Grant Spira 6-26kW, Installation, Commissioning And Servicing Instructions

Page 1: ... CONDENSING WOOD PELLET BOILER GRANT SPIRA 9 36 kW CONDENSING WOOD PELLET BOILER 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 ...

Page 2: ...s 5 3 Pipe work 5 4 External pipework 5 5 Condensate soak away 5 6 Condensate trap 5 7 Inspection and cleaning of trap 6 Flue system Air supply 6 1 Air supply 6 2 Flue position and clearances 6 3 Flue Components assembly 7 Electrical 7 1 Connecting the power supply 7 2 Frost protection 8 Burner 8 1 Burner operation 8 2 Burner modes 8 3 Operational sequences 8 4 Burner display screen 8 5 Burner con...

Page 3: ...3 Grant SPIRA Condensing Wood Pellet Boiler Intermediate Hopper ...

Page 4: ...efficiency the boiler return temperature should be 55 C or less minimum of 40 C at maximum operating temperature This will enable the latent heat to be condensed out of the flue gases The boiler will achieve full load efficiency as follows SPIRA 6 26 Full output 97 4 Reduced output 96 4 SPIRA 9 36 Full output 93 1 Reduced output 98 1 The Grant SPIRA condensing wood pellet boiler operate extremely ...

Page 5: ...tted with a Burner ON STAND BY switch This switch interrupts the switched live supply to the burner it does not isolate the electrical supply to the burner The control panel is also fitted with a cleaning switch in the default position it allows the boiler cleaning system to perform automatically when pressed it allows the cleaning system to be manually tested Only operate the cleaning switch when...

Page 6: ...5 Minimum circulating head m 1 Boiler temperature set point range C 55 to 80 Boiler temperature cut out point C 65 to 80 Minimum return temperature C 40 Water system overheat cut out temp C 110 Burn back overheat cut out C 60 Electricity supply 230V 50Hz Max operating pressure sealed system bar 2 5 bar Max operating pressure open system bar 2 5 bar Maximum auger length bulk hopper meter 3 0 Minimu...

Page 7: ...site for correct operation of burner 4 The installer must amend the boiler data label if the output is changed 2 3 Flue Gas Analysis Only use a calibrated flue gas analyser that has a Wood Pellet fuel setting Setting the fuel to an alternative fuel will give incorrect readings To allow the boiler to be commissioned and serviced the boiler is supplied with a test point in the top cleaning door When...

Page 8: ...538 103 254 95 66 SIDE VIEW BOILER HOPPER FRONT VIEW BOILER HOPPER REAR VIEW BOILER HOPPER 727 770 1012 97 172 275 413 BULK HOPPER INLET OPTION 1186 1635 CLEARANCE REQUIRED FOR ACCESS TO DRAUGHT STABILIZER REMOVE WASH MANIFOLD 225 150 MINIMUM NON COMBUSTIBLE BASE AREA 125MM THICK SAME FLOOR LEVEL AS HOPPER BASE 150 ...

Page 9: ...38 103 254 195 66 SIDE VIEW BOILER HOPPER FRONT VIEW BOILER HOPPER REAR VIEW BOILER HOPPER 727 770 1012 97 172 275 413 BULK HOPPER INLET OPTION 1186 1635 CLEARANCE REQUIRED FOR ACCESS TO DRAUGHT STABILIZER REMOVE WASH MANIFOLD 225 150 MINIMUM NON COMBUSTIBLE BASE AREA 125MM THICK SAME FLOOR LEVEL AS HOPPER BASE 150 ...

Page 10: ... of 650 kg m 3 Chlorine High levels of chlorine in the flue gases emissions can give rise to corrosion Diameter The most common diameter is 6mm with some 8mm also available This boiler is designed for 6 only Fines 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 flo...

Page 11: ...ger motor will determine the amount of pellets delivered to the boiler Contact Grant Engineering for further details The use of an intermediate hopper between the bulk hopper and the boiler is advisable as any problems with a bulk pellet quality can be isolated and the intermediate hopper can be used as the main input to the boiler Only use a bulk storage unit that is a Specifically designed to st...

Page 12: ... and any local Byelaws which you must check with the local authority for the area Model and local Water Undertaking Byelaws The installation should also be in accordance with the latest edition of the following standard codes of Practice BS 715 Metal flue pipes fittings terminals and accessories BS EN 12828 2003 Heating systems in buildings Design for water based heating systems BS EN 12831 2003 H...

Page 13: ...rom the boiler do not connect plastic piping directly to the boiler Grant Engineering do not accept any responsibility for any damage how so ever caused to plastic piping or fittings 4 7 Combined fan box flue starter Fit the combined fan box flue starter to the flue outlet of the boiler using the M8 nuts and washers supplied Ensure there is an adequate seal between the unit and the boiler Fit the ...

Page 14: ...se forms an air tight seal each end and that the pellet delivery hose is not damage Leakage of air could cause increased temperature in the pellet delivery hose and result in the SAFETY CHARGE PIPE THERMISTOR shutting down the burner WARNING ...

Page 15: ...al pipes must be fitted with a fall away from the boiler of at least 2 5 45mm fall per metre run 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 fitting a condensate pump a condensate holding tank of at least 40 litr...

Page 16: ...l is porous and drains easily Fig 5 1 5 6 Condensate Trap Grant SPIRA condensing boilers are supplied with a 1 G B female condensate connection on the rear of the boiler Fit the 1 316 fitting supplied into this connection on the boiler and fit the pipework and trap as shown in fig 5 2 A condensate discharge pipe with a minimum diameter of 38mm is required to be fitted to this connection The conden...

Page 17: ...e details shown in Fig 6 1 The flue must also discharge in a down draught free area i e at least 1 metre above the point of exit through the roof or 600mm above the apex of the roof See fig 6 1 for further details No other appliance can be connected to the flue Clearances to combustible materials must be at least 75mm The condensate may be allowed to run back into the boiler A condensate drain at ...

Page 18: ...ed with the female end of all components must be used To allow alignment there are no locating flutes on the female section of the elbow For this reason these joints MUST be secured using the locking band All flue joints must have a lip seal gasket fitted on the bead of the projecting liner spigot of every joint The lip seal should be fitted dry and lubrication applied to the internal of the socke...

Page 19: ...5mm External diameter 180mm Locking band Part no WP01 Internal diameter 125mm External diameter 180mm This item is supplied with pipes bends tees and terminals 30 Bend Part no WP 30 Internal diameter 125mm External diameter 180mm 45 Bend Part no WP 45 Internal diameter 125mm External diameter 180mm Ø125 Ø180 EFFECTIVE LENGTH 66 5 7 Ø125 Ø180 30 79 Ø125 Ø180 70 45 ...

Page 20: ...e A 483 B 208 160 Eff pipe A 368 B 142 Viton Seal Part no WP02 Internal diameter 125mm ø125mm Wall Band 50mm Internal external Code WP WB50 External diameter 180mm Roof Support Code WP RS External diameter 180mm Fire stop plate Code WP FP External diameter 180mm B A Ø125 Ø180 E F F E C T I V E L E N G T H ...

Page 21: ...SP Diameter 180mm Support plate Code WP SP External diameter 180mm Storm collar Code WP SC Diameter 180mm Angled Uniflash CodeWP UF200 Diameter 180mm Straight Uniflash Diameter 180mm Rain cap terminal Code WP RC Diameter 180mm ...

Page 22: ...22 6 2 Typical flue installations details 1000 MINIMUM 600 MINIMUM 30 STRAIGHT PIPE 460 30 ELBOW 1500 MINIMUM STRAIGHT PIPE 960 LIP SEAL CLAMP LIP SEAL CLAMP WALL BAND WALL BAND EXTENSION 600 MINIMUM ...

Page 23: ...useholder that the pellets in the hopper have reached its 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 figure 7 3 If fitting a bulk hopper then the Grant hopper can control the feed auger from the bulk hopper to the Grant hopper When using a bulk hopper to supply the Grant hopper then a low pellet indic...

Page 24: ...s 4 Secure all cables fitted in the cable clamp and refit the panel cover 7 2 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 it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property The pipe the...

Page 25: ...6B 5B 4B 3A 2A 1A SEVEN WAY FEMALE SEVEN WAY MALE G Y N 4 3 1 2 6 5 7 8 9 3 core 0 75mm sq black insulation 1450mm long no Earth 3 core 0 75mm sq black insulation 1700mm long 3 core 0 75mm sq black insulation 1200mm long BL 300mm BL 400mm BR 500mm GY 500mm GY 100mm RD 320mm BL 650mm 3 core 0 75mm sq white insulation 550mm long fir black sleeves to inner insulation 4 core 0 75mm sq white insulation...

Page 26: ...26 NO 1 NO 2 NO 3 GRANT WOOD PELLET 6 26 9 36 BURNER WIRING DIAGRAM FIGURE 7 4 ...

Page 27: ...ER TO BULK HOPPER AUGER Frost thermostat 1 2 Pipe Stat BULK HOPPER FEED MAIN SUPPLY SWITCHED LIVE Nc C Supply to CH valve Switched Live Permanent Live Supply to CH valve with CH valve fitted connect pipe stat between L4 L7 without CH valve fitted connect pipe stat between L4 L5 LIMIT SWITCH LIMIT SWITCH N SL1 SL2 PL1 L1 L2 L3 L4 L5 L6 L7 N SL1 SL2 PL1 L1 L2 L3 L4 L5 L6 L7 with CH valve fitted conn...

Page 28: ...ing of pellets into the brazier to enable combustion to start Activated with a switched live input signal and or temperature drops below the DELTA RESTART temperature Deactivated after time exceeds T08 WAIT LIGHTING IGNITION operation code 41 Period of time given for pellets to light Activated after Pre load operation is complete Deactivated once photocell lux reading exceeds FLAME ON setting WAIT...

Page 29: ...UT OFF SWITCHED LIVE INPUT OFF SWITCHED LIVE INPUT OFF SWITCHED LIVE INPUT OFF SWITCHED LIVE INPUT OFF WAIT CLEANING BOILER 03 Auger run time TIME CLEAN BRAZ Auger run time TIME CLEAN BOILER FLASH CLEANING 1 Auger run time TIME CLEAN BRAZ or TIME CLEAN BOILER TURNING OFF BRAZIER 14 FLASH CLEANING 0 Auger run time TIME CLEAN BRAZ Auger run time TIME CLEAN BOILER WAIT PRE LOAD BRAZIER PRESSURE SWITC...

Page 30: ...ime pause min flame SEC max flame SEC time pause T06 firing SEC time load T08 time SEC pre load T09 reduced SEC time lighting cycle T10 lighting SEC time load T11 lighting SEC time pause T13 SEC flame stabilization 2 5 65 0 120 4 0 15 0 10 240 240 60 5 80 5 2 5 240 240 60 1 500 17 26 100 T22 Time post purge SEC 60 TO RE LOAD FACTORY SETTING 2 1 4 0 0 0 50 0 10 0 200 0 0 10 T19 n a MEnu MANUFACT IN...

Page 31: ... setting 6 26 9 36 5 5 C b TEMP OFF H2o Temperature the burner shuts down Units Celsius Default setting 6 26 9 36 80 80 C c DELTA RESTART Temperature drop before burner re starts Units Celsius Default setting 6 26 9 36 5 5 C 4 MEnu MANUFACT INSTAL 1 MEnu MANUFACT INSTAL 2 MEnu VIEW MANUFACT 3 MEnu USER VIEW 4 1 2 3 3 3 TO STEP BACK MEnu PSW 0 INSTAL CODE 3 MEnu PSW 0 INSTAL CODE Installer folder E...

Page 32: ...on the max min load pause settings 8 7 1 3 menu 3 4 CLEAN 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 determined by FLASH CLEANING see 8 3 1 3 d Default setting 6 26 9 36 240 240 Minutes b TIME CLEAN BOILER Total pellet feed auger run time before boiler cleaning operati...

Page 33: ...loads T10 x no pauses T09 Activated after pro load Deactivate once time has exceeded time setting for parameter T09 If set too low the flame may not be sufficiently established resulting in the flame being smothered when the function changes to max flame feed If set too high pellets could burn away faster than the pellets were delivered Units 000 0 seconds Default setting 6 26 9 36 0120 120 second...

Page 34: ...er T22 Units 0000 seconds Default setting 6 26 9 36 60 60 seconds T23 Delayed start on the flue fan start Units 0000 seconds Default setting 6 26 9 36 0 0 seconds T24 Default setting 6 26 9 36 10 required for modulation do not adjust FLAME ON Flame lux reading to a Activate countdown of T13 to switch off ignition element during lighting b Deactivate the Turning off brazier function when the burner...

Page 35: ...ence Resets after each brazier clean d VIEW CLE BOILER Total pellet feed auger run time since boiler last cleaned When T17 boiler cleaning operation will commence Resets after each boiler clean 8 7 4 USER menu folder USER folder allows the user change the language on the burner display To access the menu displays within the USER folder from the main burner display navigate as follows The language ...

Page 36: ... boiler top access doors Check that the spiral baffles in both the primary and secondary heat exchangers are in place 4 Test the boiler cleaning function by operating the momentary CLEANING TEST switch on the boiler control panel a Check the wash system located under the top rear access door is spraying water directly into each flue gas tube of the unit If the water jets are not spraying directly ...

Page 37: ... is correct See section 8 for access to the burner menu The data table shown in section 2 2 1 is when using a Grant Intermediate Hopper only When using a different hopper to feed the boiler directly contact Grant Engineering IRL Ltd for advice 9 3 Priming the pellet feed auger 1 Disconnect the 7 pin plug and 6 pin socket from the left hand side of the burner Fig 9 6 2 Disconnect the pellet deliver...

Page 38: ...ighting running and shut down sequence of operation 4 Check the flue fan is operational 5 Check the combustion chamber draught when the burner operation mode is POWER 100 only by inserting the draft meter probe into the test point located to the left of the burner on the combustion chamber door Fig 9 9 A draught reading of between 0 1 0 15 mbar should be achieved To adjust the combustion chamber d...

Page 39: ...the burner door is opened during the operation of the burner there can be a large uncontrollable flame emitted from the brazier 11 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 A damaged pellet delivery hose can allow a back draft through the boiler resulting in burner displaying error SAFETY CHARGE PIPE THE...

Page 40: ...ure check the operation of the pressure relief valve and check the expansion vessel air charge The expansion vessel air charge should be 1 0 bar when the system pressure is zero 3 Check the burner parameters setting correspond with the commissioning sheet attached to the boiler 4 Ensure all connections and fittings are sound Remake any joints and check tightness of any fitting that may be leaking ...

Page 41: ...l of the brazier as shown in fig 10 4 below Remove any ash from within the brazier Close the brazier manually by pulling up on the red slider of the electromechanical motor and at the same time pushing on the end wall of the brazier Fig 10 4 Do not to force the brazier end wall without disengaging the servo motor release switch Failure to release servo motor release switch WILL damage servo motor ...

Page 42: ...sary Refit the burner and tightening the M8 nut each side h Refit the burner cover and tighten the two M5 screws each side 10 3 Cleaning the Boiler Flue Fig 10 8 1 Remove the boiler top panel remove both top access cleaning covers 2 Remove the mild steel spirals from the chamber at the front of the boiler examine condition and clean down or replace if necessary Remove any ash on the chamber walls ...

Page 43: ...necessary Refit the baffle in position ensuring it is seated correctly on the fixing brackets 13 Refit the ash pan in the base of the combustion chamber 14 Grease the front cleaning door latch mechanism and close the door 15 Remove the boiler control panel cover to gain access to the boiler cleaning mechanism Grease the cam edge using high temperature grease Refit the boiler control panel Also rem...

Page 44: ...necessary A damaged pellet delivery hose can allow a back draft through the boiler resulting in burner displaying error SAFETY CHARGE PIPE THERMOSTAT 21 On the burner menus reset the service time by pressing the SET button 3 when the burner display shows RESET SERVICE See section 8 6 To ensure safe and efficient operation of the boiler it is important that re commissioning is carried out refer to ...

Page 45: ...iate hopper has insufficient pellets 3 Refer to diagram in section 7 1 2 4 Refer to section 7 Electrical YES NO NO FAULT BOILER WAITING FOR SYSTEM TEMP TO DROP CURSER BESIDE THERMOSTAT SYMBOL OF BURNER DISPLAY BURNER SWITCH IN THE ON MODE OF THE BOILER CONTROL PANEL NO PRIMARY FAULT SECONDARY FOLLOW ON CHECKS 1 2 3 6 5 4 SET RESET SET 80 C H2o 60 C WAIT BOILE WAIT BOILER THERMOSTAT note 1 POSITION...

Page 46: ...OR CHECK BURNER DOOR CLOSED CHECK POWER TO L1 OF SUPPLY LEAD IN REAR OF BOILER NO CHECK ELECTRICITY SUPPLY TO BOILER 1 2 3 6 5 4 SET RESET BLANK SCREEN YES NO FIT PLUGS YES CHECK POWER TO L1 OF PLUG IN BURNER NO CHECK DOOR MICRO SWITCH OPERATIONAL CHECK BURNER FUSE FOR CONTINUITY NO REPLACE BURNER FUSE YES CHECK RIBBON CABLE FITTED TO BACK OF DISPLAY YES REPLACE BURNER PCB NO REFIT RIBBON CABLE NO...

Page 47: ... messages FAILED PELLET LIGHTING Step Auto function 33 See section 11 1 SERVO MOTOR BLOCKED Step Auto function 34 See section 11 2 SAFETY CHARGE PIPE THERMOSTAT Step Auto function 46 See section 11 3 SAFETY BOILER THERMOSTAT Step Auto function 46 See section 11 4 PROBE FAULT Step Auto function 47 See section 11 5 AIR PRESSURE ERROR Step Auto function 29 See section 11 6 1 2 3 6 5 4 SET RESET SET 6...

Page 48: ... establish Too short a time prevents the flame from developing or too long a period allows the flame burn up the fuel Ideal time is 2 minutes or a T13 setting of 20 If the flame drops below 5 lux in this function then error message FAILED PELLET LIGHTING is displayed 10 See section 8 7 3 a VIEW menu folder To display the photocell value view LUX NO NO CHECK PELLETS DELIVERED TO BURNER YES FILL HOP...

Page 49: ...and 5 minutes Do not to force the brazier end wall without first disengaging the servo motor release switch Failure to release servo motor release switch will damage servo motor gears NO YES OPEN BURNER DOOR CHECK BRAZIER FOR BLOCKAGE YES MANUALLY OPEN BRAZIER CHECK IS BRAZIER SIZED CLEAR BLOCKAGE AND CLOSE BURNER DOOR CHECK BRAZIER CLEARANCE CORRECT YES RESET BRAZIER CLEARANCE NO CHECK BRAZIER FO...

Page 50: ... CLEAR FLUE BLOCKAGE IS THE ASH PAN OVER FLOWING NO CLEAN OUT ASH PAN AND BOILER IS THE WASH CLEANING SYSTEM WORKING WHEN CLEANING TEST SWITCH ACTIVATED YES NO RESET T17 OR T18 IS CLEANING SYSTEM PARAMETERS T17 T18 SET CORRECT NO CHECK WATER MAINS ON YES YES CHECK SOLENOID OPERATING CORRECTLY YES CHECK JETS BLOCKED IN CLEANING MANIFOLD CHECK CLEANING MOTOR OPERATION NO IS ROOM VENTILATION ADEQUATE...

Page 51: ...AILURE THERMISTOR Notes 1 See diagram 9 3 1 11 3 6 AIR PRESSURE ERROR CHECK HEATING THERMISTOR FITTED IN POCKET YES NO NO YES REFIT HEATING THERMISTOR AND RESET OVERHEAT RESET OVERHEAT STAT CHECK CONTINUITY REPLACE OVERHEAT STAT IS BOILER VENTED CORRECTLY NO VENT BOILER 1 2 3 6 5 4 SET RESET SET 60 C H2o 60 C SAFETY BO Error symbol SAFETY BOILER THERMOSTAT OVERHEAT note 1 note 2 note 3 note 4 PRIM...

Page 52: ...Note 3 Check the condition of the air supply tube to the pressure switch replace if necessary Note 4 Using a digital manometer set for positive pressure connected as shown below Check the burner fan is generating a minimum air pressure of 0 8mbar to activate the air pressure switch FIRE BOILER CHECK FOR FAULT DURING LIGHTING SEQUENCE NO YES RESET ERROR MESSAGE BY PRESSING RESET ON BURNER DISPLAY 1...

Page 53: ...53 12 Spare parts 12 1 Burner Burner controls Exploded view Fig 12 1 ...

Page 54: ...54 Burner Brazier Exploded view Fig 12 2 ...

Page 55: ...ube gasket WP14 1 1 15 Burner mounting gasket WP15 1 1 16 Ignition element housing WP16 1 1 17 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 M6 nut WP21 8 8 22 Ignition element mounting plate WP22 1 1 23 Photocell back plate WP23 1 1 24 Burner fan gasket WP24 1 1 25 Boiler water thermistor WP25 1 1 26 Controls chassis left ...

Page 56: ...56 12 2 Boiler Exploded view Fig 12 3 SPIRA 6 26 boiler displayed Boiler parts list ...

Page 57: ...pipe manifold 9 36 WP71 1 28 Cleaning door shaker chamber 6 26 WP72 1 Cleaning door shaker chamber 9 36 WP73 1 29 Fibre rope shaker chamber door 6 26 WP74 1 Fibre rope shaker chamber door 9 36 WP75 1 30 Solenoid valve WP76 1 1 31 Secondary heat exchanger spiral baffle WP77 18 24 32 Spiral hanger 6 26 WP78 1 Spiral hanger 9 36 WP79 1 33 Shaker assembly mounting flange WP80 1 1 34 Spring anchor mova...

Page 58: ...58 Fig 12 4 Intermediate Hopper parts list ...

Page 59: ...nt panel WP151 1 7 Grid WP152 1 8 Top front panel WP153 1 9 Door hinge WP154 2 10 Top rear panel WP155 1 11 Left side panel WP156 1 12 Castor Wheel WP157 2 13 Rubber diaphragm flange WP158 1 14 Rubber diaphragm WP159 1 15 Wiring centre WP160 1 16 Pellet damper WP161 1 17 Rear panel WP162 1 18 Wiring centre access cover WP163 1 19 Low level limit switch WP164 1 20 Limit switch bracket WP165 1 ...

Page 60: ...h 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...

Page 61: ...correct installation neglect misuse accident or failure to operate this boiler in accordance with the manufacturer s instructions 6 This guarantee is non transferable unless sanctioned by the company 7 The company will endeavour to provide prompt service in the unlikely event of a problem occurring but cannot be held responsible for any consequence of delay however caused 8 This guarantee does not...

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Page 63: ...sted below complies with the requirements of the The Low Voltage Directive LVD 2006 95 EC Standard used EN60335 1 2002 The Electromagnetic Compatibility Directive 2004 108 EC Standard used EN 55014 1 2007 Product Category Floor Standing Domestic Condensing Wood pellet boiler Model Grant Spira 6 26 Wood Pellet Boiler Grant Spira 9 36 Wood Pellet Boiler ...