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

Grant spira condensing wood pellet boiler
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IRL NO.011
Rev;3
July 2011
INSTALLATION, COMMISSIONING
AND

SERVICING INSTRUCTIONS

GRANT SPIRA 6-26 kW 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.
- 1 -

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  • Page 1: Servicing Instructions

    IRL NO.011 Rev;3 July 2011 INSTALLATION, COMMISSIONING SERVICING INSTRUCTIONS GRANT SPIRA 6-26 kW 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: Installation Information

    Index of Wood pellet Boiler installation manual 1. Introduction How the wood pellet boiler operates Boiler description Boiler components 2. Technical data Boiler & Hopper technical data Boiler output data Flue gas analysis Boiler & hopper set up Dimensions 3. Pellet specification & storage Pellet specification Pellet storage 4.
  • Page 3 Grant SPIRA Condensing Wood Pellet Boiler & Intermediate Hopper...
  • Page 4 1 Introduction extracting more sensible heat and some of the latent heat. This is achieved by cooling the flue gases to their dew point. This manual is intended to guide Engineers who have completed the Grant Wood Pellet Boiler Installer training To ensure maximum efficiency, the boiler return temperature course on the installation, commissioning and servicing of the should be 55°C or less (minimum of 40°C) at maximum...
  • Page 5 The boiler needs to be connected to a conventional flue be manually tested. Only operate the cleaning switch when the boiler is in „WAIT BOILER THERMOSTAT‟. See figure 1.1 system. There is no provision for connection to a balanced flue system as there is draft regulator 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 a system with a buffer tank/ thermal store there is no effect...

  • Page 6: Technical Data

    2 Technical Data 2.1 Boiler & Hoper technical data SPIRA Model Units 6-26 9-36 Water content Litres 51.5 Weight boiler heat-exchanger 8.35 Weight of auger 8.35 Weight burner 25.5 25.5 Weight intermediate hopper (empty) Weight intermediate hopper (full) Weight fan box Maximum heat Output 122,800 Btu/hr...
  • Page 7 Settings in the table below are based on the boiler using the Grant fixed angle pellet feed auger at 45° and an auger motor fixed speed of 8.5 rpm using 6mm „BNM Premium ‟, 6mm „Balcas Brites‟ or 6mm „GWP‟ pellets For settings on other brand pellets contact Grant Engineering 2.2.1 Burner settings...
  • Page 8 1021 SIDE VIEW - BOILER & HOPPER FRONT VIEW - BOILER & HOPPER FLUE EXHAUST FAN BULK HOPPER INLET OPTION DRAUGHT REGULATOR CLEARANCE REQUIRED MINIMUM NON-COMBUSTIBLE BASE AREA FOR ACCESS TO - 125MM THICK DRAUGHT STABILIZER & -SAME FLOOR LEVEL AS HOPPER BASE REMOVE WASH MANIFOLD REAR VIEW - BOILER &...
  • Page 9 1021 SIDE VIEW - BOILER & HOPPER FRONT VIEW - BOILER & HOPPER FLUE BULK HOPPER EXHAUST FAN INLET OPTION DRAUGHT REGULATOR CLEARANCE REQUIRED FOR ACCESS TO DRAUGHT STABILIZER & MINIMUM NON-COMBUSTIBLE BASE AREA REMOVE WASH MANIFOLD - 125MM THICK -SAME FLOOR LEVEL AS HOPPER BASE REAR VIEW - BOILER &...
  • Page 10 3. Pellet Specification, Storage & Delivery 3.1 Pellet specification. This Grant SPIRA boiler is designed to run on wood pellets that meet the following criteria; Key Parameter Limits Category as per prCEN/TS 14961:2004 Diameter D06, Average length L<5 x diameter Maximum length 40mm S0.05...
  • Page 11 Check with the pellet the pellet feed auger motor will determine the amount of supplier/manufacturer you wish to use before installing a pellets delivered to the boiler. Contact Grant Engineering bulk hopper system. for further details.
  • Page 12 Remove the packing list and check all items are present. Boiler operates. 4 Installation Information Fit the ash-pan in place in the combustion chamber and close the front cleaning door. 4.1 Introduction The appliance comes complete on one pallet, this consists of the boiler, burner, intermediate hopper (fitted with pellet feed auger) and combined fan box &...
  • Page 13 4.5 Installing the boiler 4.7 Combined fan box & flue starter The boiler and hopper must be positioned on a level, solid, non-combustible material of at least 125mm thick. It must Fit the combined fan box & flue starter to the flue outlet of the also extend past the boiler and hopper by 225mm at the front boiler using the M8 nuts and washers supplied.
  • Page 14 Fig 4.2 WARNING Ensure the pellet delivery hose 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‟...

  • Page 15: Condensate Disposal

    5 Condensate Disposal 5.1 General Requirements Condensate disposal pipes must be fitted with a fall (away When in condensing mode the Grant SPIRA condensing from the boiler) of at least 2.5° (~45mm fall per metre run). wood pellet boilers produce condensate from the water vapour in the flue gases and the fuel.
  • Page 16 condensate discharge pipe with a minimum diameter of 38mm is required to be fitted to this connection. The NOTE condensate trap must be situated where it can be easily accessed for removal and cleaning. For added frost protection leave the overflow connection open. For a boiler installed in an unheated area such as an outhouse or garage, all condensate pipework should be considered as an „external‟.

  • Page 17: Flue System And Air Supply

    3) The clearance given for A or B, as appropriate, will also apply. 6.1 for further details. No other appliance can be connected to the flue. Clearances recommended by Grant Engineering Clearances to combustible materials must be at least Limited in accordance with British Standards and 75mm.
  • Page 18 6.3 Flue components & assembly projecting liner spigot of every joint. The lip seal should be fitted dry and lubrication applied to the internal of the socket 6.3.1 Combined fan box & flue starter. The boiler is into which it is to be assembled. supplied with a combined fan box &...
  • Page 19 Ø125 Ø125 Ø180 Ø180 30° Bend Straight Pipe DN21009 Part no. WP/30 Nominal Internal diameter 125mm. External diameter 180mm Code Number Effective Length Length 1000 WP/EXT1000 WP/EXT500 WP/EXT333 WP/EXT200 Internal diameter 125mm. External diameter 180mm Ø125 Ø180 45° Bend Part no. WP/45 Internal diameter 125mm.
  • Page 20 ø125mm Wall Band (50mm) Internal/external Code WP/WB50 External diameter 180mm. Ø125 Ø180 Double 30° Bend and straight pipe length 960 Eff pipe 1061 460 Eff pipe Roof Support 293 Eff pipe Code WP/RS 160 Eff pipe External diameter 180mm. Fire stop plate Code WP/FP Viton Seal Part no.
  • Page 21 Support plate Code WP/SP Angled Uniflash CodeWP/UF200 Diameter 180mm. Diameter 180mm. Support plate Code WP/SP Straight Uniflash Diameter 180mm. External diameter 180mm. Storm collar Code WP/SC Diameter 180mm. Rain cap terminal Code WP/RC Diameter 180mm.
  • Page 22 1500 MINIMUM WALL BAND WALL BAND EXTENSION 30° ELBOW LIP SEAL & CLAMP 30° LIP SEAL & CLAMP STRAIGHT PIPE 960 STRAIGHT PIPE 460 6.2 Typical flue installations details.
  • Page 23 7 Electrical The boiler requires a permanent mains supply and a switched The Grant Spira Condensing Wood Pellet boiler requires a live supply to control the boiler. Do not interrupt the permanent 230/240 V ~50 Hz supply. If installed in the Republic of Ireland supply with any external controls.
  • Page 24 Fig 7.2 Make the electrical connection to suit either of the following. -Grant hopper only and low pellet indicator lamp see figure 7.3. -Grant hopper supplied by bulk hopper system see figure 7.4. NOTE The electrical supply to the bulk feed auger will need a mains isolator to isolate the auger when the hopper is empty of pellets.

  • Page 25: Boiler Wiring Diagram

    GRANT WOOD PELLET 6-26 & 9-36 BOILER WIRING DIAGRAM SEVEN WAY MALE SEVEN WAY FEMALE SIX WAY FEMALE THERMISTOR 2 core 3 core 3 core 3 core 0.75mm/sq 3 core 0.75mm/sq 0.75mm/sq 0.75mm/sq 0.75mm/sq 2 core black black insulation black black black 0.75mm/sq...
  • Page 28 8. Burner Activated after ignition mode. Deactivated after time exceeds „T13‟ 8.1 Burner Operation The burner controls the pellet feed auger, flue fan, boiler „WAIT LIGHTING‟ –LIGHTING FEED REDUCED (operation temperature and also the boiler and brazier cleaning systems. code 42) Period of time intermittent quantities of pellets The burner comes with a display screen and six control supplied to the brazier to increase the flame.
  • Page 29 8.3 Burner operation sequence 8.4 Burner display screen FLOW CHART OF OPERATION OF WOOD PELLET BOILER TEMP > 'DELTA RESTART' TEMP OR SWITCHED LIVE INPUT OFF WAIT BOILER THERMOSTAT H2o 60°C SET 75°C TEMP < 'DELTA RESTART' TEMP RESET & SWITCHED LIVE INPUT ON PELLET BU BURNER POWER...
  • Page 30 8.6 Burner menu navigation chart and factory default settings SET POINT RANGE 55°- 75°C X = BURNER CONTROLS BUTTON H2o XX°C SET 75°C RESET PELLET BU  CODE menu 1-4     MEnu MEnu INSTAL TEMP DELTA 5° INSTAL INSTAL ...
  • Page 31 8.7.1 „INSTAL‟ menu folder 8.7 Burner menu Using the main menu flow chart shown in fig. 8.6 navigate the menus using the buttons as described in section 8.5. MEnu INSTAL MANUFACT Each of the four main folders is described in further detail as follows;...
  • Page 32 activates. (If the burner shuts down immediately or CAUTION 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) Settings in the burner menu‟s below are based on the TIME CLEAN BOILER;...
  • Page 33 „T07‟n/a 8.7.2 „MANUFACT‟ menu folder. „T08‟ PRELOAD TIME; Time the pellet feed auger runs during the lighting sequence to initially charge the brazier MEnu INSTAL with pellets. If set too low there may be insuffient pellets MANUFACT to cover the element. If set too high it could cover the photocell and obscure the view of the photocell.
  • Page 34 Units 0000 seconds. „FLAME OFF‟ ; In “PELLET BURNER FIRING” mode if Default setting 6-26 & 9-36 = 200 (200 seconds) the flame Lux value is less than the „FLAME OFF‟ setting for 15 seconds, then error „FAILED PELLET LIGHTING‟ „T16‟...
  • Page 35 boiler is in when viewing. List of functions are as follows; 8.7.4 USER menu folder. 03 -WAIT BOILER THERMOSTAT 13 -PELLET BURNER FIRING MEnu 14 -TURNING OFF BRAZIER VIEW 26 -POST PURGE USER 29 -AIR PRESSURE ERROR „USER‟ folder; allows the user change the language on the 33 -FAILED PELLET LIGHTING burner display.
  • Page 36 Check the quality of the wood pellets to be used wash pipe on the right-hand side panel.) (see section 3 Pellet specification and storage). Do not use wood pellets that have not being approved By Grant Engineering (IRL) Ltd. for Jets spraying correctly use with this boiler.
  • Page 37 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 Fig. 9.8...

  • Page 38: Maximum Value

    WARNING Ensure the pellet delivery hose forms an air tight seal each end and that the hose is not damage. Leakage of air could cause increased temperature in the pellet delivery hose and result in the burn-back thermistor shutting down the burner . Refit the 7 pin socket and 6 pin plug into the original position on the side of the burner.
  • Page 39 Also record the combustion analysis details from CLEANING OPERATION) is not set greater than the combustion analyser and record the details 600 (60 seconds) and that „T17‟ (TIME (MIN) on the commissioning sheet. BETWEEN CLEANINGS) is not set less than When the „Burner display reads „WAIT PELLET 240 minutes, as modifying these times could THERMOSTAT‟, remove the burner burn-back...

  • Page 40: Boiler Servicing

    Ensure all connections and fittings are sound. Remake any joints and check 10. Boiler Servicing tightness of any fitting that may be leaking. To ensure a safe and efficient operation of the boiler Refill, vent and re-pressurise the system as the ash pan must be emptied after each 3 tonne of necessary.
  • Page 41 Fig 10.2 Clean out the brazier and remove all ash ensuring all air holes are free. Remove the burner cover by loosening the two M5 screws each side of the burner and lifting off the cover. Remove the M8 nut each side of the burner and withdraw the burner from the boiler.
  • Page 42 tapping each side of the brazier as shown in fig 10.6, remove the steel strip when finished. e. Tighten the screws each side. f. Remove gauge. Fig 10.8 Remove and check the condition of the heating element. Replace if damaged. Also check the pellet feed pipe, clean out if necessary.
  • Page 43 needs to be aligned once the unit is powered persons of property. Ensure the ash is disposed of in a safe manner. up). 6. Remove the flue inspection plate and examine 11. Clean down the combustion chamber and the flue condition. Clean the flue by sweeping it combustion chamber door fully.
  • Page 44 19. Disconnect the drain trap located on the condensate drain system from the back of the boiler. Clean thoroughly and re-fit. 20. 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.

  • Page 45: Fault Finding

    11 Fault finding 11.1 Boiler won‟t fire (no error message) = PRIMARY FAULT H2o 60°C = SECONDARY FOLLOW ON CHECKS SET 80°C RESET WAIT BOILE WAIT BOILER THERMOSTAT CHECK 'BURNER' SWITCH CHECK POWER CURSER BESIDE SUFFICIENT TIMER AND OR CONTINUITY TO L2 OF THERMOSTAT IN THE 'ON' MODE...
  • Page 46 Boiler won‟t fire (Blank screen) 11.2 = PRIMARY FAULT = SECONDARY FOLLOW ON CHECKS RESET BLANK SCREEN CHECK POWER CHECK BURNER CHECK RIBBON CHECK POWER CHECK BURNER CHECK TO L1 OF PLUG REPLACE CABLE FITTED TO L1 OF PLUG ? FUSE FOR BURNER BURNER PCB...

  • Page 47: Failed Pellet Lighting

    11.3 Error messages When a fault occurs with the burner, the burner display screen displays a block to the right of the error symbol as shown below. The lower area of the text screen also displays a message of the fault that occurred. H2o 60°C SET 60°C RESET...
  • Page 48 11.3.1 FAILED PELLET LIGHTING = PRIMARY FAULT H2o 60°C = SECONDARY FOLLOW ON CHECKS SET 60°C RESET FAILED PEL Error symbol FAILED PELLET LIGHTING SUFFICIENT UN-BURNT CHECK AUGER CHECK PELLETS QUANTITY OF PELLETS PRIMED DELIVERED TO PELLETS IN IN THE FULLY BURNER BRAZIER...

  • Page 49: Servo Motor Blocked

    The brazier cleaning operation will now commence. Ensure „T16‟ is reset to its original setting or else the brazier operation will be activated after each lighting operation. The stroke of the servo motor is factory set and should not be adjusted. Check with Grant Engineering for correct setting.
  • Page 50 11.3.3 SAFETY CHARGE PIPE = PRIMARY FAULT H2o 60°C = SECONDARY FOLLOW ON CHECKS SET 60°C RESET SAFETY CH Error symbol Error symbol SAFETY CHARGE PIPE DOES PRESSING PELLET FEED IS CONDENSATE IS COMBUSTION PELLET FEED BURNER REST IS THE ASH PAN TUBE AIR TIGHT TRAP/PIPE CHAMBER DRAFT...

  • Page 51: Air Pressure Error

    11.3.4 SAFETY BOILER THERMOSTAT = PRIMARY FAULT H2o 60°C = SECONDARY FOLLOW ON CHECKS SET 60°C RESET SAFETY BO Error symbol SAFETY BOILER THERMOSTAT (OVERHEAT) CHECK HEATING RESET IS BOILER THERMISTOR OVERHEAT STAT VENTED FITTED IN CHECK CORRECTLY POCKET CONTINUITY note 1 note 3 note 4...
  • Page 52 = PRIMARY FAULT H2o 60°C = SECONDARY FOLLOW ON CHECKS SET 60°C RESET AIR PRESS Error symbol AIR PRESSURE ERROR FIRE BOILER, RESET ERROR CHECK BURNER MESSAGE BY CHECK FOR CHECK BURNER FAN IS FAULT DURING FAN PRESSURE IS PRESSING OPERATIONAL &...

  • Page 53: Spare Parts

    Spare parts 12.1 Burner Burner controls –Exploded view Fig 12.1...
  • Page 54 Burner Brazier –Exploded view Fig 12.2...
  • Page 55 Burner parts list Item Description Part No. Quantity Quantity 6-26 9-36 Pressure switch WP111 Primary printed circuit board c/w enclosure WP112 Burner fan WP03 Servomotor WP04 LED display unit c/w enclosure WP05 Mounting bracket set (LED display) WP06 Electrical connector 7 way female WP07 Electrical connector 7 way male WP08...
  • Page 56 12.2 Boiler Exploded view Fig 12.3 SPIRA 6-26 boiler displayed Boiler parts list...
  • Page 57 Item Description Part No. Quantity Quantity 6-26 9-36 Rear lower panel WP34 5 way mains connection –male fixed WP 35 Rear upper panel WP36 5 way mains connection –female detachable WP37 5 way flue fan / cleaning solenoid connection –male detachable WP38 5 way flue fan /cleaning solenoid connection –...
  • Page 58 Fig. 12.4 Intermediate Hopper parts list...
  • Page 59 Item Description Part No. Quantity 6-26 & 9-36 Castor Wheel (c/w brake) WP146 Caster wheel flange WP147 Right side panel WP148 Pellet feed Auger shield WP149 Base WP150 Front panel WP151 Grid WP152 Top front panel WP153 Door hinge WP154 Top rear panel WP155 Left side panel...

  • Page 60: Health And Safety Information

    After handling always follow normal good hygiene 13. Health and Safety Information practices. Under the Consumer Protection Act 1987 and section Protection: Use eye protection. Rubber or plastic 6 of the Health & safety at Work Act 1974, we are gloves should be worn where repeated contact occurs required to provide information on substances and a face mask worn when working in confined...

  • Page 61: Warranty

    Grant Engineering (Ireland) Limited. 10. All claims under this guarantee must be made and agreed with by Grant Engineering (Ireland) Ltd. prior to any work being carried out. Proof of purchase and date of installation must be provided on request. Invoices for call out/repair work carried out by any third party will not be acceptable unless previously authorised by the company.
  • Page 62 15. Notes _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________...

  • Page 63: Ec Declaration Of Conformity

    EC Declaration of Conformity We Grant Engineering (Ireland) Limited under our sole responsibility declare that the Grant Spira Wood pellet boiler as listed 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;...

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