
54. Cylinder Room Stat Pipe Thermostat if fitted 919 7 JA 3 9465 6 e7 9899910 Wiring Centre Pump O Frost Thermostat Grant 2 Channel Wall Mounted Programmer See Figure 8 11 for wiring Pressure Switch Kit for use with plastic pipe in installation ar Wall mounted ETNIA Junction box Use four core flex at least 0 75 mm between junction box and hopper NEUTRAL SWITCHEDAIVE Four way plug comes fitted to four way socket on rear of Grant Spira hopper OC PERMANENT LIVE OZ OS Figure 8 9 Heating system controls S plan type system connection diagram Blue 240 V 50 HZ Green Yellow r Z ur ole Room Stat 2 1 3 Y 91 42 Pipe Thermostat if fitted White 3 port Mid Position Zone Valve Grey Orange Cylinder Stat 1o C 2 oO Wiring Centre Pump Pd O Frost Thermostat O wO RO ZO ro Grant 2 Channel Wall Mounted Programmer See Figure 8 11 for wiring Pressure Switch Kit for use with plastic pipe in installation Figure 8 10 Heating system controls Y plan type system connection diagram PERMANKNT LIVE NEUTRAL SWITCHEDAIVE Wall mounted Junction
55. D T LL 9 T 2 10 Commissioning damaged pellet delivery hose allow a back draught through the boiler resulting in the pellet tube burn back thermostat operating and shutting down the burner e Finally re fit both the 6 way and then 7 way plugs to their corresponding sockets on the left side of the burner Ensure that both plugs are fully pushed home until the small catch clicks into place Refer to Figure 10 9 WARNING Ensure the pellet delivery hose forms an air tight seal each end and that the hose is not damaged Leakage of air could cause increased temperature in the pellet delivery hose and result in the burn back thermostat shutting down the burner 10 8 Lighting the Boiler Ensure that the electrical supply to the hopper and boiler is switched on connected and that the heating system controls are operating and are calling for heat Set the burner ON STANDBY switch to ON The flue fan will start and pellets will be delivered to the burner Refer to Section 9 1 for details of the burner start up running and shut down sequences NOTE If the boiler ON STANDBY switch is set to STANDBY during the initial pellet pre load period the pellet feed will continue until the pre load is complete The burner will then complete the shut down sequence before it can start up again even if the ON STANDBY switch is reset to ON
56. Disconnecting hopper 5 way plug Figure 11 2 Disconnecting fan 5 way plug GRANT 11 3 Heating System If boiler is part of a sealed heating system check the following e System pressure e Pressure relief valve operation e Expansion vessel air charge pressure when the system pressure is zero Check the boiler for any indication of leaks from e Flow and return connections e Automatic air vent at rear of boiler e Drain cock at lower rear of boiler Remake any joints and re check tightness of any fitting that may be leaking Re fill and vent the system to the required pressure Refer to Section 6 On either sealed or open vented systems e Inspect and clean the in line magnetic filter in accordance with the filter manufacturer s instructions e Ensure that adequate corrosion protection is present in system 11 4 Flue System 11 4 1 Flue Terminal Check the flue terminal and ensure that it is not blocked or damaged 11 4 2 Fan Box Unscrew the eight screws securing the flue inspection plate on to the fan box and remove the plate Inspect inside of both flue and fan box Refer to Figure 11 3 Clean any ash deposits from the inside of the fan box as necessary Clean the flue by sweeping as required Heplace plate and secure using the eight screws ensuring that it is correctly sealed to the fan box on the neoprene gasket O i c o gt KO Figure 11 3 Fan bo
57. NG MOTOR 3KET NO 5 REAR UPPER IGHT OF BOILER WHEN IEWED FROM FRONT EE PERMANENT LIVE DOOR INTERLOCK DOOR INTERLOCK w BLK BLK BR SOCKET NO 4 REAR UPPER LEFT OF BOILER WHEN VIEWED FROM FRONT FAN rey DOOR ISOLATION O SWITCH I2 NL FAN BOX ASSEMBLY PLUG FROM GRANT HOPPER Colour code BR Brown BL Blue RD Red G Y Green Yellow BLK Black OR Orange Y Yellow 34 Figure 8 5 Boiler internal wiring diagram ON LANDOS CON LANDOS SOLIINNDI 3494 3 IWW 3 1W34 4i LANDOS zl LYLSOWYSHL 334 13713d SYOLIANNOD 3 0Vds 3 WW 3 WwW34 3 INANE NADJE JONVAO 1N3W313 NDILINDI 1039010Hd AN 14a AWTASIO O DNINVITI 3124944 010 DANIS HOLIAS F3YINSSIYI AIV A Figure 8 6 Burner wiring diagram 8 Electrical pa HOPPER LIMIT SWITCH Or Rd Supply to CH valve Blk with CH valve fitted connect pipe stat between L4 amp L7 without CH valve fitted connect uem M c 1 MERE uw M RH m rm DI 1 1411 1 i I Frost Pipe thermostat Stat l option option
58. Primary Fault FINISSE Secondary follow on checks WAIT BOILER THERMOSTAT Is there sufficient quantity of pellets in the pellet hopper Is the burner ON STANDBY switch set to ON position Is there power at relay in boiler control panel on Terminals 21 amp 24 when coil is energised the cursor next No to the thermostat symbol on burner display Are the heating M system controls Programmer Room Stat at rear of CALLING for hopper heat E 1 Is there power to terminal L2 on 4 way plug NO Is there continiuty between terminals T1 amp T2 on burner plug No2 Is there power across the boiler ON OFF switch es Yes Note 4 Note 5 15 2 Temp No No No No higher than the i set point minus the Delta restart temperature Check the switched live supply to hopper Set burner ON STANDBY switch to ON Fill hopper with E correct grade of gg pellets Set system controls to call for heat Check plug is corrctly fitted Replace faulty switch Replace faulty relay NO FAULT Boiler is waiting for system temp to drop Note 1 Is the curser next to the thermostat symbol on the burner display When there is a switched live supply to the burner i e when the heating system controls are calling and the ON STANDBY switch is set to ON the burner screen display shows a cursor hi
59. T does NOT operate the burner cleaning function but only that of the two heat exchangers WARNING Ensure that fingers are clear of all moving parts inside the top of the primary heat exchanger BEFORE operating CLEANING TEST switch Primary Heat Exchanger Check the shaker unit located in the top of the primary heat exchanger is operating freely and that the spirals are moving up and down with two intermittent vertical motions Secondary Heat Exchanger Check the wash system manifold located under the top rear access door is spraying water directly into each flue gas tube of the unit Refer to Figure 10 4 If the water jets are not spraying directly into the flue gas tubes adjust the spray as follows e Slacken the two screws securing the manifold pipe flange to the boiler side panel e Carefully rotate the pipe until jets spray directly into tubes e Tighten the two screws to secure manifold pipe in this position JET SPRAYING DIRECTLY INTO TUBE Figure 10 4 Correct jet spray into tubes Figure 10 5 Incorrect jet spray Hefit both front and rear access panels and secure with the nuts previously removed Do not overtighten 10 4 Pellet Hopper Check the pellet feed auger is fully inserted into the pellet hopper and secured with the single screw through the auger fixing flange Refer to Figure 10 6 Do NOT fill hopper with pellets until AFTER the auger is fitted and secu
60. UST be connected between both the boiler flow and return connections and the plastic pipe DO NOT CONNECT PLASTIC PIPE DIRECTLY TO THE BOILER Grant UK do not accept any responsibility for any damage however caused to plastic piping or fittings Sealed Systems If plastic pipe is to be used the installer must check with the plastic pipe manufacturer that the pipe to be used is suitable for the temperature and pressures concerned Plastic pipe must be Class S to BS 7291 Part1 2001 WARNING The system MUST incorporate low level pressure switch to shut off power to the boiler if the system pressure drops below 0 2 bar A suitable low pressure switch kit is available to purchase from Grant UK Part No MPCBS62 Refer to Figure 8 11 for the electrical connection details on this switch Underfloor Pipework Plastic pipe may be used on underfloor floor systems where the plastic pipe is fitted after the thermostatic mixing valve Copper tube must be used for at least the first metre of flow and return primary pipework between the boiler and the underfloor mixing blending valves 4 8 Pipe Connections Flow and return connections The flow and return connection are at the rear of the boiler see Section 2 4 and the sizes are as follows SPIRA 6 26 Flow 1 BSP Female Heturn 1 BSP Female SPIRA 9 36 Flow 1 BSP Female Return 1 14 BSP Female Drain Cock Fit the 12 drain cock to the bottom r
61. adhesive notice plate is supplied with the Grant Black flue system and this must be completed by the installer and displayed in an unobtrusive but obvious position within the building concerned e g next to the flue system boiler 7 5 Carbon Monoxide Alarm The Building Regulations Approved Document J requires a Carbon Monoxide alarm to be fitted in the room where the boiler is located This should be positioned between 1 and 3m horizontally from the boiler either a on the ceiling at least 300mm from any wall or b on a wall as high up as possible above any windows or doors at least 150mm from ceiling Air Supply JO 9 z d o Pa V o LL 7 Flue System and Air Supply 7 6 Flue System Components WPO1 Locking band e WPUF 200 Uni flash WPADJ 250 EXT 250 CH WPFP Firestop plate 2PC 50 WPGB Guy wire bracket WPEXT333 Extension 333mm WPEXT500 Extension 500mm WPEXT 1000 Extension 1000mm WP45 45 Bend WPRC Rain WPTP Intermediate top plate WP30 30 Bend Air Supply O o Pe V LL WPAP Anchorplate to chimflex adaptor WPWS Wall support plate WPCA ICID to chimflex adaptor Air Supply JO 9 z d o Pa V o LL 7 Flue System and Air Supply 7 7 Flue Component Dimensions revised drawings to come i 45 ag j L
62. aining in the brazier e Activated once switched live input signal is switched off or the boiler temperature exceeds TEMP OFF H20 setting e Deactivated once photocell lux reading has dropped below the FLAME ON setting less WAIT POST PURGE operation code 26 Period of time after burn down is complete to ensure no unburnt pellets ignite e Activated after TUNNING OFF BRAZIER is complete e Deactivated after time exceeds Eus 9 3 Burner Operational Sequence Flow Chart of Operation of Wood Pellet Boiler Temp gt Delta Restart Temp or 03 Switched Live Input Off Wait Boiler Thermostat Temp lt Delta Restart Temp Wait Pre Load Brazier amp Switched Live Input On Pressure Switch Check Pressure Switch Check OK Burner Power Activated 40 Min Wait Pre Load Brazier T gt T08 Pre Load Time Switched Live a Wait Lighting Ignition Lux Flame on Switched Live Wait Lighting Flame Stabilisation gt T13 Flame Stabilisation Switched Live input gt E 2 Wait Lighting Lighting Feed Reduced T gt TO9 Lighting Feed Reduced Switched Live Input of 13 Pellet Burner Firing Max Flame Temp within Temp Temp Temp is ua pala Range Delta Range witched Live Input O 13 Pellet Burner Firing ug em i Modulating Auger run time gt Temp gt Temp Time Clean Braz amp or i Delta Range Delta
63. an blocked pressure switch operational Is the burner fan pressure correct Remove any Is fan air pressure Replace burner Replace blockage or replace i tube OK fan if necessary Check operation of pressure switch that the burner fan speed is correct It does not check if the fan is generating enough air pressure If during the PELLET BURNER FIRING operation the burner fan speed is not correct then the warning AIR PRESSURE ERROR is displayed on the burner screen Check that the fan inlet is not blocked and that the fan blades are free to rotate If necessary thoroughly clean and remove any dust or debris If fan still does not rotate freely replace fan DIGITAL m T Pi a ai le Figure 12 7 Checking air pressure from fan fan Is burner control PCB fan pressure now correct Note 3 Is the air pressure switch operational Check that air supply tube is correctly connected to the pressure switch and not blocked or twisted Refer to Figure 12 6 Rectify as necessary Check condition of tube and replace if damaged Check operation of air pressure switch Note 4 Is fan air pressure tube OK Check that the plastic tube from the fan is not twisted kinked or blocked Check that it is correctly connected to the both the fan and pressure switch lower of the two connections on the pressure switch Note 5 Is burner fan pressure correct
64. ar Hadiator valves must comply with the requirements of BS 2767 10 1972 One or more drain taps to BS 2879 must be used to allow the system to be completely drained 6 2 Filling the Sealed System Filling of the system must be carried out in a manner approved by the local Water Undertaking WARNING Only ever fill or add water to the system when it is cold and the boiler is off Do not overfill The procedure for filling the sealed system is as follows 1 Checkthe air charge pressure in the expansion vessel BEFORE filling the system NOTE The air charge pressure may be checked using a tyre pressure gauge on the expansion vessel Schraeder valve The vessel may be re pressurised when necessary using a suitable pump When checking the air pressure the water in the heating system must be cold and the system pressure reduced to zero The expansion vessel charge pressure should always be slightly greater than the maximum static head of the System in bar at the level of the vessel 1 bar 10 2 metres of water See Figure 6 2 The charge pressure must not be less than the actual static head at the point of connection 2 Check that the small cap or screw on all automatic air vents including the one fitted at the left rear of the boiler is open at least one turn The cap or screw remains in this position from now on 3 Ensure that the flexible filling loop is connected and that the dou
65. arameter Parameter Change amp Exit O arameter Increase decrease Change p Parameter Parameter amp Exit cB cB The language options are Italian or English Once exited the language 46 The VIEW menu folder has 4 readout displays as follows a LUX Light illumination measured by the Photocell Headout is instantaneous b STEP AUTO Each boiler function is allocated a two digit number This menu displays the function the boiler is in when viewing The list of the functions are as follows Wait Boiler Thermostat 13 Pellet Burner Firing 14 Turning Off Brazier selection shown on screen becomes the displayed language 15 Brazier is moving back 15 Brazier is moving forward 26 Post Purge 29 Air Pressure Error 33 Failed Pellet Lighting 34 Servo Motor Blocked 40 Pre load 41 Wait Lighting Ignition 42 Wait Lighting Lighting Feed Reduced 45 Wait Lighting Flame Stabilisation 46 Safety Charge Pipe Thermostat 46 Safety Boiler Thermostat 47 Probe Fault c VIEW CLE BRAZ Total pellet feed auger run time since brazier last cleaned When T10 brazier cleaning operation will commence Resets after each brazier clean d VIEW CLE BOILER Total pellet feed auger run time since boiler last cleaned When 2 T17 boiler cleaning operation will commence Hesets after each boiler clean 10 Commissioning It is important that the follow
66. arings Unscrew and remove the plug from the centre of the pump motor Using a suitable screwdriver rotate the pump spindle about one turn Replace the plug in the motor Do not overtighten 6 4 Pressure Relief Safety Valve Operation Check the operation of the pressure relief safety valve as follows 1 Turning the head of the valve anticlockwise until it clicks The click is the safety valve head lifting off its seat allowing water to escape from the system 2 Check that the water is escaping from the system 3 lop up the system pressure as necessary NOTE The expansion vessel air pressure system pressure and operation of the pressure relief valve must be checked on an annual service Refer to Section 11 jud 9 Pa o a Air Supply O z o Pe V o LL 7 Flue System and Air Supply 7 1 Air Supply The Grant SPIRA wood pellet boiler draws air for combustion from the room in which it is located Any such room or space containing an appliance must have sufficient permanent air supply to the boiler a To ensure correct combustion of the fuel and effective operation of the flue system i e to discharge of combustion products to the open air b To supply enough free air to the draught stabiliser The ventilation area provided must be in accordance with the requirements of The Building Regulations Appr
67. as specified in Building Regulations Approved Document J Also refer to Approved Document J of either the England and Wales or Irish building regulations for further requirements on the installation of flue systems for solid fuel appliances 7 3 Flue System Assembly 7 3 1 Fan Box amp Flue Starter The fan box supplied with the boiler packed in the accessories carton incorporates e Flue exhaust fan e Draught stabiliser e Flue starter connection to fit Grant Black flue system e Clean out hatch The fan box is supplied with a neoprene gasket for connection to the boiler This neoprene gasket is to accommodate the low temperature wet flue system of the Grant SPIRA boilers Refer to Section 4 15 for fitting details The lead for the flue fan Supplied factory fitted to the fan box is connected to the same 5 way plug as the lead for the wash system solenoid valve Refer to Section 4 15 for connection details When fitting the flue system to the flue starter connection on the fan box the lip seal supplied with the flue component must be fitted to the inner flue liner and the locking band fitted to secure the joint When installed the draught stabiliser must not be boxed in or obstructed from operation in any way The clean out hatch allows access to the inside of the fan box for inspection and where necessary removal of any ash that may have dropped down inside the flue system The clean out hatch MUST
68. asing panel from the boiler The test point should be at the back left corner of the rear cleaning door If it is located at the front right corner of the cleaning door then remove the door and refit it with the test point in the correct position Auger TIME TIME angle LOAD PAUSE MAX 6 26 2 5sec 2 5sec 89 735 92 500 0 04 0 06 14 0sec 22109 9 36 6 5sec 2 5 sec 122 832 132 000 0 04 0 06 25sec uu 1 Heat input is based on a calorific value of 4 81 kWh kg 2 Heat input and output data given above is approximate only die E Eff kg hr in wg PAUSE n Boiler and Hopper Weights Spira Model Model Number Units 6 26 9 36 Weight boiler less burner and fan box empty kg 201 291 Weight burner kg 25 5 2 9 Weight fan box kg 5 Total weight of boiler empty kg 231 5 261 5 Total weight of boiler full kg 283 321 5 Weight 110kg pellet hopper empty incl auger kg 459 41 35 Weight 110kg pellet hopper full incl auger kg 19165 5 35 Weight 200kg pellet hopper empty incl auger kg Tt T Weight 200kg pellet hopper full incl auger kg PANATA 27 Weight of auger kg 8 35 8 35 Weight 140kg double pellet hopper empty kg 42 42 incl 2 augers Weight 140kg double pellet hopper full kg 82 182 incl 2 augers NOTE CAUTION Use only a calibrated flue gas Do not sample the flue gases analyser with a Wood Pellet fuel thr
69. ates using brush and vacuum e Clean and check condition of all spiral baffles e Re fit spiral baffles into heat exchanger tubes fitting them through shaker plates e Lift and drop each spiral to check that all spirals are free to move in their respective tubes Secondary heat exchanger clean as follows e Shut off cold water supply to wash system manifold e Remove the securing clip from the end of the solenoid valve shaft Then separate solenoid head from valve body e Unscrew the two screws securing the manifold pipe flange to the boiler side panel e Carefully remove the wash system manifold pipe through the side of the secondary heat exchanger and boiler e Check and clean the manifold tube thoroughly ensuring that all the jets are clear Rinse inside of manifold pipe to ensure all ash deposits and other debris is removed e Remove all of the stainless steel spirals from the secondary heat exchanger tubes e Clean down any ash inside tubes using a suitable pipe brush into the base of the condensing heat exchanger below e Clean all ash deposits from top chamber of secondary heat exchanger above tubes and from rear flue gas duct at rear of secondary heat exchanger using brush and vacuum e Clean and check condition of all spiral baffles Replace if necessary e Re fit baffles into heat exchanger tubes such that all the top edges of the baffles are running front to back Refer
70. augers pellet hopper or bulk pellet store e Problems due to the flue system being incorrectly fitted or not installed to meet installation requirements e Boiler servicing de scaling or flushing e Cleaning condensate traps pipework or thawing frozen condensate pipework e Electrival cables and plugs heating System controls not supplied by Grant UK e Heating system components such as radiators pipes fittings pumps and valves not supplied by Grant UK e Consumable items including but not limited to gaskets seals etc Remember before you contact Grant Ensure the boiler has been commissioned and serviced by a competent persion in accordance with the Installation and servicing manual Ensure there is an adequate quantity of the approved type of pellets in the hopper and bulk store if fitted to supply the burner Ensure the problem is not being caused by the heating system or its controls Consult the User Instructions supplied with the boiler for guidance NOTE Do not wait until your wood pellet supply runs out before you order some more Dust in the bottom of the pellet store or hopper may prevent the supply of pellets to the burner It is important that this is checked for and if dust is present removed on an annual service to prevent nuisance stoppage of the boiler Terms of Manufacturer s Guarantee 1 The Company shall mean Grant Engineering UK Limited 2 The boiler is guaran
71. aught stabiliser damper on the fan box is unobstructed and free to move Ensure that the damper locking lever is in the unlocked position Refer to Figure 10 1 stopper Figure 10 1 Draught stabiliser e he flue system conforms to the relevant requirements of The Building Regulations Approved Document J for solid fuel appliances 9 2 6 Combustion Ventilation Check that the combustion air supply conforms to the relevant requirements of The Building Regulations Approved Document J for solid fuel appliances with a draught stabiliser Refer to Section 7 1 10 3 Boiler 10 3 1 Control Panel Isolate the electrical power to the hopper and boiler Unscrew and remove the six self tapping screws securing the boiler control panel cover and lift the cover off the control panel Check the following e hat both the overheat thermostat probe and thermistor bulb are fully inserted in the boiler waterway pocket and the retaining clip is fitted Refer to Figure 10 2 e he condition of thermistor cable and thermostat capillary i e not damaged broken or kinked Refit the control panel cover and secure with the six screws previously removed Figure 10 2 Boiler control panel cover removed 10 3 2 Combustion Chamber Open front access cleaning door and check e he ash pan is empty and correctly positioned on the base of the combustion chamber e The baffle in the top of the combustion chamb
72. away from the boiler of at least 2 5 45mm fall per metre run NOTE Where it is not possible for the pipe to fall towards the point of discharge either internally into a waste system or externally to a gulley e g for boilers installed in a basement it will be necessary to use a condensate pump When using a condensate pump with a Grant SPIRA boiler a condensate holding tank of at least 40 litres is required This is to ensure that when the boiler cleaning cycle has operated the holding tank can collect the total volume of the water used in the wash down and the condensate pump can then discharge the waste water effectively A boiler interlock should be fitted to shut off the boiler in the event of a malfunction of the condensate pump WARNING When using condensate pump and holding tank the burner settings for TIME CLEAN PERIOD time boiler cleaning is in operation must not be set greater than 600 60 seconds and the TIME CLEAN BOILER time between boiler cleaning operations must not be set less than 180 minutes as modifying these times could result in larger and more frequent wash down of the boiler which could exceed the capabilities of the tank and condensate pump Refer to Section 8 for further details of the burner settings 5 4 External Pipework Ideally external pipework or pipework in unheated areas should be avoided If unavoidable external pipework should be kept as
73. ay 5 6 Condensate Trap Grant SPIRA condensing boilers are supplied with condensate trap This trap must be used No alternative trap should be used in place of the trap supplied with the boiler The 114 BSP female condensate outlet connection is located at the rear of the boiler Fit the 174 311 fitting supplied into this connection Using the elbow and pipe supplied connect the trap to the condensate outlet on the boiler as shown in Figure 5 2 A condensate discharge pipe with a minimum diameter of 38mm 172 must be fitted to the outlet connection at the base of the trap In all cases the overflow pipe see Figure 5 2 must be fitted to the trap and the end left open This will protect the boiler from becoming blocked with condensate in the event of the condensate discharge pipe blocking or frozen 4h CAUTION All condensate pipework must be adequately protected against freezing however if the condensate pipe is frozen water will build up and discharge through the overflow on the trap If connecting the condensate discharge into a waste system or soil stack either internally or externally a second trap must be fitted in the condensate discharge pipe This trap must provide the required 75mm water seal It must be located between the boiler condense trap and the connection to the soil stack in a position accessible for checking and cleaning 5 7 Inspection and Cleaning of Trap The boiler co
74. be correctly fitted during normal boiler operation See Section 10 Servicing A condensate drain at the base of the flue is not required as the flue system is designed to allow the condensate to run back into the boiler 7 3 2 Flue System The Grant Black flue system is a fully insulated stainless steel twin wall flue finished with a Black Polyester Powder paint finish This insulated flue system reduces the possibility of the condensate freezing in the flue and also has a high corrosion resistance suitable for solid fuel The 125mm 5in Black twin wall flue system is suitable for BOTH the SPIRA 6 26 amp 9 36 models Masonry chimneys MUST be lined using the 125mm stainless steel flexible smoothbore liner available as part of the Black system due to the condensate produced from the boiler NOTE The Grant BLACK flue system is the ONLY flue system suitable for use with the Grant SPIRA Wood pellet boilers The use of other flue systems will invalidate the product warranty on the boiler 6 3 3 Joining Components All the Black system twin wall flue components with the exception of the elbows use a twist lock jointing system Male collar Stainless steel outer case Insulation Stainless steel inner liner Female collar Capillary break Figure 7 2 Male and female flue connections The male collar end of the flue component MUST always be uppermost whe
75. ble check shut off valve connecting it to the water supply is closed A valve is open when the operating lever is in line with the valve and closed when it is at right angles to it 3 Open the fill point valve 4 Gradually open the double check valve from the water supply until water is heard to flow 5 When the needle of the pressure gauge is between 0 5 and 1 0 bar close the valve 6 Vent each radiator in turn starting with the lowest one in the system to remove air 7 Continue to fill the system until the pressure gauge indicates between 0 5 and 1 0 bar Close the fill point valve The system fill pressure cold should be 0 2 0 3 bar greater than the vessel charge pressure giving typical system fill pressures of approx 0 5 bar for a bungalow and 1 0 bar for a two storey house Refer to the Domestic Heating Design Guide for further information if required 8 Hepeat steps 5 and 6 as required until system is full of water at the correct pressure and vented 9 Water may be released from the system by manually operating the safety valve until the system design pressure is obtained 10 Close the fill point and double check valves either side of the filling loop and disconnect the loop 11 Check the system for water soundness rectifying where necessary 6 3 Venting the Pump It is important that the pump is properly vented to avoid an air lock and also prevent it running dry and damaging the be
76. content reduces the calorific value of the pellet and requires the appliance to be cleaned more frequently To provide a predictable flow of fuel into the burner the recommended length of a pellet is deemed greater than 5mm and less than 5 times the diameter Bulk density is the ratio between the weight of the pellet and the amount of space they take up A good quality pellet will have a density of 650 kg m High levels of chlorine in the flue gases emissions can give rise to corrosion The most common diameter is 6mm with some 8mm also available This boiler is designed for 6mm only Pellets are made from compressed wood As pellets rub together they can break down slightly producing dust or fines Too many fines indicate a poor quality pellet and can impede pellet flow in addition to causing dust problems when delivering and storing the pellets This is a measure of how stable the pellet is and how likely it is to produce fines from normal handling A high durability percentage is an indicator of a good quality pellet Moisture affects the calorific value of the pellet Low moisture content guarantees constant and predictable combustion efficiency Higher moisture contents can result in pellet breakdown This is the useful energy contained in a kilogram of fuel This value is affected by the amount of non combustible materials ash and the moisture content of the pellet Typical values range from 4 8 KWh kg to 5 2 KWh kg High levels o
77. control panel Refer to Section 10 3 1 Ensure that both thermistor and thermostat sensor are held in place with the retaining clip supplied gt Primary Fault Secondary follow on checks Note 3 Is thermistor connected to burner PCB With electrical supply to boiler still isolated remove both the burner cover and PCB cover Check the thermistor connections to the PCB from terminals S3 and B4 on plug socket No 2 Refer to Section 8 and Figure 8 6 If fault still exists replace thermistor 12 9 Air Pressure Error gt Primary Fault CARO Secondary follow on checks Reset error Restart the the burner fan Nag Is the fan Is air by pressing the boiler does the operational RESET button fault occur during on burner control the lighting panel sequence Check plug connections between the burner fan amp control PCB Note 1 Does fault occur during lighting sequence During the PRE LOAD operation the burner controls check that burner fan is generating enough air pressure to close the air pressure switch If the pressure switch is not closed during pre load then the warning AIR PRESSURE ERROR is displayed on the burner screen Note 2 Is the burner fan operational During the PELLET BURNER FIRING operation the burner controls checks AIR SUPPLY E TORE SWITCH N Pa z fi A Figure 12 6 Air pressure switch amp f
78. d Button No 4 Normal mode Reset fault Menu mode Scroll back D Button No 5 Menu mode Decrease parameter value D Button No 6 Menu mode Increase parameter value K 9 6 Burner Menu Navigation Chart and Factory Default Settings Set Point Range 55 75 BURNER CONTROL BUTTON CP CODE EB mui oo INSTAL TEMP DELTA 5 H20 MANUFACT i EN TEMP OFF H20 80 o IG DELTA RESTART 5 menu 2 4 3 power TE ive con PELLET a oc EN TIME PAUSE 2 5 cB 6 26 14 mi 0 20 a e TIME PAUSE MIN 9 36 25 sg menu 3 4 gt INSTAL TIME CLEAN BRAZ 180 crie TIME CLEAN BOILER 180 117 TIME CLEAN PERIOD 60 118 c a PB FLASH CLEANING 1 500 TO STEP BACK cB menu 4 4 lt sep POM emma Ta FAN 36 POWER MINIMUM 8128 21 c POWER LIGHTING 20 ved POWER TEST 100 LOAD DEFAULT lt 3 TO RE LAOD MEnu NOT APPLICABLE FACTORY INSTAL SETTING MANUFACT 9 UE gt nu MANUFACT VIEW cb STEP AUTOMA VIEW CLE BRAZ VIEW CLE BOIL gt lt amp CES 9 Burner 9 7 Burner Menu 9 7 1 INSTAL menu folder INSTAL represents the Installer folder It enables the installer access relevant parameters for adjustment during the installation commissioning of the Using the main menu flow chart shown in Section 9 6 navigate the menus using the buttons as described in Section 9 5 Each of the fou
79. der the terms of their warranty providing that the boiler has been correctly installed commissioned and serviced if the appliance has been installed for more than twelve months by a competent person and the fault is not due to tampering running out of fuel the use of unapproved wood pellets contamination system water contamination misuse or the failure of any external components not supplied by Grant UK e g motorised valve etc This extended two year warranty only applies if the boiler is registered with Grant UK within thirty days of installation In the first Instance Contact your installer or commissioning engineer to ensure that the fault does not lie with the system or any other components or any incorrect setting of the system controls that falls outside the manufacturer s warranty otherwise a service charge could result If a fault covered by the manufacturer s warranty is found Ask your installer to contact Grant Engineering UK Ltd Service Department on 01380 736920 who will arrange for a qualified service engineer to attend to the fault Free of Charge Repairs During the first two years no charge for parts or labour will be made provided that the boiler has been installed and commissioned correctly in accordance with the manufacturer s instructions it was registered with Grant UK within thirty days of installation and for boilers over twelve months old details of annual maintenance is availabl
80. e The following documents must be made available to Grant UK on request e Proof of purchase e Grant Commissioning report form e Service documents Chargeable Repairs A charge may be made if necessary following testing of parts at Grant UK if the cause of the breakdown is due to any faults caused by the plumbing or heating system e g contamination of parts due to system contamination sludge scale debris or trapped air See Extent of Manufacturer s Warranty below Extent of Manufacturer s Warranty The Manufacturer s Warranty does not cover the following e fthe boiler has been installed over two years e f the boiler has not been commissioned or serviced by a competent person in accordance with the installation and servicing manual e Faults due to tampering unauthorised adjustment neglect misuse or operating the boiler contrary to the manufacturer s User Instructions e Damage due to external causes such as bad weather conditions flood storms lightening frost snow ice fire explosion accident or theft e Faults due to incorrectly sized expansion vessel s or incorrect vessel charge pressure e Faults caused by external electrics and external components e Problems caused by lack of pellets the use of unapproved pellets or faults with the pellet storage and supply system if not supplied by Grant Uk e Removing any pellet store or hopper contamination or blockages in the pellet
81. e expansion vessel is connected via a flexible hose care must be taken to ensure that the hose is not twisted The pressure gauge must have an operating range of to 4 bar It must be located in an accessible place next to the filling loop for the system Safety Valve The safety valve provided with the boiler is set to operate at 2 5bar It should be fitted in the flow pipework near to the boiler The pipework between the safety valve and boiler must be unrestricted i e no valves The safety valve should be connected to a discharge pipe which will allow the discharge to be seen but cannot cause injury to persons or property Figure 6 1 Sealed heating system components Figure 6 2 Heating system Pressure Gauge Filling Loop Provision should be made to replace water lost from the system This can be done manually where allowed by the local water undertaking using an approved filling loop arrangement incorporating a double check valve assembly The filling loop must be isolated and disconnected after filling the system Heating System The maximum temperature of the central heating water is 75 C Refer to Section 1 1 An automatic air vent should be fitted to the highest point of the system If thermostatic radiator valves are fitted to all radiators a system by pass must be fitted The by pass must be an automatic type All fittings used in the system must be able to withstand pressures up to 3 b
82. e Disconnect the three plugs from the left side of the burner Refer to Figure 11 9 Figure 11 10 Burner plugs e Remove the steel clip from the burn back thermostat on the pellet feed pipe and disconnect the lead from the thermostat terminals e Remove the red burner cover by loosening the four M5 screws two each side of the cover and lifting it off the burner e Whilst supporting the burner unscrew and remove the two M8 burner securing nuts one on each side of the burner Refer to Figure 11 10 Figure 11 11 Burner fixing nuts e Carefully withdraw the burner from the combustion chamber door taking care not to damage the burner door gasket e the burner on a suitable bench e g portable workmate type bench or similar to work on 11 7 2 Cleaning Burner Brazier Dismantle and clean the burner as follows e Remove the burner hood by loosening the two M5 bolts highlighted below each side of the brazier Slide the forwards and then up to disengage the hood from the burner Refer to Figure 11 11 Figure 11 12 Removal of burner hood e Clean and inspect the hood for any damage or distortion Replace if necessary Remove all ash deposits and check that all air holes on the inside surface of the hood are clear NOTE After a period of time in use the semi circular end wall of the brazier hood may distort or show minor cracks This does not affect the operation of the burner The ho
83. e damper or add extra weights if necessary see right e decrease draught move the weight closer to the damper Refer to Figure 10 13 Figure 10 13 Draught stabiliser arm If it is necessary to increase the draught but the weight fitted is already at the end of the damper arm extra slotted disc weights supplied with the boiler can be used These weights are fitted on the flue end of the damper arm as follows e Slacken the grub screw and slide the fitted weight along the arm towards the damper e Fit one of the slotted weights onto the arm e Secure by inserting a flat bladed screwdriver into the slot and twisting it Refer to Figure 10 14 e Slide both the weights to the end of the shaft and secure by tightening the grub screw in the fitted weight Refer to Figure 10 15 Hepeat this process as necessary to achieve the required draught Figure 10 14 Fitting slotted disc weight Figure 10 15 Draught stabiliser weights 10 9 3 Fan Box SliderPlate If the combustion chamber draught is too high and adjustment of the draught stabiliser alone cannot bring it within the required range of 0 1 to 0 15mbar 0 04 and 0 06 in wg it may be necessary to adjust the setting of the fan box slider plate This is located within the fan box and is supplied set fully closed Opening this slider plate allows some of the flue gases to by pass the flue fan and reduces the combustion chamber d
84. e greater the input alternatively the smaller the load time the lower the input see table Section 2 2 1 Units 000 0 seconds Default setting 6 26 25 2 5 seconds Default setting 9 36 65 6 5 seconds b TIME PAUSE MAX Time between pellet feed auger operations when the burner is in max flame mode Adjusting this time adjusts the boiler input in max flame i e the larger the pause time the lower the input alternatively the smaller the pause time the higher the input see table Section 2 2 1 Units 000 0 seconds Default setting 6 26 amp 9 36 0025 2 5 seconds c TIME PAUSE MIN Time between pellet feed auger operations in min flame Adjusting this time adjusts the boiler input in min flame i e the larger the pause time the lower the input alternatively the smaller the pause time the higher the input see table Section 2 2 1 Units 000 0 seconds Default setting 6 26 140 14 0 seconds Default setting 9 36 250 25 seconds NOTE Adjusting this setting will also result in the input during the modulation period being adjusted as the modulation input is automatically calculated on the max min amp load pause settings 9 7 1 3 menu 3 4 CLEAN The parameters stored within this folder are a TIME CLEAN BRAZ Total pellet feed auger run time before burner brazier cleaning operation activates If the burner shuts down immediately or waits for the next shut down is deter
85. ear 1 BSP connection Fit the air vent assembly into the 72 connection on the rear of the boiler this is to vent the secondary unit only the flow pipe from the boiler must be vented Condensate Connection The1 4 BSP female condensate outlet connection is located at the rear of the boiler Refer to Section 5 for details on condensate connection and disposal pipework 4 9 Wash System Manifold The boiler is supplied with a cleaning manifold system to wash the condensing unit of any ash build up in the tubes NOTE A minimum running dynamic pressure of 0 8 to 1 0 bar pressure as shown on the gauge when the system is operating is required to maintain an adequate supply for cleaning purposes The wash system manifold pipe is factory fitted through the right hand side of the boiler This manifold pipe can be fitted in either one of two different positions depending on the location of the pellet hopper as follows With hopper located on the left side of the boiler the wash system manifold if fitted from the right hand side of the boiler through the holes provided in the right hand side panel of the boiler and both sides of the heat exchanger chamber With hopper located on the right side of the boiler the wash system manifold if fitted from the left hand side of the boiler A semi pierced hole provided in the left hand side panel of the boiler must be pushed out to allow the manifold to be fitted
86. een the different pellet brands and this will affect the frequency of cleaning and maintenance required Pus Q O gt Pu Q i La 2 lechnical Data 2 1 Boiler amp Hopper Technical Data Model Number Maximum heat Output Flow connection Return connection Water content Waterside resistance AT 10 C Waterside resistance AT 20 C Mains water cleaning system Condensate connection Conventional flue Combustion chamber draught requirement Maximum static head Minimum circulating head Boiler temperature set point range Boiler temperature cut out point Minimum return temperature Water system overheat cut out temp Burn back overheat thermostat cut out Electricity supply Max operating pressure sealed system Max operating pressure open system Maximum auger length bulk hopper Maximum auger speed bulk hopper Minimum flue length Maximum flue length Heating element rating Intermediate auger motor power Intermediate auger motor starting current Intermediate auger motor running current Intermediate auger speed Flue fan motor power Flue fan motor starting current Flue fan motor running current Cleaning solenoid power Cleaning solenoid current Burner fan motor power Total burner start current Total burner run current Units kW Btu hr Litres mbar mbar bar bar bar metres rom m m Watts Watts Amps Amps rom Wa
87. ellet Hopper Auger Pellets Safety Device Checks Burn back thermostat Combustion chamber door switch Priming Pellet Feed Auger Lighting the Boiler Combustion Chamber Draught Flue Gas Analysis Customer Handover 000o D D Commissioning Report Form 11 Boiler Servicing 11 1 General It is essential that the Grant Spira boiler is serviced at regular intervals of no longer than 12 months OR when the SERVICE is shown on the burner control panel display The burner will automatically indicate SERVICE on the burner control panel display once the pre set period of pellet feed auger run time HOURS SERVICE is achieved Refer to Section 9 7 for details on how to access and check this setting in the INSTAL CLEAN sub menu of the burner settings This interval is based on the auger running time i e the actual quantity of pellets used based on the pellet feed auger rate and pellet delivery settings Refer to Section 9 7 for details on how to access and check this setting in the POWER PELLET sub menu of the burner settings The ash pan located inside the combustion chamber will need to be periodically emptied This simple task must be carried out by the user at MONTHLY intervals for the FIRST THREE MONTHS Thereafter the ash pan should be emptied regularly on at least a monthly basis or as indicated by the amount of ash found during the first three months Two carryin
88. ent mounting plate and remove it from the brazier chassis e From below the burner unscrew and remove the single cap screw attaching the push rod of the moveable brazier base to the shaft of the servo motor e Disengage the push rod from the motor shaft and remove brazier base assembly from the brazier chassis Inspect all components for distortion or damage and replace if necessary Clean all ash and clinker deposits from all surfaces in particular the upper surface of the brazier chassis and the underside of the brazier base assembly using wire bush and where necessary a flat scraper Ensure that all air holes are clear Reassemble the brazier using the following procedure e Fit the moveable brazier base assembly to the burner and reconnect the pushrod to the motor shaft using the cap screw e Whilst operating the servo motor release switch push the brazier base assembly fully back into the brazier chassis e Insert the brazier clearance gauge plate Supplied with the boiler between the brazier chassis and brazier base assembly Refer to Figure 11 13 e The clearance gauge should slide in using manual force only DO NOT FORCE THE GAUGE INTO THE BRAZIER e Heassemble the remainder of the brazier using the reverse of the dismantling procedure e Leave all screws loose until all components excluding the burner hood are assembled correctly e BEFORE fitting the burner hood tighten the two
89. er is correctly located on the fixing brackets at both sides Refer to Figure 10 3 Close the front access cleaning door and ensure that door catch is fully engaged to activate door cut out switch D T LL D 9 T OD 48 10 Commissioning Figure 10 3 Combustion chamber baffle 10 3 3 Heat Exchangers To gain access to the top of both heat exchangers e Remove the boiler top casing panel e Unscrew and remove the two nuts securing the front access panel and remove it from the primary heat exchanger e Unscrew and remove the two nuts securing the rear access cover and remove it from the secondary condensing heat exchanger Check that the spiral baffles in the primary heat exchanger are all in place Lift and drop each one to check all are free to move in their respective tubes Check that the spiral baffles in the secondary heat exchanger are all in place and are all aligned with the top edges running front to back Test the automatic cleaning functions as follows e Set the ON STANDBY switch to STANDBY e Switch on the electrical supply to the hopper and boiler The burner fan should briefly run e Press and hold down the CLEANING switch on the boiler control panel in the TEST position e Release switch to automatically reset cleaning function back to AUTO e Note that setting this switch to TES
90. erted in the socket at the top right rear of the boiler Refer to Figure 8 2 e The two 7 way plugs from the boiler control panel are fully inserted into the corresponding two lower connections on the left side of the burner Refer to Figure 8 4 e The 6 way plug from the pellet auger is fully inserted into the upper connection on the left side of the burner Refer to Figure 8 4 On double boiler installations repeat the process for the second boiler 10 2 3 Washdown System Check the following e The washdown system manifold pipe is correctly fitted into either the right or left side of the boiler as required to suit the type of hopper used e The solenoid valve head is correctly fitted and secured in position with the steel clip provided with the boiler e The solenoid valve is connected to an uninterrupted mains water supply via the flexible hose and valve with integral check valve provided with the boiler e All valves in this water supply are open On double boiler installations repeat the process for the second boiler 10 2 4 Condensate Disposal System Check the following e The condensate trap Supplied with the boiler and condensate disposal pipework has been fitted correctly Refer to Section 5 e condensate pump is fitted that a condensate holding tank of at least 40 litres capacity has also been installed Refer to Section 5 10 2 5 Flue System Check the following e The dr
91. es given in BS 7593 1992 for long term protection against corrosion and scale Grant UK strongly recommend that a magnetic in line filter is fitted in the heating system pipework A magnetic in line filter must be fitted in the heating system pipework This should be installed and serviced in accordance with the filter manufacturer s instructions 4 14 Completion Please ensure that the Grant SPIRA Commissioning form supplied with the boiler is completed in full and that it is signed by the householder user Leave the White copy with the user retain the Pink copy for your own records and return the Yellow copy to Grant UK to register the installation of the boiler Ensure that the User Information pack supplied with the boiler is handed over to the householder along with this Installation and Servicing manual pum O SO o E gt Information Par O o Qo o O Disposal 5 Condensate Disposal 5 1 General Requirements When in condensing mode the Grant SPIRA condensing wood pellet boilers produce condensate from the water vapour in the flue gases This condensate is slightly acidic with a ph value of around 6 Provision must be made for the safe and effective disposal of this condensate Condensate can be disposed using one of the following methods a Into a soil stack either directly or via an existing waste system b I
92. et feed auger is a hollow spiral type Its function is to deliver the pellets from the hopper to the burner The output of the boiler is determined by varying the on off periods of the pellet feed auger motor Refer to Section 2 2 for pellet feed data 1 5 Boiler Cleaning and Servicing Grant SPIRA condensing wood pellet boilers are equipped with an automatic cleaning system for each of the two heat exchangers and also for the burner brazier CAUTION The ash pan located inside the combustion chamber will need to be periodically emptied This simple task must be carried out by the user at MONTHLY intervals for the FIRST THREE MONTHS Thereafter the ash pan should be emptied regularly on at least a monthly basis or as indicated by the amount of ash found during the first three months Two carrying handles are supplied with the boiler to allow removal of the ash pan when hot WARNING Care must be taken to avoid contact with hot surfaces Always wait for the boiler to cool down before opening the combustion chamber door and removing the ash pan The boiler MUST be serviced either ANNUALLY or when a service is indicated on the burner control panel display whichever comes first Servicing should only be carried out by a Grant Approved Installer and details of each service should be recorded in the Service Log in the back of the User Operating Manual NOTE The amount of ash produced varies betw
93. f nitrogen in the flue gases emissions can give rise to corrosion High levels of sulphur in the flue gases emissions can give rise to corrosion Storage amp Delivery O Q dp o Q c O pu O i9 Q Q dp o Q Storage amp Delivery 3 Pellet Specification Storage amp Delivery 3 2 Pellet Storage 3 2 1 Pellet Hoppers amp Pellet Feed Auger All Grant SPIRA boilers are supplied with a pellet hopper Refer to Section 1 4 4 for further details of the hoppers All Grant hoppers are supplied with either one or on a double boiler hopper two 1 2 m pellet feed augers to deliver the pellets from the hopper to the boiler Refer to Section 1 4 5 The pellet hopper along with the boiler or boilers it is supplying MUST be installed in a dry indoor environment free from dampness The hopper and boiler s must be located on the same floor level If a bulk hopper is to be used there are two methods of transferring the pellets from the bulk store to the intermediate hopper a Via a bulk pellet feed auger b Via the Grant SPIRA VAC vacuum pellet feed system boiler pellet hoppers are supplied to accept either of these two pellet supply systems as required Refer to Section 1 4 4 for further details on the hoppers The electrical connections to the boiler s are all made to the 4 way electrical plug on one of the three
94. g 9 36 26 c POWER LIGHTING Burner fan speed setting when burner in lighting mode Default setting 6 26 amp 9 36 20 d POWER TEST Used to simulate the burner fan speed for test purposes only Once the POWER TEST is cancelled from the screen the burner fan reverts to its required operational speed e LOAD DEFAULT Load factory default settings Press button 3 to activate factory default settings 9 7 2 MANUFACT Menu Folder 2 MEnu INSTAL MANUFACT MANUFACT displays the manufacturer folder it enables the manufacturer set parameters required for an individual boiler This folder should not be accessed or modified in anyway 9 Burner 9 7 3 VIEW Menu Folder 3 MENU MANUFACT VIEW VIEW folder displays the function or status of the boiler To access the menu displays within the 9 7 4 USER Menu Folder USER folder allows the user change the language on the burner display To access the menu displays within the VIEW folder from the main burner display navigate as follows USER folder from the main burner display navigate as follows 1 PG MEnu INSTAL MANUFACT cB 2 MEnu INSTAL Enu MANUFACT INSTAL MANUFACT lt 3 MEnu MANUFACT VIEW lt G ca TO STEP TO STEP BACK ERA Men gt 3 Bi 4 Ss LANGUAGE 4 USER cB ENGLISH To Accept To Increase To decrease Parameter E 3 us A P
95. g handles are supplied with the boiler to allow removal of the ash pan when hot Servicing and replacement of parts must only be carried out by a Grant Approved installer who has successfully completed the Grant Spira wood pellet boiler training course NOTE Details of every service should be entered in the Service log at the front of this manual WARNING Before starting any work on the boiler or on the pellet storage and supply installation please read the health and safety information in Section 15 11 2 Checks Before Servicing BEFORE starting any service work on the boiler or pellet storage supply installation e Set the ON STANDBY switch on the boiler control panel to STANDBY If the boiler was operating wait for it to shut down and WAIT BOILER THERMOSTAT is shown on the burner control panel display before proceeding further e solate the electrical supply to the hopper and boiler and remove the 5A fuse from the fused spur e Disconnect the 5 way plug on the lead from the hopper from the Socket at the left rear of the boiler Refer to Figure 11 1 e double boiler installation remove the 5 way plug from both boilers e Disconnect the 5 way plug on the lead from the flue fan and solenoid from the socket at the right rear of the boiler Refer to Figure 11 2 This will allow the hopper to be moved to give easy access to the rear of the boiler for servicing Figure 11 1
96. g water directly into each flue gas tube of the unit Refer to Figure 11 4 If the water jets are not spraying directly into the flue gas tubes adjust the spray as follows e Slacken the two screws securing the manifold pipe flange to the boiler side panel e Carefully rotate the pipe until jets spray directly into tubes e Tighten the two screws to secure manifold pipe in this position Inspect the condition of the two access panels before re fitting Replace any damaged or worn rope seal or gaskets if necessary Hefit both front and rear access panels and secure with the nuts previously removed Do not overtighten Ensure that the rear access panel is fitted with the flue gas sample point in the rear left hand corner gt gt Mm gt co S gt Mm E CO 11 Boiler Servicing 11 6 3 Combustion Chamber WARNING Ensure the electrical supply to the hopper and boiler is isolated by disconnecting the 4 way plug from the socket on the flying lead at the rear of the hopper before proceeding Disconnect the pellet delivery hose from the burner pellet feed tube Then fully open the combustion chamber door on the front of the boiler and clean as follows e Before moving the combustion chamber baffle located in the top of the combustion chamber remove all ash deposits from the upper surface using a vacuum Refer to
97. ghlighted next to the boiler thermostat symbol Refer to Figure 12 4 Figure 12 4 Burner screen display Note 2 Is the boiler above DELTA RESTART temperature If the boiler has exceeded the TEMP OF H20 setting 80 the boiler will shut down The boiler temperature will have to fall to below the DELTA RESTART value 5 C below the boiler set point temperature before it can start again Refer to Section 9 1 boiler and rectify as necessary Note 3 Is there a sufficient quantity of pellets in the pellet hopper The effect of insufficient pellets will depend on the type of pellet storage used as follows Using a pellet hopper only if there are insufficient pellets the hopper contents switch will break the switched live to the boiler causing WAIT BOILER THERMOSTAT to be displayed Refill the hopper to start the boiler Refer to Section 1 4 4 for further details Using a bulk pellet store the hopper contents switch will control the operation of either the bulk store auger of Grant Spira vac system It will NOT interrupt the switched live to the boiler and thus WAIT BOILER THERMOSTAT will NOT be displayed The boiler would continue to operate until ALL pellets in the hopper are used and then stop with FAILED PELLET LIGHTING displayed on the burner control screen In this case check that e there are pellets in the bulk store e the bulk store auger or Grant Spira
98. he combustion chamber door e Operate the door catch and open the door e he burner display screen should automatically go blank as all power to the burner has been interrupted To restart the display close the door and fully engage the door catch to re make the cut out switch Refer to Figure 10 8 Closing the door will reconnect the power supply to the burner and the display will return confirming that the door interlock is operating correctly Figure 10 8 Combustion door catch WARNING The interlock on the combustion chamber door Interrupts the power supply to the burner if the door is opened IT DOES NOT IMMEDIATELY EXTINGUISH THE BURNER FLAME If the burner door is opened whilst the burner is firing there can still be a large uncontrolled flame from the brazier 10 6 Burner Settings The boiler comes with the burner pre set from the factory However the burner settings should be checked as part of the commissioning process and recorded on the Commissioning Report form Refer to Section 10 12 With the electrical power to the hopper and boiler Switched on and the burner ON STANDBY switch set to STANDBY check that ALL burner settings in the INSTAL Installer menu are as given in Section 9 6 Refer to Section 9 7 for details of how to access and check these settings Set the boiler temperature set point using buttons 1 or 2 on the burner control panel Refer to Section 1 1 for required flo
99. he feed and pause time of the pellet feed auger supplying pellets to the burner See Section 8 for details of burner operation The boiler is suitable for use on a sealed or open vented central heating system When commissioned and set correctly Grant SPIRA condensing wood pellet boilers will operate automatically using a typical heating control system All models are supplied with the control panel and burner factory fitted The combined fan box amp flue starter pellet feed auger and hopper are supplied separately and are fitted by the installer See Section 4 for boiler installation 1 3 Boiler Models The Grant SPIRA condensing wood pellet boiler is available in eleven different models Product The boiler needs to be connected a conventional flue system There is no provision for connection to a balanced flue system as there is draft stabilizer fitted to the appliance The boiler is not designed specifically for operation on a system with a buffer tank thermal store however when used on such a system there is no effect on the boiler performance 1 NOTE The only flue suitable for use with the Grant SPIRA condensing wood pellet boiler is the Grant Black twin wall insulated conventional flue system This 125mm 5 diameter black powder coated stainless steel flue system is suitable for both 6 26kW and 9 36kW Spira models For the 52kW 62kW and 72kW double boiler installations
100. iances with a draught stabiliser Refer to Section 6 1 Check that all ventilation openings are free from any obstructions both inside and outside If necessary remove any blockages e g fluff dog hair leaves etc 11 6 Boiler 11 6 1 Contro Panel WARNING Ensure the electrical supply to the hopper and boiler is isolated by disconnecting the 4 way plug from the socket on the flying lead at the rear of the hopper Unscrew and remove the six self tapping screws securing the boiler control panel cover and lift the cover off the control panel Proceed as follows e Check both the overheat thermostat probe and thermistor bulb are fully inserted in the boiler waterway pocket and the retaining clip is fitted Refer to Figure 11 6 e Check the condition of thermistor cable and thermostat capillary i e not damaged broken or kinked e Grease the edge of the shaker motor cam with high temperature grease Refer to Figure 11 7 Refit the control panel cover and secure with the six screws previously removed Figure 11 6 Boiler control panel cover removed Figure 11 7 Shaker motor cam location 11 6 2 Heat exchangers To gain access to the top of both heat exchangers Refer to Figure 11 7 e Remove the boiler top casing panel e Unscrew and remove the two nuts securing the front access panel and remove it from the top of the primary heat exchanger e Unscrew and remove the two nuts securing
101. if there is an inspection hatch between the second and third elbows An Inspection Pipe incorporating an inspection hatch Grant ref WP IP is available as part of the Grant Black flue system Any Inspection hatch must be accessible for checking and cleaning purposes WARNING Failure to maintain a clean flue can result in the emission of flue gases into the dwelling or damage from fire in the flue See Section 11 4 Cleaning the Boiler amp Flue WARNING No horizontal section or no bend greater than 45 should be used as these can cause a build up of ash and condensate in the flue 7 3 7 Wall Sleeves In accordance with the Building Regulations Approved Document J a wall sleeve should be used where the flue system passes through a wall A suitable wall sleeve is available as part of the Grant Black flue system This 45 angled wall sleeve gives a 60mm clearance all round from the outer surface of the flue passing through it The sleeve is 45 mitred at one end The other end of the sleeve should be cut on site to the correct length to leave it flush with the wall on both sides The gap between the sleeve and flue should be adequately weatherproofed using a good quality mastic and fibre rope 7 4 Flue Notice Plate The Building Regulations Approved Document J requires a notice plate that conveys essential information regarding the flue installed to be permanently displayed A suitable self
102. ing commissioning procedure is carried out following installation to ensure safe and efficient operation of the boiler For double boiler installations this procedure must be carried out in full on both boilers 10 1 Equipment Required To carry out a complete and comprehensive commissioning of the Grant Spira wood pellet boiler the following equipment is required e Draught meter e Flue gas analyser with wood pellet fuel setting e Container of at least 1 litre capacity 10 2 Preliminary Inspection Before switching on the power supply to the hopper and boiler check the following 10 2 1 Heating System Check the following e That corrosion inhibitor and where necessary antifreeze is present in the system water Refer to Section 4 6 e That a magnetic in line filter has been fitted in the system Refer to Section 4 6 e The auto air vent Supplied with the boiler is open e The boiler drain cock Supplied with the boiler is closed e Both the boiler and heating system is filled and vented e On sealed systems the expansion vessel charge pressure is correct and system is filled to correct pressure e For any leaks at joints fittings etc 10 2 2 Electrical Connections Check the following e The 5 way plug from the hopper is fully inserted in the socket at the top left rear of boiler Refer to Figure 8 3 e The 5 way plug from the flue fan and washdown solenoid valve is fully ins
103. ircuit open and that there are no blockages Rectify as necessary D o TE 2 Tw 12 5 Pellet Tube Thermostat When pellet tube has cooled does pressing RESET button on stat correct the fault Is the lead correctly fg connected Is there continiuty between the terminals Is the pellet delivery hose damaged Replace pellet delivery hose Is the room ventilation adequate Unblock or increase ventilation as required Is the pellet Ves delivery hose air tight at both ends Correctly fit pellet delivery hose or replace if necessary the mains water Yes supply to boiler connected amp switched on Connect the mains water supply amp switch on x Primary Fault Isthe ash pan N overflowing Is there a build up of ash on the combustion chamber baffle 06 4 Clean out the ash pan amp boiler Clean all ash from the combustion chamber baffle Is the boiler wash WAS system operating correctly when tested using the test switch Is solenoid valve operating correctly Check that manifold jets are clear amp correctly set Secondary follow on checks Is the combustion chamber draught correct Check the switched live supply to hopper boiler and rectify as necessary Is the shaker cleaning system operating correctly when tested using the test switch Check operation No Yes of cleaning motor im
104. irs floor using the Support Plate with clamp band Grant ref WP SP A four sided square opening formed by timber stringers between the joists is required to support the plate Ensure that the minimum distance of 60mm is achieved between the flue outer surface and the any combustibles e g timber joists A Fire Stop plate Grant ref WP FP is also required to be fixed to the ceiling below When passing through a second upstairs floor in a 3 storey house either a second support plate can be fitted or only two fire stop plates one above and one below need be fitted as the flue is adequately supported at the first upstairs floor level Intermediate Top Plate Flue systems running up against either an Internal or external wall surface can be supported using the Intermediate Top Plate Grant Ref WP TP This is mounted on a pair of Wall Support Side Plates Grant Ref WP WS which are fastened to the wall to provide support at either the base or part way up a vertical section of flue The female collar on the underside of the plate is fitted into the flue below and the male collar on the upper side of the plate is a twist lock connection into the flue above Both joints are secured using the clamp bands provided Wall and Roof Brackets Both the Wall bracket Grant ref WP WB50 and the Adjustable Wall Bracket Grant ref WP WB300 are NOT load bearing and are designed to give lateral support only Wall
105. 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 25 C Refer to Figures 8 9 or 8 10 as appropriate for connection details 8 5 Connecting the Power Supply WARNING Before making any connections to the heating systems controls ensure that the electrical supply is isolated at the fused spur serving the controls and boiler that the fuse has been removed and the isolator is locked off Do NOT connect the electrical supply to the hopper by connecting the 4 way plug and socket together untill ALL plug connections have been correctly made between the hopper boiler and if fitted the bulk pellet supply system The boiler requires a permanent mains supply and a switched live supply to control the boiler For details of Controls refer to Section 8 4 and Figures 3 9 or 8 10 Do NOT interrupt the permanent supply to the hopper boiler with any external controls The power supply cable and flex should be at least 0 75mm2 PVC as specified in BS 6500 Table 16 Connect the mains supply using the following procedure 1 Press down on the small catch between the two parts of the factory fitted 4 way plug socket connector to release it 2 Separate the two parts and remove the cover from the male 4 way plug 3 Connect the flex to the 4 way male plug as follows
106. itch on the control panel or automatically by the boiler control stat or the heating system controls the burner needs to burn down the remaining pellets in the brazier Do not open the front combustion chamber access door until the burner display reads WAIT BOILER THERMOSTAT 1 4 4 Boiler Pellet Hoppers All single boilers Spira 6 26 and 9 26 models come with a pellet hopper Two sizes of hopper are available for use with single boilers as follows e 110 kg hopper for storing maximum of 110kg 170 litres of wood pellets e 200kg hopper for storing a maximum of 200kg 308 Litres of wood pellets There are two versions of both the 110kg and 200kg pellet hopper available for use with a single boiler Left hand hopper to be positioned on the left hand side of the boiler This is the standard option and will be automatically supplied with the boiler unless specified otherwise Right hand hopper to be positioned on the right hand side of the boiler This is the non standard option and must be specified when ordering the boiler Both hoppers are supplied with a single 1 2m pellet feed auger to be fitted to the hopper on site by the installer All double boiler installations Spira 12 52 15 62 and 18 72 models come with one double hopper to feed both boilers This hopper is positioned between the two boilers and stores a maximum of 140 kg 215 litres AUTO CLEANING TEST
107. kin After handling always follow normal good hygiene practices Protection Use eye protection Rubber or plastic gloves should be worn where repeated contact occurs and a face mask worn when working in confined spaces First Aid Eyes Flush eyes with water for 15 minutes See immediate medical attention Skin Wipe off and wash with soap and water Inhalation Remove to fresh air 15 EC Declaration of Conformity In accordance with BS EN ISO IEC 17050 1 2004 We GRANT ENGINEERING IRL LTD Or Crinkle Birr Co Offaly Ireland Telephone 057 9120089 Fax 057 9121060 Email info grantengineering ie Website www grantengineering ie Declare that Equipment Floor Standing Domestic Condensing Wood pellet boiler Model name number Grant Spira 6 26 Wood Pellet Boiler Grant Spira 9 36 Wood Pellet Boiler In accordance with the following Directives 2006 95 EC Conforms with the safety objectives of the Low Voltage Directive and its amending directives 2004 108 EC Conforms with the essential protection requirements of the Electromagnetic Compatibility Directive and its amending directives has been designed and manufactured to the following specifications EN60335 1 2002 A1 2004 A11 2004 A2 2006 A12 2006 A13 2008 A14 2010 Clause 19 11 4 requirements EN 55014 1 2006 A1 2009 EN 303 5 1999 Conformity y O le Fa S O Pa
108. l hoppers are supplied with a rectangular blanking plate fitted on the top rear panel This can be removed as required to allow the fitting of the Grant SPIRA VAC pellet feed system Refer to Installation Instructions supplied with the Grant SPIRA VAC system for further details This blanking plate has a single round knock out to provide an entry into the hopper from an auger supplying pellets from a bulk hopper system This knockout is positioned to ensure the pellets drop into the hopper and operate the hopper contents switch Only this opening MUST be used as making another opening in the intermediate hopper could affect the operation of the contents switch Electrical connection for either a bulk auger or Grant SPIRA VAC system if required is made using the 6 way electrical plug and flying lead supplied factory fitted at the rear of the hopper Refer to Section 7 for connection details Always ensure that the door and top panel of the boiler hopper are fitted to ensure no foreign debris enters the hopper If a bulk system with an auger is fitted ensure that the bulk auger does not impede the opening of the hopper door 1 4 5 Pellet Feed Auger All Grant hoppers are supplied with either one or on double boiler hoppers two 1 2m pellet feed augers These are set at a fixed angle of 45 to maintain a consistent feed If the pellet feed auger angle is altered the input to the boiler will also be altered The pell
109. l out repair work by any third party will not be accepted unless previously authorised by the Company 10 Proof of purchase and date of installation commissioning and service documents must be provided on request 11 If a replacement boiler is supplied under the warranty due to a manufacturing fault the product warranty continues from the installation date of the original boiler and not from the installation date of the replacement Hard Water Advice If you live in a hard water area protection against scaling of the wash system manifold in your boiler must be provided You should fit an appropriate scale inhibitor or water softener as any breakdown caused by water scaling is not covered by either the manufacturer s warranty Ask your installer for advice X gt GRANT Hopton House Hopton Industrial Estate Devizes Wiltshire SN10 2EU Telephone 01380 736920 Fax 01380 736991 Email info grantuk com Website www grantuk com
110. lly empty the ash pan Refer to Section 1 5 and the User instructions e he need to have the boiler serviced either annually or when SERVICE is shown on the burner control panel display whichever comes first Refer to Section 1 5 and User Instructions e That servicing should only be carried out by a Grant Approved installer 10 12 Commissioning Report Form The Commissioning Report form supplied with the boiler must be completed at the end of the commissioning process Hefer to Section 4 7 For a double boiler installation a commissioning form must be completed for each of the two boilers The following information must be entered on the form e Boiler details model serial No etc e Combustion readings e Installation details e Burner settings e Customer handover details The completed form must be signed by both installer and customer user A copy of the completed form must be left with the customer user one must be returned to Grant UK and the remaining third copy retained by the Installer 10 13 Commissioning Check List The following checklist must be used in conjunction with the preceding information given in this section Tick box Heating system Preliminary Inspection Electrical connections Condensate disposal Flue system SM oO H Combustion ventilation Boiler Control panel Combustion chamber Heat exchangers primary LI O O Ll Heat exchangers secondary P
111. mes of the pellet feed auger supplying the burner See Section 8 for full burner operation details 1 4 2 Boiler The SPIRA condensing boiler is supplied with a combined primary and secondary heat exchanger Both heat exchangers are equipped with a self cleaning system 1 4 3 Boiler controls The set point temperature of the boiler is user adjustable via two push buttons on the burner control panel see Section 8 4 for details The boiler control panel See Figure 1 1 is located at the top of the boiler and is fitted with three controls as follows ON STAND BY switch to switch off the burner when required by interrupting the switched live supply to the burner This switch does not isolate the electrical supply to the burner OVERHEAT thermostat this allows the boiler to be used on a sealed central heating system and will automatically switch off the boiler if the pre set temperature of 110 C is exceeded CLEANING switch when pressed and held in the TEST position it allows the cleaning system to be manually operated and tested When released it will automatically return to the default AUTO position to allow the boiler cleaning system to perform automatically Only operate the cleaning switch when the boiler is in WAIT BOILER OVERHEAT RESET STANDBY BURNER Figure 1 1 Boiler control panel WARNING After the burner has been switched off either manually by the sw
112. mined by FLASH CLEANING see 8 3 1 3 4 Default setting 6 26 amp 9 36 2180 180 minutes b TIME CLEAN BOILER Total pellet feed auger run time before boiler cleaning operation activates Default setting 6 26 amp 9 36 180 180 minutes c TIME CLEAN PERIOD Time period boiler cleaning function is operational once TIME CLEAN BOILER has elapsed Default setting 6 26 amp 9 36 260 60 seconds d FLASH CLEANING Commencement of brazier cleaning 1 Interrupt burner firing shut down and clean brazier when time is greater than TIME CLEAN BRAZ O at next burner shut down clean brazier when time is greater than TIME CLEAN BRAZ Default setting 6 26 amp 9 36 1 e HOURS SERVIC Time lapse period before the burner screen displays SERVICE This is to indicate a service is now due Default setting 6 26 amp 9 36 500 500 hrs RESET SERVICE to cancel the SERVICE display on the burner screen after the boiler has been serviced Press button 3 SET followed by button 4 RESET five times to exit the menu TU ESSENTACTO RESET THRE SERVICE DISPLAY AND AFTER EACH SERVICE 9 7 1 4 Menu 4 4 SETUP FAN a POWER MAXIMUM Burner fan speed setting when burner in max output mode Default setting 6 26 36 Default setting 9 36 43 b POWER MINIMUM Burner fan speed setting when burner in min output mode Default setting 6 26 21 Default settin
113. n fitted To join two components together First fit the lip seal supplied into the groove in the inner flue liner at the female collar end of the flue component to be fitted All flue joints must have a lip seal gasket fitted The lip seal should be fitted dry and the lubricating grease supplied with the component applied to the internal surface of the socket into which it is to be fitted Loosen the locking band at the female collar end Insert the male collar into the female collar and twist through 1 6 of a turn to lock in place Refer to Figure 7 3 Air Supply JO 9 z d o Pa V o LL Air Supply O o Pe V o LL 7 Flue System and Air Supply Figure 7 3 Twist lock joint between components Ensure that the two beaded ends of the flue components are in contact with each other all round Position the locking band so that it grips the beaded edge of both components and fasten using the spring clip The locking bands provided MUST be fitted at ALL flue joints Refer to Figure 7 4 Locking band Figure 7 4 Fitting of locking band To allow for alignment the female collars of the eloows do NOT have the twist lock flutes but the locking band MUST still be used to secure the two flue components together To temporarily assemble the flue system components to check component lengths alignment of connections e
114. ndensate trap and any second trap fitted must be checked at regular intervals e g on every annual service and cleaned as necessary to ensure it is clear and able to operate CAUTION Failure to regularly check and clean the condensate trap or traps may result in damage to the boiler and this will not be covered by the product warranty Disposal o o o O Tw 0 Pa 02 oO 22 6 Sealed Systems 6 1 Sealed System Requirements All Grant Spira boilers are suitable for use with sealed systems complying with the requirements of BS5449 The system must be provided with the following items e Diaphragm expansion vessel complying with BS 4814 e Pressure gauge e Pressure relief safety valve e Approved method for filling the system Expansion vessel NOTE Ensure that the expansion vessel used is of sufficient size for the system volume Refer to BS 7074 1 1989 or The domestic Heating design Guide for sizing the required vessel The expansion vessel can be fitted in either the return or flow pipework in any of the recommended positions as shown in Figure 6 1 To reduce the operating temperature of the expansion vessel diaphragm position it below the pipe to which it is connected The expansion vessel may be positioned away from the system providing the connecting pipe is not less than 13 mm diameter If th
115. nto an existing brick or clay lined chimney All masonry flues must be lined using the Grant Black system stainless steel flexible flue liner e No other appliance can be connected to the boiler flue e The minimum clearance between the outer flue surface and any combustible material is 60Mm e Any condensate in the flue can run back into the boiler A condensate drain at the base of the flue system is not required Point where flue passes through weather surface Note 1 2 A Ator within 600mm of the ridge B Elsewhere on a roof whether pitched or flat C Below on a pitched roof or within 2300mm horizontally to an openable rooflight dormer window or other opening Note 3 D Within 2300mm of an adjoining building whether or not beyond the boundary Note 3 Notes Clearance to flue outlet At least 600mm above the ridge At least 2300mm horizontally from the nearest point on the weather surface and a at least 1000mm above the highest point of intersection of the chimney and the weather surface or b at least as high as the ridge At least 1000mm above the top of the opening At least 600mm above the adjacent building 1 The weather surface is the building external surface such as its roof tiles or external walls 2 A flat roof has a pitch less than 10 3 The clearance given for A or B as appropriate will also apply Figure 7 1 Flue terminal positions The above clearances are
116. nto an external gulley C Into a purpose made soakaway All condensate disposal pipes must be fitted with a trap whether they are connected internally or externally to a domestic waste system soil stack or run externally to a gully hopper or soakaway Every Grant SPIRA boiler is supplied with a trap and this MUST be used Hefer to Section 5 6 for trap details 5 2 Connections Connections into a rainwater hopper external drain or gulley should be terminated inside the hopper drain gulley below the grid level but above the water level Condensate disposal pipes must not be connected directly into rainwater downpipes or to waste soil systems connected to septic tanks Condensate must not be discharged into grey water systems that re use water used in the home not including water from toilets It should be noted that connection of a condensate pipe to the drain may be subject to local Building Control 5 3 Pipework Condensate disposal pipework must be plastic Copper or steel pipe is not suitable and must NOT be used All condensate disposal pipes connected to a Grant SPIRA boiler must have a minimum nominal diameter of 38mm 1 12 plastic pipe Condensate disposal pipes should be kept as short as possible and the number of bends kept to a minimum Pipes should be adequately fixed to prevent sagging i e at no more than 0 5 metre intervals Condensate disposal pipes must be fitted with a fall
117. od should only be changed if there is considerably deterioration e Open the brazier manually by operating the release switch on the servo motor and carefully pulling on the end wall of the brazier e To operate the switch and release the motor either press and hold down the switch down or lift and hold the switch up depending on motor type used Refer to Figure 11 12 Figure 11 13 Manual opening of brazier WARNING DO NOT ATTEMPT TO FORCE THE BRAZIER OPEN WITHOUT OPERATING THE SERVO MOTOR REALEASE SWITCH Failure to operate the servo motor release switch WILL result in damage to the servo motor gears With the brazier open dismantle the brazier to thoroughly clean all parts as follows referring to Figure 13 2 e Unscrew and remove the upper two M6 nuts and washers on either side of the brazier chassis securing the two brazier flame plates e Remove the four M6 screws from the inside of the brazier e Unscrew and remove the two M6 screws securing the photocell back plate to the burner e Remove both the two brazier flame plates and photocell back plate from brazier e Unscrew and remove the two M6 nuts and washers on either side of the brazier chassis securing the 3 sided grate enclosure e Remove the four M6 screws from inside the brazier and remove the grate enclosure e Unscrew and remove the two M6 screws and washers one each side of the brazier chassis Securing the ignition elem
118. oes this by cooling the flue gases to below 90 C thus extracting more sensible heat and some of the latent heat This is achieved by cooling the flue gases to their dew point The boiler has been independently tested to BS EN303 5 and will achieve the following full load efficiencies when both the boiler and system are correctly set Reduced Output SPIRA 6 26 97 4 96 4 Model Nominal Output SPIRA 9 36 93 1 98 1 To ensure maximum efficiency from the Grant SPIRA boiler the boiler return temperature should be 55 C or less but NOT less than 40 C at maximum operating temperature This will enable the latent heat to be condensed out of the flue gases The boiler is capable of a maximum flow temperature of 75 C To achieve the required return temperature 55 C or less it is recommended that the heating system is designed and balanced to operate with a temperature differential of 20 C between flow and return The use of modulating circulating pumps now widely available and effective control systems should be considered Grant SPIRA condensing wood pellet boilers will still operate at extremely high efficiencies even when not in condensing mode and are therefore suitable for fitting to an existing heating system without alteration to the radiator sizes 1 2 Boiler Description The Grant SPIRA boiler uses a drop feed type burner with modulated heat output The burner output is determined by varying t
119. on combustible base of at least 125mm thick This must also extend past the boiler and hopper by 225mm at the front and 150mm on the remaining sides The boiler position must comply with clearances shown in Section 2 4 4 5 Regulations Installation of a Grant SPIRA wood pellet boiler and hopper must be in accordance the following recommendations e National Building Regulations and any local Byelaws which you must check with the local authority for the area e Model and local Water Undertaking Byelaws The installation should also be in accordance with the latest edition of the following standards and codes of Practice e BS 715 2005 Metal flue pipes fittings terminals and accessories e BS EN 12828 2003 Heating systems in buildings Design for water based heating systems e BS EN 12831 2003 Heating systems in buildings Method for calculation of the design heat load e BS EN 14336 2004 Heating systems in buildings Installation and commissioning of water based heating systems e BS 7593 2006 Code of Practice for treatment of water in heating systems e BS 76 1 2008 Requirements for electrical installations IEE wiring regulations e ONORM M7137 standard should be used as a guideline for DIY bulk storage units NOTE Failure to install and commission the appliance correctly will invalidate the boiler warranty PINA WARNING Before starting any work on the boiler or fuel supply please read the
120. onds Contact GRANT for assistance Is the pellet pre load time correctly set Contact GRANT for advise to reset pellet pre load time Is the TIME LIGHTING CYCLE REDUCED time 120 seconds Contact GRANT for assistance 5 TE 5 Tw D o TE Tw 12 Fault Finding 12 6 Failed Pellet Lighting Note 1 Is there a sufficient quantity of pellets in the pellet hopper The effect of insufficient pellets will depend on the type of pellet storage used as follows Using a pellet hopper only if there are insufficient pellets the hopper contents switch will break the switched live to the boiler causing WAIT BOILER THERMOSTAT to be displayed Refill the hopper to start the boiler Refer to Section 1 4 4 for further details Using a bulk pellet store the hopper contents switch will control the operation of either the bulk store auger of Grant Spira vac system It will NOT interrupt the switched live to the boiler and thus WAIT BOILER THERMOSTAT will NOT be displayed The boiler would continue to operate until ALL pellets in the hopper are used and then stop with FAILED PELLET LIGHTING displayed on the burner control screen In this case check that e there are pellets in the bulk store e the bulk store auger or Grant Spira vac system is operating correctly refer to instructions supplied with the Spira vac system
121. ons supplied with each kit For details of capacities and dimensions contact Grant UK The use of a self constructed wood pellet storage facility should be pre approved by the fuel supplier before any pellets are delivered and must meet relevant building and fire regulations The ONORM M7137 standard should be used as a guideline for DIY bulk storage units A storage unit should not be positioned where it would result in a fire risk The store should be located on a suitable base e g concrete capable of supporting the weight of the store when full of pellets T NOTE Each bulk pellet supplier has clear guidelines on the requirements of a bulk storage hopper used to store their pellets together with requirements on positioning access and minimum deliveries ALWAYS check with the pellet supplier you wish to use BEFORE installing a bulk storage system 3 2 3 Bulk Pellet Feed Auger When installing a bulk pellet store with a bulk pellet feed auger consideration must be given to the position of the store in relation to the hopper as this will dictate the length of the auger The length of the pellet feed auger supplying pellets from the bulk store is limited to a maximum of 6 metres in length as a longer auger can damage the pellets Figure 3 2 Bulk hopper feeding intermediate hopper Grant UK offer a range of eight bulk pellet augers from 2 5m to 6m in length in O 5m steps as given in the table below
122. ough either the draught stabiliser setting Setting the fuel to anything or from within the flue as they will other than wood pellets will give an have been diluted with air entering incorrect reading through the draught stabiliser Only use the combustion test point in the top rear access door to check IN CAUTI N the CO content of the flue gases See Fg 10 17 To ensure correct combustion the burner settings given in the table above must NOT be changed unless instructed to do so by Grant UK MAX Flame MIN MINFlame Pellet Burner setting Heat Heat Draught Burner Heat feed A d Setting A Full Input mbar TIME e 2 2 lechnical Data 2 4 Boiler and Hopper Dimensions and Clearances 2 4 1 Single Boiler with Left Hand Hopper 1613 1535 WASH DOWN MANIFOLO CONNECTION RETURN e CONNECTION n DRAIN HOPPER 1 WIRING CENTRE 237 775 150 Plan View 107 Rear View S Spira Wood Pellet Boiler Dimensions A Model 6 26 110kg left hand hopper 1056 518 DIS 1 7 96 661 1160 1210 6 26 200kg left hand hopper 1256 618 13 120 44 713 1160 1120 iz 9 36 110kg left hand hopper 1056 518 DIS 196 661 1260 1220 z 9 36 200kg left hand hopper 1256 618 713 144 713 1260 1220 gt If the measurement from the flue centre line to the rear wall
123. ove until it remains within the required maximum and minimum limits Hecord the maximum and minimum values on the Commissioning Heport form Refer to Section 10 12 NOTE is essential to continue to monitor the combustion chamber draught whist adjusting the CO in the flue gases and to adjust the draught stabiliser to keep it within the required limits Refer to Section 10 9 On double boiler installations the above process as covered in Sections 10 3 to 10 10 must be fully carried out on BOTH boilers 10 11 Customer Handover The customer user must be informed of the correct operation and use of their Grant Spira wood pellet boiler installation This must include the following information The use of the boiler controls how to switch the boiler off and on as required Refer customer to the User Instructions at the back of this manual 5 T ED 9 T OD 10 Commissioning e Theuseofthe heating system controls how to set the programmer room and cylinder thermostats etc e The importance of using the correct type of wood pellet e he need to routinely check the pellet level in the pellet hopper and how to re fill it hopper only installations e he need to routinely check the pellet level in the bulk pellet store bulk pellet store installations only e How to access the ash pan and the need to periodica
124. oved Document J Section 2 Appliances burning solid fuel For a boiler with a draught stabiliser a permanent air vent with a total free area of at least 850mm per kW of appliance rated output is required To achieve this the following minimum vent opening areas are required Minimum Vent Open Area 221cm 5 2 306cm 48in Boiler Model Grant SPIRA 6 26 Grant SPIRA 9 36 Grant SPIRA 15 62 527cm 832 EUN in Grant SPIRA 12 52 442cm 70 2 Grant SPIRA 18 72 612cm 96in2 If a bulk pellet store is fitted internally refer to the manufacturer s instructions for any ventilation requirements 7 2 Flue Position and Clearances The Grant Spira wood pellet boilers have high operating efficiencies and low flue gas temperatures Only the Grant BLACK insulated twin wall flue system must used with the Grant SPIRA boilers e The flue terminal should be located in a downdraught free area i e above the roof where it can discharge freely and not present a fire hazard whatever the wind conditions e The flue outlet positions shown in Figure 7 1 taken from Approved Document J Section 2 can meet the above requirement e The heights and separation distances shown in Figure 7 1 may have to be increased in particular cases e g where high wind exposure surrounding tall buildings or adjacent trees can cause adverse wind effects e The boiler flue cannot terminate i
125. r flue outlet flange Secure the fan box using the nuts and washers previously removed Ensure that the fan box is vertical and the neoprene gasket is evenly compressed to give an adequate seal between the fan box and the boiler flange Fit the solenoid head fitted to the same 5 way plug as the lead from the flue fan motor on to the solenoid valve shaft and secure with the steel clip provided Fit the 5 way plug from the flue fan solenoid valve into the socket at the top right rear of the boiler Ensure that the plug is fully pushed home See Figure 4 1 c O SO o E gt Information em O SO nf o gt Q Information 4 Boller Installation Information Figure 4 1 Flue fan solenoid valve plug connection 4 11 Pellet Hoppers 4 11 1 Single Boiler Installation Position the pellet hopper on the same firm level surface as the boiler on either the left hand or right hand side of the boiler depending on hopper type used with the top access door facing forwards Refer to Figure 2 1 or 2 2 as required for clearance dimensions 4 11 2 Double boiler installation Position the pellet hopper on the same firm level surface as and in between the two boilers with the top access door facing forwards Refer to Figure 2 3 for clearance dimensions Failure to adhere to these measurements can cause blockage of the pellets in the pellet deliver
126. r main folders is appliance Only accessible with an described in further detail as follows access code INSTAL Installer folder see Section The INSTAL folder has four sub folders 9 7 1 e menu 1 4 20 MANUFACT not applicable e menu 2 4 POWER PELLET VIEW folder see Section 9 7 3 e menu 3 4 CLEAN USER folder see Section 9 7 4 e menu 4 4 SETUP FAN To access the parameters within the INSTAL folder from the main burner display navigate as follows Press button 3 to open the menu settings Once the menu settings option is activated there are four folders to choose from as shown below CP CODE cre ud E See Section H20 9 7 1 1 MANUFACT Installer folder Enables the installer access relevant parameters for adjustment during the installation commissioning of the appliance Accessible only with an access code See Section 9 7 1 TO STEP BACK B o menu 2 4 gt C POWER PELLET See Section 9 7 1 2 2 MEnu INSTAL MANUFACT See Section 9 7 1 3 menu 3 4 gt F INSTAL CLEAN Manufacturer folder Displays the To Accept manufacturing folder it enables the To To Parameter manufacturer set parameters Increase decrease Change required for an individual range of Parameter Parameter amp Exit boilers This folder should not be cB cB BD accessed or modified in anyway menu 4 4 gt 3 SETUP re FAN See Section 9 7 1 4 9 7 1 1 menu
127. raught Refer to Figure 10 16 PO A SEA Figure 10 16 Fan box slider plate If required adjust the slider plate as follows e With the boiler firing at maximum output and the burner display is showing BURNER FIRING 100 e Set the draught stabiliser weight midway on the damper arm e Unscrew and remove the single screw securing the end of the slider plate arm e This screw is located on the right hand side of the fan box immediately above the draught stabiliser e Carefully pull out the end of the slider arm whilst monitoring the combustion chamber draught on the draught gauge e When the draught gauge indicates a draught midway between 0 1 to 0 15mbar the slider position is Eolo e Without moving the position of the slider plate bend up the end of the slider arm so the nearest hole in the arm lines up with the threaded hole in the fan box e Secure the slider arm to the fan box using the screw previously removed e f necessary make any fine adjustment of the combustion chamber draught by altering the position of the weight on the damper arm NOTE The normal means of setting the correct combustion chamber draught is by adjusting the position of the damper weight as detailed in Section 10 9 2 ONLY adjust the slider plate when absolute necessary i e when the draught reading is too high and beyond the adjustment range of the damper weight 10 10 Flue Gas Analysis Check the 9
128. red AUGER FIXING FLANGE Figure 10 6 Auger fixing WARNING Before filling the pellet hopper for the first time with pellets ensure that hopper is empty of all other debris or objects e g screws nuts etc Ensure that only pellets that comply with ENplus A1 standard to EN14961 are used with the Grant Spira boiler Refer to Section 3 Fill the hopper with pellets either e By hand from bags or e Automatically from a bulk pellet store via a bulk auger or Grant SPIRA VAC vacuum pellet feed system When using a Grant SPIRA VAC System refer to the Installation instructions supplied with the Grant SPIRA VAC vacuum pellet feed system 10 5 Safety Device Checks 10 5 1 Burn Back Thermostat When the burner display reads WAIT BOILER THERMOSTAT check the operation of the burn back thermostat on the pellet feed tube as follows e Remove the steel clip from the thermostat e Disconnect the lead from the thermostat terminals Refer to Figure 10 7 The burner display screen should automatically go blank as all power to the burner has been interupted To make the burner operational again e Re connect the lead e Refit the clip Figure 10 7 Disconnecting burn back thermostat 10 5 2 Combustion Chamber Door Switch When the burner display reads WAIT BOILER THERMOSTAT check the operation of the combustion chamber door interlock as follows e The interlock is activated by opening t
129. remove the black cover from the overheat reset button on the boiler control panel to check if boiler overheat thermostat has tripped If YES go to Section 12 4 for further guidance Note 4 Has the pellet feed tube thermostat tripped Remove the steel retaining clip and disconnect the lead from the pellet feed tube burn back thermostat Check the reset button to see if thermostat has tripped if YES go to Section 12 5 for further guidance Check continuity Ives of burner fuse on PCB Is it OK Replace burner fuse Is the ribbon cable fitted correctly to PCB and back of display Correctly fit ribbon cable at both ends Yes Replace burner PCB does this rectify the problem Correctly fit ribbon cable at both ends Note 5 Is the combustion chamber door closed and catch fully engaged The combustion chamber door is fitted with a safety interlock Once the door catch is disengaged all power to the burner is interrupted Refer to Section 10 5 2 Check that catch is FULLY engaged when door is closed Note 6 Is the door micro switch operational Check electrical continuity of door micro switch Replace if faulty Refer to Figure 8 5 and 12 4 Figure 12 5 Location of door micro switch Note 7 Is the fuse on the PCB OK Remove fuse from holder on PCB and check Replace if necessary Fuse type F5AL250V Refer to Figure 12 5 Figure 12 6 Location of fuse on PCB 5
130. screws securing the photocell back plate to the front of the burner e Fit the burner hood and then finally tighten all remaining burner fixings e Remove brazier clearance gauge from burner brazier e Operate servo motor release switch and manually open and close brazier to check it is free to move CLI thee Paget Figure 11 14 Fitting brazier clearance gauge 11 8 Burner Components Check the burner fan inlet is clear of debris If there is a build up of debris remove the burner fan and clean the fan blades and fan housing Refer to Figure 11 14 11 8 1 Burner Fan Check the burner fan inlet is clear of debris If there is a build up of debris remove the burner fan and clean the fan blades and fan housing Refer to Figure 11 14 Burner x Photocet T mao T 5 2 gt o e 5 Figure 11 15 Interior of burner enclosure O S gt Mm CO 11 Boiler Servicing 11 8 2 Photocell Remove photocell from mount Check and clean the photocell Replace if damaged Refer to Figure 11 14 Remove the two screws securing the photocell mount and pull out the photocell tube Check the condition and thoroughly clean the inside of the tube Refit tube to burner Ensure the photocell clamp is fitted 25mm from end as shown in Figure 11 15 Refit into photocell mount Figure 11 16 Photocell clamp position
131. tc DO NOT fit the lip seals However for FINAL assembly the lip seals provided MUST be fitted at EVERY joint WARNING All joints in the flue system must be accessible for inspection No joints should be located within a wall floor or ceiling spaces or any other inaccessible place 7 3 4 Adjustable Length The Grant Black flue system includes an Adjustable flue extension Refer to Section 7 6 This allows any of the straight flue extension components to be extended in length by between 75mm to 250mm This adjustable extension must be used in conjunction with any straight extension 1000mm 500mm or 333mm to achieve the actual straight length required To fit the adjustable extension first remove insulation from between the inner and outer walls of the component as necessary Fit the open end over the male collar end of the fixed extension and adjust to achieve the required overall length Secure the two components together using the wide locking band supplied NOTE The adjustable section is not load bearing therefore adequate support of the flue system MUST be provided immediately above the adjustable extension 7 3 5 Support Components The weight of the flue system is considerable It must NOT be carried by the fan box fitted to the appliance but requires independent support Support Plate On internal systems the weight can often be supported where the flue passes through an upsta
132. teed for two years from the date of purchase providing that after twelve months the annual service has been completed and the boiler registered with the Company within thirty days of the installation date Any work undertaken must be authorised by the Company and carried out by an approved service agent 3 The shell heat exchanger of the pellet boiler supplied by the Company is covered by a five year parts only guarantee from the date of purchase subject to correct operation of the boiler Proof of annual maintenance must be provided 4 This guarantee does not cover breakdowns caused by incorrect installation neglect misuse accident or failure to operate the boiler in accordance with the manufacturer s instructions 5 The boiler is registered with the Company within thirty days of installation Failure to do so does not affect your statutory rights 6 This guarantee is not transferable unless sanctioned by the Company he Company will endeavour to provide prompt service in the unlikely event of a problem occurring but cannot be held responsible for any consequences of delay however caused 8 his guarantee applies to Grant boilers installed on the UK mainland Isle of Man and Channel Islands only Provision of in warranty cover elsewhere in the UK is subject to agreement with the Company 9 All claims under this guarantee must be made to the Company prior to any work being undertaken Invoices for cal
133. ting the boiler back into operation 11 12 1 Burn Back Thermostat Check operation of burn back thermostat Follow the procedure given in Section 10 5 1 11 12 2 Combustion Chamber Door Switch Check operation of combustion chamber door switch Follow the procedure given in Section 10 5 2 11 13 Combustion Checks To ensure safe and efficient operation of the boiler it is essential that the boiler combustion is re checked and adjusted as necessary 11 13 1 Combustion Chamber Draught Check the combustion chamber draught and adjust the draught stabiliser setting as required Follow the procedure given in Section 9 9 11 13 2 Flue Gas Analysis Check the 96CO in the flue gases and adjust the burner fan setting as required Follow the procedure given in oection 10 10 WARNING To ensure safe and efficient operation of the boiler it is important that boiler burner is re commissioning as detailed in Section 10 S gt gt Mm gt co D o TE Tw 12 Fault Finding 12 1 General If a fault occurs with the boiler the display screen on the burner control panel helps to identify the nature and cause of that fault There are THREE basic screen displays that can be seen in the event of a fault as follows a Normal screen display with WAIT BOILER THERMOSTAT continuously scrolling across the lower part of the screen Refer to Figure
134. to guide Installers who have completed the 71 WARNING N OTE Grant Wood Pellet Boiler Installer training course on the installation commissioning and servicing of the Warning of possible human injury as Note text Used for emphasis or Grant SPIRA Condensing Wood Pellet a consequence of not following the information not directly concerned instructions in the warning with the surrounding text but of Boiler importance to the reader A separate manual is available to guide users in the operation of the boiler 4h CAUTION The following special text formats are used in this manual for the purposes Caution concerning likely damage to equipment or tools as a consequence of not following the instructions in the Caution C Le pu Q O pus Par 1 1 How the Condensing Wood Pellet Boiler Operates During the combustion process hydrogen and oxygen combine to produce heat and water vapour The water vapour produced is in the form of superheated steam in the heat exchanger This superheated steam contains sensible heat available heat and latent heat locked up in the flue gas A conventional boiler cannot recover any of the latent heat and this energy is lost to the atmosphere through the flue The Grant SPIRA Condensing wood pellet boiler contains an extra secondary heat exchanger which is designed to recover the latent heat normally lost by a conventional boiler It d
135. tts Amps Amps Watts Amps Watts amp amp Spira Model 6 26 9 36 26 36 88 700 122 800 1 BSP Female 1 1 4 BSP Female 1 BSP Female 1 1 4 BSP Female 51 5 60 26 0 9 5 1 bar operating pressure 11 4 BSP Female 125mm 5 Black system 0 10 to 0 15 running 25 1 55 lo 75 65 to 80 C 40 C 110 60 230V 50Hz 2 0 bar 2 0 bar 6 0 30 2 0 12 0 450 05 0 64 0 64 8 1 32 0 27 0 13 10 0 087 56 2 5 0 60 2 2 Boiler Input and Output Data The settings in the table below are based on the boiler using the Grant fixed angle pellet feed auger at 45 with an auger motor fixed speed of 8 1 rpm Only ENplus A1 EN14961 2 pellets MUST be used with the Grant SPIRA boilers These pellets must be bark and sand free AND approved by Grant UK BEFORE being used in the Spira boilers Failure to use approved pellets will invalidate the product warranty 2 2 1 Burner settings All burner settings must be checked as part of commissioning and servicing Refer to Section 9 6 for full details of the burner settings and how to access check and where necessary how to adjust them 2 3 Flue Gas Analysis As part of both the commissioning and servicing procedures the CO content of the flue gases must be checked To enable this to be done the boiler is supplied with a combustion test point in the top rear cleaning door Refer to Figure 10 17 To gain access to this test point first remove the top c
136. ulk pellet store is to be used e Hemove the wiring centre cover from the rear of the hopper e Unclip the 6 way plug from diaphragm switch bracket e Pass the 6 way plug lead through the grommet just below the wiring centre cover e Set the toggle switch on the diaphragm switch bracket to BULK STORE See Figure 8 1 e Replace the wiring centre cover and fasten in place using the screws previously removed e Connect the 6 way plug to the corresponding 6 way connector on the pre wired flying lead fitted to either the bulk pellet auger or Grant SPIRA VAC system e f using the Grant SPIRA VAC system refer to the installation instructions supplied with the system for further details on its installation and operation Figure 8 1 Hopper selector switch 8 2 4 For Installations using the Pellet Hopper only When used without a bulk pellet store the pellet hopper has the facility for the connection of a 230V low pellet indicator lamp not supplied This will indicate to the householder that the pellets in the hopper have reached the minimum level and the hopper needs to be topped up The indicator lamp should be positioned so it can be easily viewed by the householder See either Figure 8 7 or 8 8 as applicable for the connection details If a bulk store is used with either the Grant SPIRA VAC system or a Grant bulk auger a low pellet indicator lamp cannot be fitted to the pellet hopper
137. upply to the boiler and check left rear of the boiler is open and the overheat thermostat terminals that the heating system controls are vented Vent the primary heat exchanger on the heating flow pipe If installed on a sealed system check expansion vessel charge pressure and correct as necessary Check system calling Set the switch to ON and the With electrical supply isolated reset the pump should be running overheat thermostat and check electrical continuity across the If not check that terminals If no continuity found replace the pump is vented the overheat thermostat pressure and top up as necessary e there is power to the pump Refer to Section 7 for sealed system Note that the thermostat continuity can e that the pump is not seized stuck details be checked by removing the 7 way If pump has failed then replace it i plug plug No 1 from the socket on the Note 2 Is the heating thermistor correctlv fitted left of the burner and testing between Note 5 Is there any restriction to y terminals 1 and 2 Refer to Section 8 flow from the boiler Isolate electrical d ee IR and Figure 8 5 Check that all valves on the heating boiler control panel cover Check that the heating thermistor and the overheat thermostat sensor are correctly fitted into the pocket inside the boiler control panel Refer to Section 10 3 1 Ensure that both are held in place with the retaining clip supplied c
138. ure This is the target flow temperature from the boiler As the temperature of the boiler increases and reaches the set point less 5 C the output of the boiler is reduced by one step Each subsequent 1 C increase in boiler temperature reduces the output of the boiler by one modulation step until the temperature reaches the set point plus 5 C At this point the boiler output is MINIMUM FLAME which is minimum output setting of the boiler The percentage increase or decrease in power is calculated on the rate of temperature change The sequence of operation is described in Section 9 3 9 2 Burner Operational Modes BOILER WAIT THERMOSTAT operation code 03 Boiler is in standby awaiting the following e A switched live input signal from a control system e The boiler temperature to drop below the DELTA RESTART temperature DELTA RESTART is the temperature the burner restarts after Maximum temperature has been reached e The ON STANDBY switch on the control panel is set to the ON position WAIT PRELOAD BRAZIER operation code 40 Initial loading of pellets into the brazier to enable combustion to start e Activated with a switched live input signal and or temperature drops below the DELTA RESTART temperature e Deactivated after time exceeds TOR WAIT LIGHTING IGNITION operation code 41 Period of time given for pellets to light e Activated after PRE LOAD
139. vac system is operating correctly refer to instructions supplied with the Spira vac system Hectify as necessary Note 4 Is there a switched live from the heating system controls connected to the hopper boiler Check that switched live from the controls is correctly connected to terminal L2 on the 4 way plug at the rear of the hopper Also check that this 4 way plug is fully pushed into the socket on the flying lead at the rear of the hopper Refer to Sections 8 4 and 8 5 for further details Check that ALL controls programmer and room thermostats are calling and that there is a 230V output to the boiler Note 5 Is there continuity between terminals T1 and T2 on burner plug No 2 Disconnect the plug from left side of burner and check for continuity between terminals T1 and T2 Refer to Figure 8 5 for wiring details 5 TE 5 Tw D o TE Tw 12 Fault Finding 12 3 No Screen Display Boiler will not fire blank screen HO EN BLANK DISPLAY SCREEN Is electrical supply switched on Is there power to terminal L1 on 4 way plug at rear of hopper Check electrical supply to hopper boiler amp rectify as Are all plugs correctly fitted i e the three burner plugs amp the plug from hopper to the boiler Correctly fit all plugs push fully into sockets Has the boiler overheat stat tripped Unscrew black cover on control
140. w and return temperatures 10 7 Priming the Pellet Feed Auger The pellet feed auger MUST be fully primed BEFORE attempting to start the boiler Prime the auger as follows e Disconnect the 6 way plug No 3 from the pellet feed auger from the upper socket on the left side of the burner Refer to Figure 10 9 Figure 10 9 Pellet feed auger plug 3 Disconnect the 7 way plug No 1 from the socket on the left side of the burner Refer to Figure 10 9 Disconnect the pellet delivery hose from the pellet feed tube on the burner and place in a container of at least 1 litre capacity Refer to Figure 10 10 Figure 10 10 Pellet delivery hose Insert the 6 way plug into the 7 way plug Refer to Figure 10 11 It is not possible to connect these two plugs incorrectly as they will only fit together one way The feed pellet feed auger will now run continuously until the plug and Socket is disconnected Figure 10 11 Connection the two plugs Leave the auger running until there is a continuous flow of pellets from the pellet delivery hose This will take between 15 to 20 minutes Disconnect the two plugs from each other and the auger will stop The pellet feed auger is now fully primed Refit the pellet delivery hose onto the pellet feed tube of the burner Check the condition of the pellet delivery hose and ensure it forms an air tight seal each end Check for damage and replace if necessary
141. warranty 11 10 2 Condensate Disposal Pipe Check entire length of discharge pipe for any leaks or blockages Clean or replace as necessary Check any other traps in the condensate disposal pipework Dismantle and thoroughly clean to remove any deposits Re fit to condensate disposal System pipework Check that any outlets to a gully or hopper are not obstructed Remove any blockages 11 10 3 Burner Settings If a condensate pump is fitted to the System check e The condition of the holding tank Thoroughly clean to remove any deposits e Operation of the overflow cut out float switch e he pump is operating correctly 11 11 Burner Settings With the electrical power to the hopper and boiler Switched on and the burner ON STANDBY switch set to STANDBY check that ALL burner settings in the INSTAL Installer menu are as given in Section 9 6 Check the burner control settings match those set on commissioning i e as recorded on the Commissioning Heport form a copy of which was left with the householder user Hefer to Section 9 7 for details of how to access and check these settings Heset the SERVICE timer as follows e Goto the CLEAN sub menu in the installer INSTAL menu e Go to the RESET SERVICE setting e Press button 3 to reset timer to zero Refer to Section 9 7 1 3 for further details on settings 11 12 Safety Device Checks The following safety checks must be made before put
142. x inspection opening S gt Mm E CO 11 Boiler Servicing 11 4 3 Draught Stabiliser Check draught stabiliser damper is free to move Remove draught stabiliser from fan box and clean if required Refer to Figure 11 2 Re fit draught stabiliser to fan box and check damper is free to move Draught stabiliser setting must be checked when boiler is operational Refer to Section 11 9 Figure 11 4 Draught stabiliser 11 4 4 Flue Fan Unscrew the four screws securing the flue fan to the fan box and remove the fan Clean any ash deposits from the fan blades and mounting plate Refer to Figure 11 3 Refit fan to fan box and secure with screws Ensure that it is correctly sealed to the fan box on the neoprene gasket Refit the 5 way on the lead from the flue fan and solenoid into the socket at the right rear of the boiler Refer to Figure 11 2 CAUTION When cleaning the fan blades ensure they are all thoroughly cleaned Uneven cleaning will result in the fan being out of balance and could cause damage to the fan motor Figure 11 5 Flue fan WARNING Failure to maintain a clean flue can result in the emission of flue gases into the dwelling or damage from potential fire in the flue 11 5 Combustion Ventilation Check that the combustion air supply conforms to the relevant requirements of The Building Regulations Approved Document J for solid fuel appl
143. y hose or can prevent access for servicing at a later date The hopper is supplied with castors which allows the hopper be moved during servicing Once in the correct position engage the brakes on the front casters to maintain this position Figure 4 2 Pellet feed auger fixing 4 12 Pellet Feed Auger 4 12 1 Single Boiler Hoppers The pellet feed auger is supplied packed with the hopper but not factory fitted to it To fit unpack the hopper and auger Remove the M5 screw fitted below the auger opening on the front of the hopper Fit the end of the auger into opening in the front of the hopper as far as it will go and secure by fitting the M5 screw through the auger fixing flange and tighten See Figure 4 2 4 12 2 Double Boiler Hoppers Both augers on the double boiler Intermediate hoppers are supplied factory fitted to the hopper To connect the hopper to the boiler fit one end of the pellet delivery hose onto the pellet feed auger outlet and the other end onto the burner feed tube The pellet delivery hose may need to be cut if too long A sachet of lubricant is supplied in the accessories carton apply the lubricant to the joint to ensure the pellet delivery hose is easily fitted Ensure the pellet delivery hose is not kinked in any way Figure 4 3 Auger plug connection Fit the 6 way plug No 3 from the pellet feed auger motor into the corresponding 6 way socket on the left side of the burner Ensure that

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